Service Manual BW220D-5

Service Manual
BW 220 D-5
S/N 961 587 61 1001>
Single drum roller
008 403 78 EN © 05/2021

2
Table of contents
Table of contents
1 General information.............................................................................................................................. 9
1.1 Introduction................................................................................................................................. 10
1.2 Concerning your safety.............................................................................................................. 12
1.2.1 Basic prerequisites..................................................................................................................... 12
1.2.2 Definition of responsible persons............................................................................................... 15
1.2.3 Basic safety regulations for safe operation................................................................................ 16
1.2.4 Handling fuels and lubricants..................................................................................................... 18
1.2.5 Load/transport the machine....................................................................................................... 23
1.2.6 Starting up the machine............................................................................................................. 24
1.2.7 Driving the machine; working operation..................................................................................... 25
1.2.8 Refuelling................................................................................................................................... 27
1.2.9 Emergency procedures.............................................................................................................. 28
1.2.10 Maintenance work.................................................................................................................... 29
1.2.11 Repair....................................................................................................................................... 31
1.2.12 Signage.................................................................................................................................... 32
1.2.13 Danger zones........................................................................................................................... 39
1.2.14 Safety Components.................................................................................................................. 40
1.3 Maintenance and repair.............................................................................................................. 41
1.3.1 Notes on repair........................................................................................................................... 41
1.3.2 Preliminary remarks and safety notes........................................................................................ 57
1.3.3 Preparations/concluding work.................................................................................................... 58
1.3.4 Parking the machine in secured condition................................................................................. 60
2 Technical data...................................................................................................................................... 63
2.1 Technical data............................................................................................................................. 64
2.1.1 Noise and vibration data............................................................................................................ 66
2.2 Additional technical data............................................................................................................ 68
2.3 Terms and basis of calculation.................................................................................................. 71
2.4 Fuels and lubricants................................................................................................................... 72
2.4.1 Engine oil................................................................................................................................... 72
2.4.2 Fuel............................................................................................................................................ 73
2.4.3 Coolant....................................................................................................................................... 74
2.4.4 Hydraulic oil................................................................................................................................ 77
2.4.5 Gear oil SAE 75W-90................................................................................................................. 77
2.4.6 Gear oil SAE 80W-140............................................................................................................... 77
2.5 List of fuels and lubricants........................................................................................................ 79
3 Overview of machine.......................................................................................................................... 81
3.1 General information.................................................................................................................... 82
3.1.1 BCM 05...................................................................................................................................... 86
3.1.2 BCM start................................................................................................................................... 88
3.1.3 BCM net..................................................................................................................................... 89
3.1.4 Economizer................................................................................................................................ 90
3.1.5 Terrameter.................................................................................................................................. 91
3.1.6 BOMAG Telematic...................................................................................................................... 93
3.2 Electric systems.......................................................................................................................... 95
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Table of contents
3.3 Hydraulic system........................................................................................................................ 97

3.4 Machine assemblies................................................................................................................... 98
3.4.1 Diesel engine............................................................................................................................. 98
3.4.2 Drum.......................................................................................................................................... 99
3.4.3 Air conditioning......................................................................................................................... 100
3.4.4 Auxiliary heating, AIRTRONIC................................................................................................. 101
4 Electric systems................................................................................................................................ 103
4.1 Basic principles......................................................................................................................... 104
4.1.1 Measuring technology.............................................................................................................. 105
4.1.2 Understanding circuit diagrams................................................................................................ 110
4.1.3 Telemecanique switch.............................................................................................................. 122
4.1.4 Deutsch connectors, DT and DTM series................................................................................ 124
4.2 Overview of electric system..................................................................................................... 129
4.2.1 Central electrics....................................................................................................................... 131
4.2.2 Operator’s stand...................................................................................................................... 132
4.2.3 Wiring....................................................................................................................................... 133
4.2.4 CAN BUS overview.................................................................................................................. 150
4.2.5 List of equipment...................................................................................................................... 152
4.3 Starting the engine with jump leads........................................................................................ 161
4.4 Fuse assignment....................................................................................................................... 162
4.4.1 Notes on safety........................................................................................................................ 162
4.4.2 Central electrics....................................................................................................................... 162
4.4.3 Main fuses................................................................................................................................ 163
4.4.4 Control console cabin............................................................................................................... 164
4.4.5 Auxiliary heating....................................................................................................................... 165
4.5 Central electrics........................................................................................................................ 166
4.5.1 Power board............................................................................................................................. 167
4.6 Description of electrical components..................................................................................... 173
4.6.1 Sensors and actuators............................................................................................................. 173
4.6.2 CPU control units and electrical modules................................................................................ 178
4.6.3 Cabin operating console, A178................................................................................................ 182
4.7 Training of electric system....................................................................................................... 184
4.7.1 Electrics training machine control............................................................................................ 184
4.8 Inspection and maintenance work........................................................................................... 311
4.8.1 Maintenance Table................................................................................................................... 311
4.8.2 Every 500 operating hours....................................................................................................... 311
4.8.3 As required............................................................................................................................... 312
5 Hydraulic system.............................................................................................................................. 315
5.1 Basic principles......................................................................................................................... 316
5.1.1 Open and closed hydraulic circuit............................................................................................ 317
5.1.2 Swash plate principle, pump.................................................................................................... 319
5.1.3 Swash plate principle, motor.................................................................................................... 320
5.1.4 External gear pumps................................................................................................................ 322
5.2 Overview of hydraulics............................................................................................................. 325
5.3 Description of hydraulic components..................................................................................... 328
5.3.1 Travel / vibration pump, H1...................................................................................................... 328
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Table of contents
5.3.2 Travel motor, H1....................................................................................................................... 332

5.3.3 Vibration motor A2FM.............................................................................................................. 334
5.3.4 Steering valve.......................................................................................................................... 336
5.4 Description of hydraulic circuits............................................................................................. 338
5.4.1 Charge circuit........................................................................................................................... 339
5.4.2 Travel circuit............................................................................................................................. 341
5.4.3 Vibration circuit......................................................................................................................... 346
5.4.4 Steering circuit......................................................................................................................... 353
5.5 Flushing and bleeding.............................................................................................................. 356
5.5.1 Flushing in general................................................................................................................... 356
5.5.2 Flushing the travel circuit......................................................................................................... 359
5.5.3 Flushing the vibration circuit..................................................................................................... 368
5.5.4 Bleeding................................................................................................................................... 373
5.6 Inspection and maintenance work.......................................................................................... 377
5.6.2 Checks prior to start up............................................................................................................ 378
5.6.4 Every 1000 operating hours..................................................................................................... 379
6 Machine assemblies......................................................................................................................... 383
6.1 Diesel engine............................................................................................................................. 385
6.1.1 Overviews................................................................................................................................ 386
6.1.2 Lubrication oil circuit................................................................................................................. 391
6.1.3 Cooling circuit........................................................................................................................... 393
6.1.4 Fuel system.............................................................................................................................. 395
6.1.5 Deutz Common Rail................................................................................................................. 398
6.1.6 Wastegate charge pressure controller..................................................................................... 403
6.1.7 Exhaust gas recirculation ........................................................................................................ 404
6.1.8 Engine electrics........................................................................................................................ 406
6.1.9 Inspection and maintenance work............................................................................................ 441
6.2 Drum........................................................................................................................................... 464
6.2.1 Repair overview for drum......................................................................................................... 465
6.2.2 Dismantling the drum............................................................................................................... 469
6.2.3 Dismantling and assembling the change-over weight.............................................................. 484
6.2.4 Assembling the drum............................................................................................................... 487
6.2.5 Changing the rubber buffers, adjusting the pretension............................................................ 509
6.2.6 Smooth drum scraper; installation and removal....................................................................... 514
6.2.7 Pad foot scraper; installation and removal............................................................................... 518
6.3 Padfoot shell.............................................................................................................................. 529
6.3.1 Attaching the padfoot shells..................................................................................................... 529
6.3.2 Removing the padfoot shells.................................................................................................... 541
6.4 Oscillating articulated joint...................................................................................................... 549
6.4.1 Overview.................................................................................................................................. 549
6.4.2 Dismantling the oscillating articulated joint.............................................................................. 550
6.4.3 Assembly of oscillating articulated joint.................................................................................... 551
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Table of contents
6.5 Drive axle................................................................................................................................... 555

6.5.2 Checks prior to start up............................................................................................................ 556
6.5.5 As required............................................................................................................................... 562
6.6 Air conditioning......................................................................................................................... 564
6.6.1 Overview of air conditioning system......................................................................................... 564
6.6.2 Physical principles.................................................................................................................... 567
6.6.3 Refrigerant R134a.................................................................................................................... 569
6.6.4 Compressor oil / refrigeration oil.............................................................................................. 571
6.6.5 Working principle of the air conditioning system...................................................................... 573
6.6.6 Monitoring devices................................................................................................................... 574
6.6.7 Description of components....................................................................................................... 575
6.6.8 Compressor.............................................................................................................................. 580
6.6.9 Emptying in case of repair........................................................................................................ 582
6.6.10 Drying and evacuation........................................................................................................... 583
6.6.11 Filling instructions................................................................................................................... 583
6.6.12 Steam table for R134a........................................................................................................... 586
6.6.13 Inspection and maintenance work.......................................................................................... 590
6.7 Auxiliary heating, AIRTRONIC................................................................................................. 598
6.7.1 Description of function.............................................................................................................. 599
6.7.2 Fuse assignment...................................................................................................................... 602
6.7.3 Control panel............................................................................................................................ 603
6.8 Cabin assembly......................................................................................................................... 607
6.8.1 Safety....................................................................................................................................... 607
6.8.2 Preparations............................................................................................................................. 608
6.8.3 Cabin assembly........................................................................................................................ 609
6.8.4 Final function tests and checks................................................................................................ 614
6.9 ROPS FOPS............................................................................................................................... 616
6.9.1 ROPS/FOPS assembly............................................................................................................ 616
6.10 VM31 BCM/GPS installation................................................................................................... 624
6.10.1 Safety..................................................................................................................................... 624
6.10.2 Assembly work for holding fixture and cable of BCM/GPS.................................................... 626
6.10.3 Concluding work..................................................................................................................... 632
7 Troubleshooting................................................................................................................................ 635
7.1 Preliminary remarks.................................................................................................................. 636
7.2 Emergency procedures............................................................................................................ 638
7.2.1 Actuating the emergency stop switch....................................................................................... 638
7.2.2 Machine stops in case of faults................................................................................................ 639
7.2.3 Disconnecting the battery......................................................................................................... 640
7.2.4 Emergency exit........................................................................................................................ 640
7.2.5 Towing the machine................................................................................................................. 641
7.2.6 After towing.............................................................................................................................. 643
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Table of contents
7.3 Troubleshooting, electrical systems....................................................................................... 646

7.3.1 Preliminary remarks................................................................................................................. 646
7.3.2 Starting the engine with jump leads......................................................................................... 649
7.3.3 Servicing the battery, checking the main battery isolation....................................................... 650
7.3.4 Fuse assignment...................................................................................................................... 651
7.3.5 ESX, checking the electric power supply................................................................................. 655
7.3.6 Diagnostics concept................................................................................................................. 663
7.4 Trouble shooting, diesel engine.............................................................................................. 666
7.4.1 Starting the engine with jump leads......................................................................................... 666
7.4.2 Engine malfunctions................................................................................................................. 667
7.4.3 Deutz DTC fault code list, EMR3............................................................................................. 670
7.5 Trouble shooting, hydraulics................................................................................................... 737
7.5.1 Preliminary remarks................................................................................................................. 737
7.5.2 Insufficient hydraulic power...................................................................................................... 738
7.5.3 Troubleshooting axial piston pumps......................................................................................... 741
7.5.4 Troubleshooting axial piston motors........................................................................................ 743
7.5.5 Troubleshooting table for hydraulic components..................................................................... 745
7.6 Troubleshooting the air conditioning system........................................................................ 753
7.6.1 Basic principles........................................................................................................................ 753
7.6.2 Troubleshooting....................................................................................................................... 760
7.6.3 Leak test................................................................................................................................... 773
7.6.4 Checking the magnetic clutch ................................................................................................. 774
7.7 Troubleshooting the auxiliary heating.................................................................................... 775
7.7.1 Fuse assignment...................................................................................................................... 775
7.7.2 Components............................................................................................................................. 776
7.7.3 Control and safety elements.................................................................................................... 777
7.7.4 Troubleshooting....................................................................................................................... 777
7.7.5 Diagnostics............................................................................................................................... 779
7.7.6 Check the fuel supply............................................................................................................... 782
7.7.7 Circuit diagram, AIRTRONIC D2/D4........................................................................................ 784
8 Special tools...................................................................................................................................... 789
8.1 Special tools, electrics............................................................................................................. 790
8.2 Special tools for hydraulic system.......................................................................................... 791
8.2.1 Special tools, tests and adjustments........................................................................................ 791
8.2.2 Special tools for flushing.......................................................................................................... 793
8.3 Special tools for oscillating articulated joint.......................................................................... 794
8.4 Special tools, drum................................................................................................................... 796
8.5 List of special tools................................................................................................................... 798
9 Index................................................................................................................................................... 799
Appendix............................................................................................................................................ 813
A Circuit diagrams............................................................................................ 815
A.1 Circuit diagram 643.................................................................................... 815
A.2 Hydraulic diagram...................................................................................... 917
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Table of contents
8 BW 220 D-5
General information
1 General information
BW 220 D-5 9
General information – Introduction
1.1 Introduction............................................................... 10
1.2 Concerning your safety............................................ 12
1.2.1 Basic prerequisites.................................................. 12
1.2.2 Definition of responsible persons............................. 15
1.2.3 Basic safety regulations for safe operation.............. 16
1.2.4 Handling fuels and lubricants................................... 18
1.2.5 Load/transport the machine..................................... 23
1.2.6 Starting up the machine........................................... 24
1.2.7 Driving the machine; working operation................... 25
1.2.8 Refuelling................................................................. 27
1.2.9 Emergency procedures............................................ 28
1.2.10 Maintenance work.................................................. 29
1.2.11 Repair..................................................................... 31
1.2.12 Signage.................................................................. 32
1.2.13 Danger zones........................................................ 39
1.2.14 Safety Components............................................... 40
1.3 Maintenance and repair............................................ 41
1.3.1 Notes on repair........................................................ 41
1.3.2 Preliminary remarks and safety notes..................... 57
1.3.3 Preparations/concluding work.................................. 58
1.3.4 Parking the machine in secured condition............... 60
1.1 Introduction
General This manual:
n addresses the BOMAG Customer Service and professionally
trained personnel.
n provides support for repair work or maintenance procedures on
the machine.
This manual described the deinstallation, dismantling , assembly,
installation as well as the repair of components and assembly
groups as far as this makes sense with respect to tools and spare
parts supply.
Index The index is a reference register that will help you to find informa-
tion in this Service Manual. The index lists keywords in alphabet-
ical order. Cross references (keywords related to page numbers)
enable quick and convenient search/navigation.
Keywords concerning the following subjects are listed in the index:
n Electrical operating means
n Plug designations
n Overviews
n Fault codes
n Troubleshooting
n ...
10 BW 220 D-5
General information – Introduction
Documentation For the BOMAG machines described in this manual the following
documentation is additionally available:
n Operating and maintenance instructions
n Spare parts catalogue
n Service information (if necessary)
Maintenance/parts service n Specialist teams are available for you in Germany, Europe and
overseas. This tight network ensures close customer contact
all over the world.
n Parts for maintenance, service and repair are available from
our branch offices and dealers at very short notice.
n BOMAG guarantees long-term availability of all common parts.
n Well-designed catalogues provide an easy guide to finding and
ordering the required parts.
n Only use genuine BOMAG parts. These have been specially
adapted to the corresponding machine. In this way, you will
prevent any problems arising and unnecessary downtimes of
your machine.
Updating service This manual is not subject of an updating service. For this reason
we would like to draw your attention to the additionally published
service informations.
In case of a new release all necessary changes will be included.
In the course of technical development we reserve the right for
technical modifications without prior notification.
Copyright Information and illustrations in this manual must not be reproduced

and distributed, nor must they be used for the purpose of competi-
tion without the consent of BOMAG. All rights according to the
copyright law remain expressly reserved.
BW 220 D-5 11
General information – Concerning your safety
1.2 Concerning your safety

1.2.1 Basic prerequisites
1.2.1.1 General
This machine has been built in compliance with the latest technical
standard and complies with the applicable regulations and tech-
nical rules.
However, dangers for persons and property may arise from this
machine, if:
n it is used for purposes other than the ones it is intended for,
n it is operated by untrained personnel,
n it is changed or converted in an unprofessional way,
n the safety instructions are not observed.
Each person involved in the operation, maintenance and repair of
the machine must therefore read and comply with these safety reg-
ulations. If necessary, the operating company must obtain the rele-
vant signatures as confirmation.
Furthermore, the following obviously also applies:
n applicable accident prevention instructions,
n generally accepted safety and road traffic regulations,
n country/state specific safety regulations.
It is the duty of the operator to be acquainted with the safety regu-
lations and to apply these accordingly. This also applies for local
regulations and regulations concerning different types of handling
activities. Should the recommendations in these instructions be dif-
ferent from the regulations valid in your country, you must comply
with the safety regulations valid in your country.
1.2.1.2 Explanation of signal words used
DANGER!
Danger to life if failing to comply!
Sections marked accordingly indicate an extremely
dangerous situation that could lead to fatal or
severe injuries, if this warning is disregarded.
WARNING!
Danger to life or danger of severe injuries if
failing to comply!
Sections marked accordingly indicate a dangerous
situation that could lead to fatal or severe injuries,
if this warning is disregarded.
12 BW 220 D-5
CAUTION!
Danger of injury if failing to comply!
Sections marked accordingly indicate a dangerous
situation that could lead to fatal or severe injuries,
if this warning is disregarded.
NOTICE!
Danger of material damage if failing to comply!
Sections marked accordingly indicate possible
dangers for machines or components.
Sections marked accordingly indicate technical

information or notes on using the machine or its
components.
ENVIRONMENT!
Environmental damage if failing to comply!
Paragraphs marked accordingly indicate practices
for safe and environment-friendly disposal of fuels
and lubricants as well as replacement parts.
1.2.1.3 Personal protective equipment

Depending on the work to be carried out, personal protective equipment is required (to be provided
by the operating company):
Working clothes Tight fitting working clothes with low tear resistance, tight
sleeves and without any projecting parts protect against
being caught by moving components.
Safety shoes They protect against heavy falling parts and slipping on
slippery ground.
Protective gloves They protect the hands against scrapes, punctures or

deeper injuries, irritating and caustic substances and
burns.
BW 220 D-5 13
Safety goggles They protect the eyes against airborne particles and
squirting fluids.
Face protection This protects the face against airborne particles and
squirting fluids.
Hard hat This protects the head against falling parts and injuries.
Hearing protection This protects against extreme noise.
Respiratory protection This protects the airways against substances or parti-

cles.
1.2.1.4 Intended use

This machine is intended for commercial use only.
The machine must only be used for:
n Compaction during earthwork and for road sub-base construc-
tion.
n Compaction of bituminous material, e.g. road surface layers.
Intended use also includes compliance with the specified oper-
ating, maintenance and repair measures.
1.2.1.5 Improper use

Dangers may arise with the machine if it is used other than for its
intended purpose.
Any danger caused by improper use is the sole responsibility of the
operating company or driver/operator; the manufacturer cannot be
held liable.
14 BW 220 D-5
Examples of improper use are:

n Work with vibration on hard concrete, cured bitumen layers or
extremely frozen ground
n Driving on non-load-bearing subsoil or inadequate contact
areas (danger of tilting)
n Using the machine for towing
n Using to pull down walls or demolish buildings
Transporting persons, except the machine driver, is prohibited.
Starting and operating the machine in explosive environments and
in underground mining is prohibited.
1.2.1.6 Estimated service life of the machine

If the following general conditions are met, the service life of the
machine is usually in the range of several thousand operating
hours:
n Regular safety inspections by an expert / qualified person
n Performance of the prescribed maintenance work within the
specified time
n Immediate performance of necessary repair work
n Exclusive use of original spare parts
1.2.2 Definition of responsible persons

1.2.2.1 Operating company
The operating company is the natural or juridical person who uses
the machine or in who's name the machine is used.
The operating company must make sure that the machine is only
used for the purpose it is intended for and in strict compliance with
the safety regulations mentioned in these operating and mainte-
nance instructions.
The operating company must determine and assess the danger in
its company. It must then take appropriate action to ensure health
and safety at work for its employees and point out any remaining
dangers.
The operating company must determine whether there are special
operational hazards such as a toxic atmosphere or limiting soil
conditions. Such conditions require special, additional measures to
remove or reduce the hazard.
The operating company must make sure that all users read and
understand the information concerning safety.
The operating company is responsible for the planning and profes-
sional execution of regular safety inspections.
BW 220 D-5 15
1.2.2.2 Expert / qualified person

An expert / qualified person is a person who, based on his/her pro-
fessional education and experience, has profound knowledge in
the field of construction equipment and the machine in question in
particular.
This person is acquainted with the applicable governmental indus-
trial safety regulations, accident prevention instructions, guidelines
and generally acknowledged technical rules and regulations
(standards, directives, technical rules of other member states of
the European Union or other contractual states concerning the
agreement about the European Economic Area) in as far as is nec-
essary to be able to judge the safe condition of this machine.
1.2.2.3 Driver / operator

This machine must only be operated by trained, instructed persons
entrusted by the operating company aged 18 or more.
Observe your local laws and regulations.
Rights, obligations and rules of conduct for driver or operator:
The driver or operator must:
n be instructed about his rights and obligations,
n wear protective equipment as appropriate for the application,
n have read and understood the operating instructions,
n have made himself familiar with the operation of the machine,
n be physically and psychologically able to drive and operate the
machine.
Persons under the influence of alcohol, medication or drugs are not
allowed to operate, service or repair the machine.
Maintenance and repair work requires specific knowledge and
must therefore only be performed by trained specialists.
1.2.3 Basic safety regulations for safe operation

1.2.3.1 Remaining dangers, remaining risks
Despite careful work and compliance with standards and regula-
tions it cannot be ruled out that further dangers may arise when
working with and handling the machine.
Both the machine as well as all other system components comply
with the currently valid safety regulations. Nevertheless, remaining
risks cannot be ruled out completely, even when using the machine
for the purpose it is intended for and following all information given
in the operating instructions.
A remaining risk can also not be excluded beyond the actual
danger zone of the machine. Persons remaining in this area must
pay particular attention to the machine, so that they can react
immediately in case of a possible malfunction, an incident or failure
etc.
16 BW 220 D-5
All persons remaining in the area of the machine must be informed

about the dangers that arise from the operation of the machine.
1.2.3.2 Regular safety inspections

Have the machine inspected by an expert / qualified person as
required for the conditions the machine is working under, but at
least once every year.
1.2.3.3 Modifications and alterations to the machine

Unauthorized changes to the machine are prohibited for safety rea-
sons.
Original parts and accessories have been specially designed for
this machine.
We wish to make explicitly clear that we have not tested or
approved any parts or accessories not supplied by us.
The installation and/or use of such products may have an adverse
effect on the active and/or passive safety.
1.2.3.4 Damage, defects, misuse of safety devices

Machines which are not safe to operate or in traffic must be imme-
diately taken out of service and shall not be used, until these defi-
ciencies have been properly rectified.
Safety installations and switches must neither be removed nor
must they be made ineffective.
1.2.3.5 Roll Over Protection Structure (ROPS) and Fall On Protection Structure (FOPS)
Machines with cabin already have ROPS/FOPS as

an integrated part of the cabin.
The frame of the machine must not be warped, bent or cracked in

the area of the ROPS/FOPS fastening.
The ROPS/FOPS must not have any rust, damage, hairline cracks
or open fractures.
The current machine weight must never exceed the testing weight
for the ROPS/FOPS.
No accessories may be welded or bolted on and no additional
holes must be drilled without the consent of the manufacturer,
since this will impair the strength of the unit.
The ROPS/FOPS must therefore also not be straightened or
repaired if it is damaged.
BW 220 D-5 17
A defective ROPS/FOPS must always be replaced with an original

spare part in close coordination with the manufacturer.
1.2.4 Handling fuels and lubricants

1.2.4.1 Preliminary remarks
The operating company must ensure that all professional users
have read and follow the corresponding safety data sheets for the
individual fuels and lubricants.
Safety data sheets provide valuable information about the following
characteristics:
n name of substance
n possible dangers
n composition / information on constituents
n first-aid measures
n fire fighting measures
n measures in case of accidental release
n handling and storage
n limitation and monitoring of exposure / personal protective
equipment
n physical and chemical properties
n stability and reactivity
n toxicological data
n environmental data
n notes on waste disposal
n information on transport
n legislation
n other data
18 BW 220 D-5
1.2.4.2 Safety regulations and environmental protection regulations for handling diesel fuel
WARNING!
Danger of burning by ignited diesel fuel!
– Do not allow diesel fuel to come into contact
with hot components.
– Smoking and open fire is prohibited!
– Wear your personal protective equipment (pro-
tective gloves, protective clothing).
Fig. 1 CAUTION!
Health hazard caused by contact with diesel
fuel!
– Do not inhale any fuel fumes.
– Avoid contact.
CAUTION!
Danger of slipping on spilled diesel fuel!
– Immediately bind spilled diesel fuel with an oil-
binding agent.
ENVIRONMENT!
Diesel fuel is an environmentally hazardous
substance!
– Always keep diesel fuel in proper containers.
binding agent and dispose of properly.
– Dispose of diesel fuel and fuel filters according
to regulations.
BW 220 D-5 19
1.2.4.3 Safety regulations and environmental protection regulations for handling oil
WARNING!
Danger of burning by ignited oil!
– Do not allow oil to come into contact with hot
components.
Fig. 2 CAUTION!
Health hazard caused by contact with oil!
– Do not inhale any oil vapours.
– Avoid contact.
CAUTION!
Danger of slipping on spilled oil!
– Immediately bind spilled oil with an oil-binding
agent.
ENVIRONMENT!
Oil is an environmentally hazardous substance!
– Always keep oil in proper containers.
agent.
– Dispose of oil and oil filter according to regula-
tions.
20 BW 220 D-5
1.2.4.4 Safety regulations and environmental protection regulations for handling hydraulic oil
WARNING!
Danger of injury caused by escaping pressure
fluid!
– Always depressurize the hydraulic system
before starting work in the hydraulic system.
tective gloves, protective clothing, goggles).
Should pressure fluid penetrate the skin, imme-

Fig. 3 diate medical help is required.
WARNING!
Danger of burning by ignited hydraulic oil!
– Do not allow hydraulic oil to come into contact
CAUTION!
Health hazard caused by contact with hydraulic
oil!
– Do not inhale any oil vapours.
– Avoid contact.
CAUTION!
Danger of slipping on spilled oil!
agent.
ENVIRONMENT!
Oil is an environmentally hazardous substance!
– Always keep oil in proper containers.
agent.
– Dispose of oil and oil filter according to regula-
tions.
BW 220 D-5 21
1.2.4.5 Safety regulations and environmental protection regulations for handling coolants
WARNING!
Danger of scalding by hot fluid!
– Open the compensation tank only when the
engine is cold.
CAUTION!
Fig. 4 Health hazard caused by contact with coolant
and coolant additives!
– Do not inhale any fumes.
– Avoid contact.
CAUTION!
Danger of slipping on spilled coolant!
– Immediately bind spilled coolant with an oil-
binding agent.
ENVIRONMENT!
Coolant is an environmentally hazardous sub-
stance!
– Always keep coolant and coolant additives in
proper containers.
binding agent and dispose of it according to
regulations.
– Dispose of coolant according to regulations.
22 BW 220 D-5
1.2.4.6 Safety regulations and environmental protection regulations for handling battery acid
WARNING!
Danger of cauterization with acid!
– Do not allow clothes, skin or eyes to come into
contact with acid.
– Rinse off spilled battery acid immediately with
lots of water.
Fig. 5:
Rinse acid off clothes, skin or eyes immediately
with lots of clean water.
Immediately call for medical advice in case of cau-
terization.
WARNING!
Danger of injury caused by exploding gas mix-
ture!
– Remove the plugs before starting to recharge
the battery.
– Ensure adequate ventilation.
– Do not lay any tools or other metal objects on
the battery.
– Do not wear jewellery (watch, bracelets, etc.)
when working on the battery.
ENVIRONMENT!
Battery acid is an environmentally hazardous
substance!
– Dispose of battery and battery acid according
to regulations.
1.2.5 Load/transport the machine

Use only stable loading ramps of sufficient load bearing capacity.
Loading ramps and transport vehicle must be free of grease, oil,
snow and ice.
The ramp inclination must be less than the gradability of the
machine.
Make sure that persons are not endangered by the machine tipping
or sliding off. The instructing person must stand within the view of
the operator, but outside the danger area.
BW 220 D-5 23
Secure the machine with the articulation lock after driving it on the
transport vehicle or before loading it with a crane.
Do not use damaged or in any other way impaired lashing points.
Always use appropriate lifting and lashing means on the lifting and
lashing points.
Use lifting and lashing gear only in the prescribed direction of load
application.
Lifting tackle must not be damaged by machine components.
Secure the machine on the transport vehicle against rolling, slip-
ping and turning over.
Loads must only be attached and hoisted by an expert / capable
person.
Use only lifting gear and lifting tackle with sufficient load bearing
capacity for the weight to be loaded.
Fasten the lifting gear only at the specified lifting points.
Danger to the life of persons if they step or stand under a sus-
pended load.
When lifting the machine avoid uncontrolled movements of the
load. If necessary hold the load with guide ropes.
After the transport loosen the articulation lock again, as otherwise
the machine wouild not be steerable.
1.2.6 Starting up the machine

1.2.6.1 Prior to commissioning
Only use machines which have been serviced at regular intervals.
Become acquainted with the equipment, the indicators and control
elements, the working principle of the machine and the working
area.
Use your personal protective equipment (hard hat, safety boots, if
necessary also goggles and ear protection).
Make sure that the machine is equipped with the required lighting
according to the requirements of the application.
Do not take any loose objects with you or fasten them to the
machine.
Before mounting the machine check whether:
n persons or obstructions are beside or under the machine;
n the machine is free of oily and combustible materials;
n all access steps, grips and platforms are free of obstacles,
grease, oils, fuel, dirt, snow and ice;
n all safety elements are in place;
n all maintenance flaps and doors are closed and locked.
Climb onto or off the machine only when the machine is standing.
Use the existing access steps and grips.
24 BW 220 D-5
When climbing on and off the machine use the three-point support
method: Always keep two feet and one hand or one foot and two
hands on the machine.
Never jump off the machine.
Before commissioning, carry out all required visual inspections and
function tests.
If the tests reveal damage or other defects, the machine must not
be operated until these have been rectified.
Do not operate the machine with defective indicators and control
elements.
1.2.6.2 Starting the engine

The machine must only be started and operated from the driver’s
seat.
Before starting and moving the machine, make sure that there is
nobody in the danger zone.
To start, set all control levers to “neutral position”.
Do not use any starting aids like start pilot or ether.
The machine must not be operated with damaged, missing or non-
functional safety installations.
After starting check all display instruments.
Do not inhale exhaust fumes, because they contain toxic sub-
stances, which could cause damage to health, unconsciousness or
even death.
For operation in closed or partly closed rooms ensure adequate
ventilation.
1.2.6.3 Starting the engine with jump leads

Connect positive with positive and negative with negative (ground
cable) – always connect the ground strap last and disconnect it
first! A wrong connection will cause severe damage in the electric
system.
Do not start the engine by shorting the electric terminals on the
starter motor, because the machine may start to drive immediately.
1.2.7 Driving the machine; working operation

1.2.7.1 Driving the machine
Always wear the seat belt when driving.
Only drive on load-bearing surfaces.
Do not drive on ice and snow.
BW 220 D-5 25
If the machine has touched high-voltage power lines:

n Do not leave the driver’s stand
n Warn others from coming close to or touching the machine
n If possible, drive the machine out of the danger zone
n Have the power switched off.
Operate the machine only from the driver’s stand.
Keep the cabin doors closed.
Do not adjust the driver’s seat while driving.
Do not climb onto or off the machine while the machine is driving.
Do not use the machine to transport persons.
In case of unusual noises and development of smoke perform
trouble shooting to determine the cause and have the fault cor-
rected.
Match the speed to the working conditions.
Do not make extreme steering movements when driving at high
speed: danger of tipping over!
Always give way to loaded transport vehicles.
Switch the lights on if visibility is poor.
Always keep a safe distance to excavation pit borders, embank-
ments and edges.
Refrain from any work that could adversely affect the stability of the
machine.
Always keep a sufficient distance when passing through subways,
under bridges, tunnels, electric power lines, etc.
1.2.7.2 Driving up and down slopes

Do not drive on gradients or slopes exceeding the maximum gra-
deability of the machine Ä Chapter 2 ‘Technical data’ on page 63.
Drive extremely carefully on gradients and always directly up or
down the slope.
Soil conditions and weather influences impair the gradeability of
the machine.
Wet and loose soil considerably reduces traction of the machine on
inclinations and slopes. Increased danger of accident!
26 BW 220 D-5
1.2.7.3 Cross-slope
The tipping angle was measured statically on level, hard ground
with the machine stopped and without steering.
The max. permissible inclination of the machine may be limited by
the max. permissible slanted position of the engine.
The specified angle must not be exceeded.
With loose soil, acceleration/deceleration, running vibration,
steering or attached accessories the tipping angle may be consid-
erably lower.
Driving across slopes should therefore be strictly avoided, because
of the high risk of tipping over and the related risk of severe or
Fig. 6: Maximum cross-slope even fatal accidents.
1.2.7.4 Working with vibration

When compacting with vibration you must always check the effect
of the vibration on nearby buildings and underground supply lines
(gas, water, sewage, electric power). If necessary stop compacting
with vibration.
Do not activate the vibration on hard (frozen, concrete) ground.
Components may get damaged.
1.2.7.5 Parking the machine

Park the machine on horizontal, level, firm ground.
Before leaving the machine:
n shift all control levers to “Neutral position”, “Off” or “0”,
n apply the parking brake,
n shut down the engine, pull off the ignition key,
n pull off the main battery switch,
n secure the machine against unauthorized use.
Do not jump off the machine, but use hand grips and access steps.
Mark machines, which could be in the way, with a clearly visible
sign.
When parking on ascents or descents use appropriate means to
secure the machine against rolling.
1.2.8 Refuelling
Do not inhale any fuel fumes.
Refuel only with the engine shut down.
Do not refuel in closed rooms.
No open fire, do not smoke.
BW 220 D-5 27
Static charges may be generated in the fuel as it passes through

the filling system. The discharge of these charges in the presence
of combustible vapours can cause fire or an explosion.
Ultra-low sulphur diesel fuel poses a higher risk of combustion
caused by the static charging than diesel fuel with a higher sulphur
content.
You should therefore always make sure that the filling system is
properly grounded and that there is equipotential bonding to the
machine. If necessary use a connecting cable between filling
system and vehicle ground.
Monitor the entire refuelling process.
Do not spill any fuel. Collect leaking fuel, do not let it seep into the
ground.
Wipe off spilled fuel. Keep dirt and water away from the fuel.
A leaking fuel tank can cause an explosion. Ensure tight fit of the
tank cover; if necessary replace immediately.
1.2.9 Emergency procedures

1.2.9.1 Actuating the emergency stop switch
In events of emergency and in case of danger actuate the emer-
gency stop switch immediately.
The machine is braked immediately, the engine is shut down.
Restart the machine only after the danger that caused the actua-
tion of the emergency stop switch has been eliminated.
In case of frequent use the wear on the multi-discs brakes will be
very high, you should therefore never use the emergency stop
switch as a service brake.
1.2.9.2 Disconnecting the battery

In events of emergency, e.g. in case of a cable fire, disconnect the
battery from the vehicle network.
Pull out the main battery switch or lift off the battery pole to do so.
1.2.9.3 Towing the machine

Tow the machine only in a case of emergency or to avoid an acci-
dent.
Before releasing the parking brake apply suitable measures to
secure the machine against unintended rolling.
Use a tractor vehicle with sufficient traction and braking power for
the unbraked towed load.
If no tow bar is used, towing is only permitted uphill.
28 BW 220 D-5
Before starting towing operations make sure that the fastening

means are able to withstand the load and are fastened at the
points provided for this purpose.
Before removing the towing facility apply appropriate measures to
secure the machine against unintended rolling.
1.2.10 Maintenance work

1.2.10.1 Preliminary remarks
Always carry out the prescribed maintenance work and mainte-
nance measures on time in order to maintain the safety, opera-
tional readiness and long service life of the machine.
The machine must only be serviced by qualified personnel author-
ised by the operating company.
1.2.10.2 Working on hydraulic lines

Before the hydraulic system can be depressurized, machine parts
with hydraulic movement must be safely set down or secured to
prevent them from falling.
Relieve hydraulic pressures before working on hydraulic lines.
Hydraulic oil escaping under pressure can penetrate the skin and
cause severe injury. Immediately call for medical assistance if
injured by hydraulic oil.
Do not step in front of or behind the machine when performing
adjustment work in the hydraulic system.
Do not change the setting of pressure relief valves.
Drain the hydraulic oil at operating temperature – danger of
scalding!
Any hydraulic oil must be collected and disposed of in an environ-
mentally friendly way.
Always collect and dispose of hydraulic oils separately.
Do not start the engine after draining off the hydraulic oil. Once all
work is completed (with the system still depressurized!) check all
connections and fittings for leaks.
Hydraulic hoses must be visually inspected at regular intervals.
Do not mix up hoses by mistake.
Only genuine replacement hydraulic hoses ensure that the correct
hose type (pressure range) is used at the right location.
1.2.10.3 Working on the engine

Do not work on the fuel system while the engine is running -
danger to life due to high pressures!
BW 220 D-5 29
Wait until the engine has stopped, then wait approx. another 15
minutes.
Keep out of the danger zone during the initial test run.
In case of leaks return to the workshop immediately.
Drain the engine oil at operating temperature – danger of scalding!
Wipe off spilled oil, collect leaking oil and dispose of it in an envi-
ronmentally friendly way.
Store used filters and other oil contaminated materials in a sepa-
rate, specially marked container and dispose of them in an environ-
mentally friendly way.
The settings for idle speed and highest speed must not be
changed, since this would affect the exhaust gas values and cause
damage to engine and power train.
Engine and exhaust system work at high temperatures. Keep com-
bustible materials away and do not touch any hot surfaces.
Check and change coolant only when the engine is cold. Collect
coolant and dispose of it in an environmentally friendly way.
1.2.10.4 Maintenance work on electric components and battery

Before starting to work on electric parts of the machine disconnect
the battery and cover it with insulating material.
Do not use fuses with higher ampere ratings and do not bridge
fuses.
When working on the battery, smoking or open fire is prohibited!
Do not lay any tools or other metal objects on the battery.
Do not wear jewellery (watch, bracelets, etc.) when working on the
battery.
The connection cables of the battery must not touch or rub against
machine parts.
1.2.10.5 Working on the air conditioning

Faults on the air conditioning should only be remedied by author-
ized service personnel.
Do not perform welding work in the vicinity of the air conditioning.
Danger of explosion!
Do not release refrigerant into the atmosphere, but dispose of it in
line with environmental regulations.
1.2.10.6 Working on wheels and tyres

Explosion-like bursting of tyres or parts of tyres and rims can cause
most severe or even fatal injuries.
30 BW 220 D-5
Do not drive with damaged wheels or tyres.

Install the tyres only if you are sufficiently experienced and with the
right tools at hand. If necessary have the tyres assembled in a
qualified workshop.
Always ensure the correct tyre pressure and do not exceed the
specified maximum pressure.
When checking the tyre pressure stand in the extended path of the
tyre track. Use an at least 6 meter air hose, so that you can keep a
safe distance to the tyre.
Always consider the heavy weight of a wheel during disassembly
and assembly. Use a crane or forklift truck equipped with suitable
claws or a belt-type hoisting device.
1.2.10.7 Cleaning work

Do not perform cleaning work while the motor is running.
Allow the engine to cool down before starting cleaning work on
engine and exhaust system.
Never use gasoline or other easily inflammable substances for
cleaning.
When cleaning with a high pressure cleaner, do not subject elec-
trical parts and insulation material to the direct jet of water, or cover
them beforehand.
Do not guide the water jet into the exhaust pipe and into the air
filter.
1.2.10.8 Measures for longer shut-down periods

If the machine is taken out of operation for a longer period of time,
various conditions must be met and maintenance work must be
carried out both before and after shut-down Ä Chapter 6.1.9.8.3
‘Measures prior to extended shut-down period’ on page 461.
It is not necessary to define a maximum storage period if these
measures have been performed.
1.2.10.9 After maintenance work

Reassemble all guards and protective devices.
Close all maintenance flaps and maintenance doors again.
1.2.11 Repair
Identify a defective machine with a warning sign.
Only operate the machine after it has been repaired.
BW 220 D-5 31
Repairs must only be performed by an expert/qualified person.

When replacing safety relevant components, only original spare
parts must be used.
1.2.12 Signage
Keep stickers and signage in good and legible condition and
comply with their meaning.
Replace damaged and illegible stickers or signage immediately.
WARNING
California Proposition 65 Warning
This product contains chemicals

that cause cancer + chemicals
that are reproductive toxicants
B-586-0485
Fig. 7
32 BW 220 D-5
Engine Coolant
Spec.: • MB 325.5 Diesel
• Deutz DQC CC-14
Part No.: 009 940 03 (20 l)
Hydraulic Oil
B-586-0367
Fig. 8
BW 220 D-5 33
B-586-0400
Fig. 9
Warning sticker - Danger of crushing
Fig. 10
Warning sticker - Follow operating instructions
Fig. 11
34 BW 220 D-5
Warning sticker – California Proposition 65
WARNING
California Proposition 65 Warning
This product contains chemicals

that cause cancer + chemicals
that are reproductive toxicants
B-DEC-0316
Fig. 12
Prohibition sticker - High pressure cleaning
Fig. 13
Instruction sticker - Always wear your seat belt
Fig. 14
Information sticker - Emergency exit
Fig. 15
BW 220 D-5 35
Information sticker - Lashing point
Fig. 16
Information sticker - Lifting point
Fig. 17
Information sticker - Engine oil drain
B-DEC-0211
Fig. 18
Information sticker - Coolant drain
B-DEC-0212
Fig. 19
36 BW 220 D-5
Information sticker - Hydraulic oil drain
B-DEC-0210
Fig. 20
Information sticker - Filler opening for hydraulic oil
Hydraulic Oil
B-DEC-0214
Fig. 21
Information sticker - Filler opening for diesel
Diesel
B-DEC-0215
Fig. 22
Information sticker - Disconnecting the battery
B-DEC-0219
Fig. 23
BW 220 D-5 37
Information sticker - Main battery switch plus side
Fig. 24
Information sticker - Vehicle voltage 12 V
Fig. 25
Information sticker - Guaranteed sound capacity level
Fig. 26
Information sticker - Coolant

Engine Coolant
Spec.: • MB 325.5
• Deutz DQC CC-14
Part No.: 009 940 03 (20 l)
B-DEC-0221
Fig. 27
38 BW 220 D-5
Machine type plate (example)
Fig. 28
1.2.13 Danger zones
3m 3m
B-586-0456
Fig. 29
The area around the machine is a danger zone.

Before starting the machine and during operation, the driver / oper-
ator must ensure that nobody is in the danger zone.
Give warning signals, if necessary. Stop work immediately if per-
sons are in the danger zone.
BW 220 D-5 39
1.2.14 Safety Components
10
5
8
6
7
B-586-0487
Fig. 30
1 Engine hood
2 Backup protection
3 Main battery switch
4 Fan protection (optional equipment)
5 Safety belt
6 Control system
7 Articulation lock
8 Operator detection system
9 Emergency stop switch
10 ROPS/FOPS cabin (optional equipment)
40 BW 220 D-5
General information – Maintenance and repair
1.3 Maintenance and repair

1.3.1 Notes on repair
1.3.1.1 General repair instructions
NOTICE!
Ensure strict cleanliness when performing
repair work!
– No foreign objects should enter into open sys-
tems.
– Thoroughly clean the area around the affected
components.
– Dry off wet locations with compressed air.
Before removing or disassembling parts, assembly groups, compo-

nents or hoses mark these parts for easier assembly.
1.3.1.1.1 Repair notes for electrics

Electrics and welding
NOTICE!
Electrical components may get damaged by
welding work!
– Always remove the main battery switch.
– Disconnect the batteries and connect negative
and positive cables.
– Pull the plugs off the control units.
Always fasten the earth clamp of the welding unit in the immediate
vicinity of the welding location.
When choosing the location for the earth clamp make sure that the
welding current will not pass through joints or bearings.
Battery
Maintenance free batteries also need care. Mainte-
nance free only means that the fluid level does not
need to be checked.
Every battery has a self-discharge, which may, if
not checked occasionally, even cause damage to
the battery as a result of exhaustive discharge.
Exhausted batteries (batteries with formation of
sulphate on the plates) are not covered under war-
ranty!
n When removing a battery always disconnect the minus pole

before the plus pole. When installing the battery connect the
minus pole after the plus pole to avoid short circuits.
n Assemble the battery terminal clamps without force.
BW 220 D-5 41
n Always keep battery poles and terminal clams clean to avoid

high transition resistances when starting and the related devel-
opment of heat.
n Make sure the battery is properly fastened in the vehicle.
Generator n Before removing the generator you must disconnect the ground
cable from the minus pole of the battery while the ignition is
switched off. Do not disconnect the generator while the engine
is running, because this may cause extremely high voltage
peaks in the vehicle wiring system ("Load Dump"), which could
possibly damage control units, radios or other electronic equip-
ment.
n When removing the battery cable, the B+-nut underneath on
the generator side may also be loosened. This nut must in this
case be retightened.
n When connecting e.g. the battery cable to the terminal of the
generator you must make sure that the polarity is correct (gen-
erator B+ to the + pole of the battery). Mixing up the polarities
by mistake causes short circuit and damage to the rectifier ele-
ments - the generator will be out of function.
n The generator can only be operated with the battery con-
nected. Under special conditions emergency operation without
battery is permitted, the lifetime of the generator is in such
cases especially limited.
n Plus and minus cables must be disconnected during rapid
charging of the battery or electric welding on the vehicle.
n When cleaning the generator with a steam or water jet make
sure not to direct the steam or water jet directly on or into the
generator openings or ball bearings. After cleaning the gener-
ator should be operated for about 1 - 2 minutes to remove any
deposits of water from the generator.
Starter n So-called jump starting (using an additional external battery)

without the battery connected is dangerous. When discon-
necting the cables from the poles high inductivities (arcs,
voltage peaks) may occur and destroy the electrical installa-
tion.
n For purposes like e.g. purging the fuel systems, starters may
be operated for maximum 1 minute without interruption. Then
you should wait for at least 30 minutes (cooling down) until
trying again. During the 1 minute starting period this process
should not be interrupted.
n Starter motors must not be cleaned with high pressure steam
cleaning equipment.
n The contacts on starter terminals 30, 45, 50 must be protected
against unintended shorting (jump protection).
n When replacing the starter the ring gear on the engine flywheel
must be checked for damage and its number of teeth - if nec-
essary replace the ring gear.
n Always disconnect the battery before starting assembly work in
the starter area of the engine or on the starter itself.
42 BW 220 D-5
1.3.1.1.2 Repair notes for hydraulics

Please note
Cleanliness is of utmost importance. Dirt and other
contaminations must strictly be kept out of the
system.
n Connections and screw fittings, filler neck covers and their

immediate surrounding areas must be cleaned before removal.
n Before loosening hoses, pipe lines etc. relieve all pressure
from the system.
n During repair work keep all openings closed with clean plastic
plugs and caps.
n Never run pumps, motors and engine without oil or hydraulic
oil.
n When cleaning hydraulic components take care not to damage
any fine machined surfaces.
n Chemical and rubber dissolving cleansing agents may only be
used to clean metal parts. Do not let such substances come in
contact with rubber parts.
n Rinse of cleaned parts thoroughly, dry them with compressed
air and apply anti-corrosion oil immediately. Do not install parts
that show traces of corrosion.
n Avoid the formation of rust on fine machined parts caused by
hand sweat.
n Use new O-rings or seal rings for reassembly.
n Use only hydraulic oil as sliding agent when reassembling. Do
not use any grease!
n Use only the specified pressure gauges. Risk of damaging the
pressure gauges under too high pressure.
n Check the hydraulic oil level before and after the work.
n Use only clean hydraulic oil in strict compliance with the speci-
fication in the operating and maintenance instructions to fill the
hydraulic system.
n Check the hydraulic system for leaks, if necessary find and rec-
tify the cause.
n Before taking new hydraulic components into operation fill
these with hydraulic oil as specified in the operating and main-
tenance instructions.
n After changing a hydraulic component thoroughly flush, refill
and bleed the complete hydraulic system.
n Perform pressure tests at operating temperature of the
hydraulic oil (approx. 40 °C).
n After the completion of all tests perform a test run and then
check all connections and fittings for leaks with the engine still
stopped and the hydraulic system depressurized.
Before commissioning n Fill the housings of hydraulic pumps and motors with hydraulic
oil. Use only hydraulic oils according to the specification in the
maintenance instructions.
n After changing a component flush the hydraulic system as
described in the flushing instructions.
BW 220 D-5 43
Taking into operation n Bleed the hydraulic circuits.

n Start up the hydraulic system without load.
n Check the hydraulic oil level in the tank, if necessary top up
with hydraulic oil as specified in the operating and maintenance
instructions or drain oil off into a suitable container.
After taking into operation n Check fittings and flanges for leaks.
n After each repair check all adjustment data, system pressures,
rotational speeds and nominal values in the hydraulic system,
adjust if necessary.
n Do not adjust pressure relief valves and control valves to
values above their specified values.
1.3.1.1.3 Repair notes for Common Rail engines

Special requirements with respect to cleanliness in the fuel system
do apply for commissioning, maintenance and repair work, particu-
larly for engines with the Common Rail System. Contamination like
dirt, welding residues or similar can lead to the failure of individual
components and adversely affect engine operation.
Spare parts should be left in their original packaging as long as
possible and should only be unpacked just before use.
When parts are unpacked any connections must be closed with
suitable plugs or caps, in order to prevent contamination of hose
connections. If e.g. fuel hoses are connected to one side, while the
second side cannot yet be connected, there is a danger of dirt
entering into the system. The free connection must in this case
also be appropriately closed.
Fig. 31: Example
Notes and measures to be applied n The fuel system must be closed. Visual examination for leaks /
before starting work in the fuel damage in the fuel system.
system n Before starting work in the fuel system clean the complete
engine and the engine compartment with the system still
closed.
n The engine should be dry before work is started in the fuel
system.
n Blow drying with compressed air is only permitted while the fuel
system is still closed.
44 BW 220 D-5
n When using steam cleaning equipment cover control unit,

cable plugs, all other electrical connections and the generator
beforehand and do not expose these items to the direct steam
jet.
n Electrical plug connections must be plugged in during jet
cleaning.
n Remove loose parts (e.g. paint scales that may have come off
during assembly work) with an industrial vacuum cleaner or
any means of extraction.
n Vacuum cleaning equipment must generally be used for
cleaning when the fuel system is open.
n Perform work on the fuel system only in a clean environment
(no dust, no grinding or welding work). Avoid draughts (dust).
The workshop floor must be cleaned at regular intervals. No
brake or power test stand should be present or operated in the
same room.
n Air movements, which could swirl up dust, such as brake
repairs or starting of engines, must be strictly avoided.
n For work, such as the removal and assembly of defective com-
ponents on the Common Rail System, it is highly recom-
mended to cordon off a dedicated area in the workshop. This
area must be spatially separated from other areas (which are
used for general vehicle repairs, like brake repairs)
n No general machine tools should be operated in this room.
n Periodic cleaning of this workshop area is obligatory, draughts,
ventilation system and heating blowers must be minimized.
n Engine compartment area where dirt particles could come
loose, should be covered with new, clean foil.
n Working means and tools must be cleaned before being used
for work. Use only tools without damaged chromium coating, or
tools without chromium coating.
Notes and measures to be applied n Wear clean working clothes.

during work in the fuel system n Use only lint-free cleaning cloths for work in the fuel system.
any means of extraction. Vacuum cleaning equipment must
generally be used for cleaning when the fuel system is open.
n Do not use any previously used cleaning or testing fluids for
cleaning.
n The use of compressed air for cleaning is prohibited when the
fuel system is open.
n Work on disassembled components must only be carried out at
a specially furnished work place.
n When removing or assembling components you should not use
any materials from which particles or fibres could flake off
(cardboard, wood, towels).
n Dismantled parts must only be wiped off with clean, lint-free
cloths if required. No dirt particles must be wiped into the com-
ponents.
BW 220 D-5 45
n Close openings on components and engine immediately with

suitable plugs/caps.
n Plugs/caps must only be removed just before the installation.
n Keep plugs/caps in their original packaging, where they are
protected against dust and dirt, dispose of after one time use.
n Take new parts out of their original packaging just before instal-
lation.
n Removed components must be stored in new, sealable bags or
– if available – in the packaging material of the new compo-
nents.
n Always use the original packaging material of the new part to
return the disassembled old component.
Notes and measures concerning n For work, such as the removal and assembly of defective com-
the workshop area ponents on the Common Rail System, it is highly recom-
mended to cordon off a dedicated area in the workshop. This
area must be spatially separated from other areas (which are
used for general vehicle repairs, like brake repairs)
n The workshop floor must be sealed or tiled.
n No welding equipment, grinding machines, general machine
tools, brake or power test benches must be operated in this
room.
n Periodic cleaning of this workshop area is obligatory, draughts,
ventilation system and heating blowers must be minimized.
Notes and measures for work place n A special work place must be set up for work on disassembled
and tools in the workshop components.
n Clean disassembly and assembly tools at regular intervals and
keep these in a closed tool cabinet.
any means of extraction.
1.3.1.1.4 Repair notes for gaskets and mating surfaces

Leaking sealing faces can mostly be traced back to incorrect
assembly of seals and gaskets.
n Before assembling a new seal or gasket make sure that the
sealing surface is free of pitting, flutes, corrosion or other
damage.
n Inappropriately stored or handled seals (e.g. hanging from
hooks or nails) must under no circumstances be used.
n Install seals and gaskets only with sealing compound, grease
or oil, if this is specifically specified in the repair instructions.
n If necessary remove any old sealing compound before assem-
bling. For this purpose do not use any tools that could damage
the sealing surfaces.
46 BW 220 D-5
n Sealing compound must be applied thin and evenly on the cor-

responding surfaces; take care that the compound does not
enter into oil galleries or blind threaded bores.
n Examine the contact faces for scratches and burrs, remove
these with a fine file or an oilstone; take care that no grinding
dust and dirt enters into tapped bores or enclosed components.
n Blow out lines, ducts and gaps with compressed air, replace
any O-rings and seals that have been dislodged by the com-
pressed air.
Assembly of radial seals

1. Lubricate sealing lips (2) with clean grease; in case of double
seals fill the space between the sealing lips with a generous
amount of grease.
2. Slide the seal over the shaft, with the lip facing towards the
fluid to be sealed.
NOTICE!
Use an assembly sleeve.
If possible, use an assembly sleeve (1) to
protect the lip from being damaged by
Fig. 32 sharp edges, threads or splines. If no
assembly sleeve is available, you should use
a plastic tube or adhesive tape to prevent the
sealing lip from being damaged.
3. Lubricate the outer rim of the seal (3) and press it flat on the
housing seat.
4. Press or knock the seal into the housing, until it is flush with
the housing surface.
NOTICE!
Use an assembly bell.
If possible, use an "assembly bell" (1 ), to
make sure that the seal will not skew. In
some cases it may be advisable to assemble
the seal into the housing first, before sliding it
over the shaft. Under no circumstances
should the full weight of the shaft rest on the
Fig. 33 seal.
If you have no proper service tools at hand,
use a suitable drift punch with a diameter
which is about 0.4 mm smaller than the outer
diameter of the seal. Use VERY LIGHT
blows with the hammer if no press is avail-
able.
BW 220 D-5 47
1.3.1.1.5 Repair notes for ball and roller bearings

n If one bearing of a pair of bearings shows defects, we highly
recommend the replacement of both bearings.
n Remove any lubricant residues from the bearing to be exam-
ined by washing it with a suitable degreasing agent.
n Check balls or rollers, running surfaces, outer faces of outer
races and inner faces of inner races for visible damage. If nec-
essary, replace the bearing.
n Check the bearing for clearance and resistance between the
inner and outer races, replace if necessary.
n Lubricate the bearing with the recommended type of grease
before assembly or reassembly.
n On greased bearings (e.g. wheel bearings) fill the space
between the bearing and the outer seal with the recommended
type of grease before assembling the seal.
n Check shaft and bearing housing for discolouration or other
signs of movement between bearing and seats.
n Make sure that shaft and housing are free of burrs before
Fig. 34 assembling the bearing.
n Always mark the individual parts of separable bearings (e.g.
taper roller bearings) to enable correct reassembling. Never
assemble the rollers to an outer race that has already been
used, replace the complete bearing instead.
NOTICE!
When assembling the ball or roller bearing to the
shaft load must only be applied to the inner race
(1).
When fitting the bearing into the housing load must
only be applied to the outer race (2).
Fig. 35
1.3.1.1.6 Feather keys and keyways

1. Clean the feather key, examine it and only use it again if it
had not been damaged.
2. Deburr and clean the edges of keyways thoroughly before
reassembling the feather key.
Fig. 36
48 BW 220 D-5
1.3.1.1.7 Repair notes for cotter pins

Cotter pins
In places where cotter pins are used, these must be reassembled.
Cotter pins must generally be renewed after disassembly.
Cotter pins must be assembled as shown in the illustration, unless
specified differently.
Fig. 37
1.3.1.1.8 Repair notes for screws and nuts
NOTICE!
Tighten screws and nuts in accordance with the
values in the following tables. Tightening torques
deviating from the ones in the table are specially
mentioned in the repair instructions.
Damaged screws must not be used again.
Recutting threads with thread cutters or taps
adversely affects the strength and leak tightness of
the screw joint. Damaged or corroded thread
pitches can cause incorrect torque value readings.
Self-locking nuts must generally be replaced after
disassembly.
The use of screws with too high strength can
cause damage!
n Nuts of a higher strength can generally be used instead of nuts

of a lower strength classification.
n When checking or retightening screw joints to the specified
tightening torque you should first relieve by a quarter turn and
then tighten to the correct torque.
n Before tightening you should slightly oil the thread, in order to
ensure low friction movement. This, however, does not apply
for self-locking nuts.
n Make sure that no oil or grease will enter into blind tapped
bores. The hydraulic power generated when turning in the
screw could cause breakage of the part in question.
1.3.1.1.9 Strength classes, metric screws and nuts

Strength classes, metric screws The strength classes (from 3.6 to 12.9) are specified for all strength
classes from a nominal diameter of 5 mm. The corresponding iden-
tification can be found where the shape of the screw permits it.
BW 220 D-5 49
Example: A screw is marked with 12.9.
Fig. 38: Identification of screws
Strength classes of metric nuts Nuts are differentiated by three load groups. Each load group has
a special designation system for the strength class assigned, so
that the load group can be clearly identified.
Nuts (1) for screw connections with full load capacity
In a connection with a screw, these nuts (1) must be able to bear
the full pre-load at the yield point.
Nut height above 0.8 d (d = nominal dimension).
Fig. 39: Identification of nuts

Strength class of nut Strength class of associated
screw
4 3.6, 4.6, 4.8
5 3.6, 4.6, 4.8
5.6, 5.8
6 6.8
8 8.8
9 9.8
10 10.8
12 12.8
Nuts (2) for screw connections with limited load capacity

The preceding "0" indicates that, due to their low height, nuts 2
Ä Fig. 39 in this group are only able to withstand the force of a
screw to a limited extent.
Nut height below 0,8 d (d = nominal dimension).
Nuts (3) for screw connections without specified load capacity
This standard contains strength classes (hardness classes) for
nuts 3 Ä Fig. 39, for which no load values can be specified, e.g.
because of their shape and dimensions, but which can only be
classified by their hardness.
50 BW 220 D-5
Nut height below 0,5 d (d = nominal dimension).
Identification in clock system

For small nuts Ä Fig. 40 the clock system can be used for identifi-
cation.
n The 12 o'clock position is identified by a dot or the manufactur-
er's symbol.
n The strength class is identified by a dash (b).
Fig. 40: Identification of nuts in clock
system
1.3.1.1.10 Identification of UNF-threads

Identification of UNF-threads
Studs (1)
At the outmost end a short end of the component is reduced to its
core diameter.
Nuts (2).
An uninterrupted series of stamped in circles parallel to the axis of
the nut on a hexagon area.
Screws (3)
The screw head is marked with a stamped in, round cavity.
Fig. 41
1.3.1.2 Tightening torques

The values specified in the table apply for screws:
n black oiled
n zinc plated
n zinc flake coated
The difference between Withworth and UNF/UNC

threads is the fact that UNF and UNC threads have
60° flanks, as the metric ISO-thread, whereas
Withworth has a flank of only 55°.
Tightening torques for screws with metric unified thread

Tightening torques Nm (Coefficient of friction µ tot. = 0.14)
Screw dimension
8.8 10.9 12.9
M4 3 5 5
M5 6 9 10
M6 10 15 18
M8 25 35 45
BW 220 D-5 51

Screw dimension
8.8 10.9 12.9
M10 50 75 83
M12 88 123 147
M14 137 196 235
M16 211 300 358
M18 290 412 490
M20 412 578 696
M22 560 785 942
M24 711 1000 1200
M27 1050 1480 1774
M30 1420 2010 2400
Tightening torques for screws with metric unified fine thread

Screw dimension
8.8 10.9 12.9
M8 x 1 26 37 48
M10 x 1.25 52 76 88
M12 x 1.25 98 137 162
M12 x 1.5 93 127 152
M14 x 1.5 152 216 255
M16 x 1.5 225 318 383
M18 x 1.5 324 466 554
M20 x 1.5 461 628 775
M22 x 1.5 618 863 1058
M24 x 2 780 1098 1294
M27 x 2 1147 1578 1920
M30 x 2 1568 2254 2695
Tightening torques for screws treated with anti-seizure paste OKS 240 (copper paste)
Tightening torques Nm
Screw dimension
8.8 10.9 12.9
M16 169 240 287
M16 x 1.5 180 255 307
M18 232 330 392
52 BW 220 D-5
Tightening torques Nm
Screw dimension
8.8 10.9 12.9
M18 x 1.5 260 373 444
M20 330 463 557
M20 x 1.5 369 502 620
M22 448 628 754
M22 x 1.5 495 691 847
M24 569 800 960
M24 x 2 624 879 1036
M27 840 1184 1520
M27 x 2 918 1263 1536
M30 1136 1608 1920
M30 x 2 1255 1804 2156
4² 276 388 464

3/ - 10 UNC
4² 308 432 520

3/ - 16 UNC
Anti-seizure paste (copper paste) is used for the

assembly of screw connections, which are
exposed to high temperatures and corrosive
effects. Prevents seizure and corrosion.
Tightening torques for wheel nuts (fine thread)

Tightening torques Nm (Coefficient of friction µ
Thread diameter tot. = 0.14)
10.9
M12 x 1.5 100
M14 x 1.5 150
M18 x 1.5 300–350
M20 x 1.5 400 - 500
M22 x 1.5 500–600
BW 220 D-5 53
Tightening torques for screws with UNC thread, UNC Unified Coarse Thread Series = American Uni-
fied Coarse Thread
Screw dimension
8.8 10.9 12.9
4² 11 15 19
1/ - 20
16² 23 32 39
5/ - 18
8² 39 55 66
3/ - 16
16² 62 87 105
7/ - 14
2² 96 135 160
1/ - 13
16² 140 200 235

9/ - 12
8² 195 275 330

5/ - 11
4² 345 485 580

3/ - 10
8² 560 770 940

7/ -9
1² - 8 850 1200 1450
1 1/8² - 7 1200 1700 2000
1 1/4² - 7 1700 2400 2900
1 3/8² - 6 2200 3100 3700
1 1/2² - 6 3000 4200 5100
Tightening torques for screws with UNF thread, UNF Unified National Fine Thread Series = American
Unified Fine Thread
Screw dimension
8.8 10.9 12.9
4² 13 18 22
1/ - 28
16² 25 35 42
5/ - 24
8² 45 63 76
3/ - 24
16² 70 100 120

7/ - 20
2² 110 155 185

1/ - 20
16² 155 220 260

9/ - 18
8² 220 310 370

5/ - 18
4² 385 540 650

3/ - 16
8² 620 870 1050

7/ -14
1² - 12 930 1300 1600
54 BW 220 D-5

Screw dimension
8.8 10.9 12.9
1 1/8² - 12 1350 1900 2300
1 1/4² - 12 1900 2700 3200
1 3/8² - 12 2600 3700 4400
1 1/2² - 12 3300 4600 5600
BW 220 D-5 55
Tightening torques for hydraulic fittings with metric thread - series “L” (pressures up to 250 bar)
Thread Spanner width Tightening torque [Nm]
M12 x 1.5 14 15
M14 x 1.5 17 20
M16 x 1.5 19 30
M18 x 1.5 22 35
M22 x 1.5 27 65
M26 x 1.5 32 80
M30 x 2 36 130
M36 x 2 41 160
M45 x 2 50 200
M52 x 2 60 250
Tightening torques for hydraulic fittings with metric thread - series “S” (pressures up to 400 bar)
M14 x 1.5 17 14
M16 x 1.5 19 25
M18 x 1.5 22 27
M20 x 1.5 24 48
M22 x 1.5 27 55
M24 x 1.5 30 65
M30 x 2 36 110
M36 x 2 46 140
M42 x 2 50 180
M52 x 2 60 220
Tightening torques for hydraulic fittings with UNF-thread (Unified Fine Thread)
16² 14 15
7/ - 20
2² 17 20
1/ - 20
16² 19 27
9/ - 18
4² 22 55
3/ - 16
8² 27 80
7/ - 14
1 1/16² - 12 32 110
56 BW 220 D-5

1 3/16² - 12 36 125
1 5/16² - 12 41 160
1 5/8² - 12 220
1 7/8² - 12 270
1.3.2 Preliminary remarks and safety notes
DANGER!
Danger to life caused by an operationally
unsafe machine!
– The machine must only be serviced by quali-
fied and authorized personnel.
– Follow the safety regulations for maintenance
work Ä Chapter 1.2.10 ‘Maintenance work’
on page 29.
WARNING!
Health hazard caused by fuels and lubricants!
– Safety regulations and environmental protec-
tion regulations must be followed when han-
dling fuels and lubricants Ä Chapter 1.2.4
‘Handling fuels and lubricants’ on page 18.
CAUTION!
Danger of being injured by the engine hood
dropping down!
– Always secure an opened engine hood.
Wear your personal protective equipment.

Park the machine on horizontal, level, firm ground.
Keep unauthorised persons away from the machine.
Perform maintenance work only with the engine shut down.
Make sure that the engine cannot be accidentally started during
maintenance work.
Do not touch hot components.
Thoroughly clean the machine and engine before starting mainte-
nance work.
Before mounting the machine, check whether all access steps,
grips and platforms are free of obstacles, grease, oils, fuel, dirt,
snow and ice.
BW 220 D-5 57
Use only the intended access steps and grips to mount the
machine.
For overhead maintenance work use the access steps and working
platforms provided or other secure means.
Do not step on machine parts which are not intended for this pur-
pose.
Always attach the articulation lock when working in the area of the
articulated joint.
Do not leave any tools or other objects, that could cause damage,
in or on the machine.
After maintenance work has been completed, dispose of fuels and
lubricants, filters, sealing elements and cleaning cloths in line with
environmental regulations.
After maintenance work is completed reinstall all protective
devices.
Close all maintenance flaps and doors after maintenance work has
been completed.
The terms right/left are always in relation to the

travel direction.
1.3.3 Preparations/concluding work

Certain maintenance tasks require preparations and concluding
activities.
This includes e.g. opening and closing maintenance flaps and
maintenance doors as well as securing certain components.
After this work close all maintenance flaps and doors again and
return all components to their operating condition.
1.3.3.1 Open and secure the engine hood

Opening the engine hood
1. Unlock the lock.
2. Press the button.
B-587-0041
Fig. 42
58 BW 220 D-5
Lower position
1. Pull the support out of the holding fixture and support the
hood.
B-586-0181
Fig. 43
Top position
1. Push the hood to top position.
2. Secure the engine hood with the split pin (1).
B-587-0042
Fig. 44
1.3.3.2 Engaging / releasing the articulation lock

1.3.3.2.1 Engaging the articulation lock
WARNING!
Danger of crushing by the articulating
machine!
– Do not step into the articulation area of the
machine while the engine is running.
1. Move the steering to middle position and stop the machine.

2. Shut down the engine, pull off the ignition key.
3. Engage the articulation lock and secure the bolt with the
spring pin.
Fig. 45
BW 220 D-5 59
1.3.3.2.2 Disengaging the articulation lock
WARNING!
Danger of crushing by the articulating
machine!
– Do not step into the articulation area of the
machine while the engine is running.
1. Loosen the articulation lock again, fix it in its receptacle and

lock the bolt with the spring plug.
Fig. 46
1.3.4 Parking the machine in secured condition

1. Drive the machine onto level, firm ground.
2. To stop the machine return the travel lever to the middle posi-
tion and shift it to the right to lock (parking brake position).
ð The parking brake warning light lights up.
NOTICE!
Danger of engine damage!
– Do not shut down the engine all of a sudden
from full load speed, but let it idle for about two
B-ELE-0285 minutes.
Fig. 47
3. Turn the ignition key to position “0” and pull it out.

4. Open and secure the engine hood Ä Chapter 1.3.3.1 ‘Open
and secure the engine hood’ on page 58.
B-ELE-0069
Fig. 48
60 BW 220 D-5
5. Turn the main battery switch anticlockwise and pull it out.

6. Close the engine hood and lock it if necessary.
B-SWI-0169
Fig. 49
BW 220 D-5 61
62 BW 220 D-5
Technical data
2 Technical data
BW 220 D-5 63
Technical data – Technical data
2.1 Technical data

Dimensions
H2
A W
O1 O2
D
B
L
B-587-0043
Fig. 50
A B D H H2 K L O1/2 S W
3255 2300 1600 2300 3040 495 6510 85 40 2130
(128) (91) (63) (91) (120) (19.5) (256) (3.3) (1.6) (84)
Dimensions in millimetres
(Dimensions in inches)
Weights
Max. operating weight 24900 kg
(54895) (lbs)
Operating weight with cabin 22100 kg
(48722) (lbs)
Axle load, drum 15200 kg
(33510) (lbs)
Axle load, wheels 6900 kg
(15212) (lbs)
Static linear load 71.4 kg/cm
(400) (pli)
64 BW 220 D-5
Travel characteristics
Travel speed (1) 0–4 km/h
(0–2.5) (mph)
(0–3.1) (mph)
(0–3.7) (mph)
Travel speed (4) 0-9 km/h
(0–5.6) (mph)
Max. gradeability without/with vibration (soil and weather 40/36 %
dependent)
Drive
Engine manufacturer Deutz
Type TCD 2012 L06
Cooling system Fluid
Number of cylinders 6
Rated power ISO 3046 150 kW
Rated power SAE J 1995 202 hp
Rated speed 2200 min-1
Electric system
Voltage 12 V
Tyres
Tyre size 23.1-26 12PR
Air pressure, nominal value 1.4 bar
(20) (psi)
Brakes
Service brake hydrostatic
Parking brake hydro-mechanical
BW 220 D-5 65
Steering
Type of steering Oscill.-articul.
Steering angle +/- 35 °
Oscillation angle +/- 12 °
Inner track radius 4230 mm
(167) (in)
Exciter system
Drive system hydrostatic
Frequency (1/2) 26/31 Hz
(1560/1860) (vpm)
Amplitude (1/2) 2.10/1.20 mm
(0,083/0.047) (in)
Centrifugal force (1/2) 328/240 kN
(73737/53954) (lbf)
Filling capacities
Fuel (diesel) 280 l
(74) (gal us)
2.1.1 Noise and vibration data

The following noise and vibration data were determined in accord-
ance with the following guidelines under equipment specific condi-
tions and by using harmonized standards:
n EU Machine Directive edition 2006/42/EU
n Noise Emission Directive 2000/14/EU, Noise Protection Direc-
tive 2003/10/EU
n Vibration Protection Directive 2002/44/EU
During operation these values may vary because of the prevailing
operating conditions.
2.1.1.1 Noise data

Sound pressure level at the opera- LpA = 75 dB(A), determined acc. to ISO 11201 and EN 500.
tor's stand
Guaranteed sound power level LWA = 110 dB(A), determined acc. to ISO 3744 and EN 500
66 BW 220 D-5
2.1.1.2 Vibration data

Vibration of the entire body (driv- The weighted effective acceleration value determined according to
er’s seat) ISO 2631 is ≤ 0.5 m/s2.
Hand-arm vibration The weighted effective acceleration value determined according to

ISO 5349 is ≤ 2.5 m/s2.
BW 220 D-5 67
Technical data – Additional technical data
2.2 Additional technical data

Additional engine data
Combustion principle 4-cycle diesel engine with inter-
cooler and turbo charging
Combustion method Direct fuel injection
Injection system Common rail
Exhaust gas recirculation Externally cooled
Low idle speed rpm 800-900
High idle speed rpm 2150-2250
Spec. Fuel consumption g/kWh 235
Valve clearance intake 75° ± 15°
Valve clearance exhaust 120° ± 15°
Travel pump
Manufacturer Sauer
Type H1 P089 RA (EP)
System Axial piston/swash plate
Max. displacement cm3/rev 89
High pressure limitation bar 450
Charge pressure relief valve for bar 25
high idle speed, travel pump 1
Charge pressure relief valve, against block
travel pump 2
Pressure override valve bar 400
Drum reduction gear

Manufacturer Bonfiglioli
Type 711C3
Transmission ratio 93.7
Drum drive motor

Manufacturer Sauer
Type H1 B110
System Axial piston – bent axle
Max. displacement (stage 1) cm3/rev 110
Min. displacement (stage 2) cm3/rev 51
68 BW 220 D-5
Perm. leak oil rate l/min 2

Flushing rate l/min 5
Flushing pressure limitation bar 16
Axle motor
Manufacturer Sauer
Type H1 B110
System Axial piston – bent axle
Max. displacement (stage 1) cm3/rev 110
Min. displacement (stage 2) cm3/rev 22
Perm. leak oil rate l/min 2
Vibration pump
Manufacturer Sauer
Type H1 P0 78 RA (EP)
System Axial piston/swash plate
Max. displacement cm3/rev 78
Starting pressure bar 365 ± 65
Operating pressure (soil bar approx. 100
dependent)
High pressure limitation bar 450
Charge pressure relief valve against block
Pressure override valve bar 400
Auxiliary pump cm3/rev 17
Vibration motor
Manufacturer Bosch-Rexroth
Type A2FM 80
System Axial piston/bent axle
Displacement cm3/rev 80
BW 220 D-5 69
Steering/charge pump
System Gear pump
Displacement cm3/rev 16
Max. steering pressure bar 175 + 25
Steering valve
Manufacturer Danfoss
Type OSPC 500 ON
System Rotary spool valve
Rear axle
Manufacturer Dana
Type CHC 193/98
Differential No-spin
Degree of locking % 100
Reduction ratio 65.7
70 BW 220 D-5
Technical data – Terms and basis of calculation
2.3 Terms and basis of calculation

The following terms and basis of calculation serve as a quick guide
to help you understand the technical data provided:
Seq. no. Term Units EXPLANATION

1 Dimensions mm n All dimensions given in mm
2 Axle load kg n Specification of the static weight in (kg) affecting each axle
3 Drive system - n Mechanically from the diesel/petrol engine via V-belt, toothed
belt or chain, gears, or cardan shaft
n Hydrostatically from the diesel/petrol engine via hydraulic
pump and hydraulic motor(s)
4 Amplitude mm n Half the excursion in millimetres (mm) covered by the com-
paction body (plate or drum) per revolution of the exciter shaft
5 Working speed m/min n Path covered by the machine in metres (m) in a minute (min)
6 Operating kg n Static weight of the machine, including
weight CECE - fuels and lubricants - 50% fuel tank content x 0.84 specific
weight
- 50% water tank content
- 75 kg for the driver (only in the case of sit-on machines)
7 Rated speed min-1 n Number of revolutions per minute of the diesel/petrol engine
8 Basic weight kg n Static weight of the machine without fuels and lubricants
9 Travel speed km/h n Path covered by the machine in kilometres (km) in an hour (h)
10 Frequency Hz min-1 n Number of revolutions made by the exciter shaft per second
(Hz) ore minute (min-1)
For example: 50 Hz = 50 rev./sec = 50 x 60 = 3000 rev./min (•/
min)
11 Fuel consump- l/h n Average engine fuel consumption at 70% capacity utilisation
tion
12 Rated power kW n Effective output at the engine flywheel in kilowatts (kW) at the
SAE J 1349/ISO set nominal speed
3046
13 Track radius mm n Radius in mm which the machine achieves at full steering
angle; measured from the theoretical circle midpoint to the
inner edge of the drums/wheel
14 Static surface kg/m2 n Relates to the machine operating weight in kg divided by the
load base plate contact area
15 Static linear kg/cm or n Axle load in kg divided by the working width of the drums in
load kg/m cm or m
16 Centrifugal kN n Force generated by the exciter shaft in kilonewton (kN) which
force makes the compaction body (drum or plate) oscillate. It
depends on the vibrating mass of the compaction body and
the frequency.
Attention: Specification of a greater centrifugal force is no
guarantee of high compaction power.
BW 220 D-5 71
Technical data – Fuels and lubricants
2.4 Fuels and lubricants

2.4.1 Engine oil
2.4.1.1 Oil quality
Engine oils for use in DEUTZ engines are classified in DEUTZ
Engine Oil Quality Classes (DQC).
The following engine oil specifications are permitted:

DEUTZ ACEA API DHD
DQC II-10 E3-96 CH-4 DHD-1
E4-12 CI-4
E5-02 CI-4 Plus
E7-12
DQC III-10 - - -
DQC IV-10 - - -
Avoid mixing of engine oils.
The list of approved engine oils is also available on the

Internet under the following address:
www.deutz.com
de SERVICE \ Maintenance \ Betriebsstoffe \ Öle \
DEUTZ Quality Class \ DQC Freigabeliste
en SERVICE \ Maintenance \ Operating Liquids\ Oils \
DEUTZ Quality Class \ DQC Release List
72 BW 220 D-5
2.4.1.2 Oil viscosity

Since engine oil changes its viscosity with the temperature, the
ambient temperature at the operating location of the engine is of
utmost importance when choosing the viscosity class (SAE-class).
Only use multi-purpose oils.
The temperature indications of the SAE-class always refer to fresh
oils. In travel operation engine oil ages because of soot and fuel
residues. This adversely affects the properties of the engine oil,
especially under low ambient temperatures.
Optimal operating conditions can be achieved by using the oil vis-
cosity chart as a reference.
Fig. 51: Oil viscosity diagram
2.4.1.3 Oil change intervals

If the oil change intervals are not reached over a period of one
year, the oil change should be performed at least 1 x per year, irre-
spective of the operating hours reached.
The oil change interval must be halved if at least one of the fol-
lowing conditions applies:
n Permanent ambient temperatures below -10 °C (14 °F)
n Engine oil temperatures below 60 °C (84 °F).
n Sulphur content in fuel exceeding 0.5 %
2.4.2 Fuel
2.4.2.1 Fuel quality
You should preferably use commercial diesel fuel with a sulphur
content of less than 0.5 %.
When using a diesel fuel with a high sulphur content of 0.5 % to
1.0 % the oil change intervals must be halved.
Fuels with a sulphur content of more than 1.0 % are not permitted.
BW 220 D-5 73
In order to fulfil national emission regulations one must strictly use

the legally required fuels (e.g. sulphur content).
The following fuel specifications are recommended:
n EN 590
n ASTM D975 Grade-No. 1-D and 2-D
n JIS K 2204 Grade Fuel 1 and Grade Fuel 2 with lubrication
properties acc. to EN 590
2.4.2.2 Winter fuel

For winter operation use only winter diesel fuel, to avoid clogging
because of paraffin separation.
At very low temperatures disturbing paraffin separation can also be
expected when using winter diesel fuel.
Diesel fuels suitable for temperatures down to -44 °C (-47 °F) are
available for Arctic climates.
NOTICE!
– The admixture of petroleum and the addition of
“flow enhancing additives” (fuel additives) is
not permitted.
2.4.2.3 Storage
Even traces of zinc, lead and copper can cause deposits in the
injection nozzles, especially in modern Common-Rail injection sys-
tems.
Zinc and lead coatings in refuelling systems and fuel lines are not
permitted.
Copper containing materials (copper lines, brass items) should be
avoided, because they can cause catalytic reactions in the fuel with
subsequent depositing in the injection system.
2.4.3 Coolant
2.4.3.1 General
For fluid cooled engines the cooling fluid must be prepared by
admixing a cooling system protection agent to the fresh water and
should be checked within the specified maintenance intervals.
This prevents damage caused by corrosion, cavitation, freezing
and overheating.
74 BW 220 D-5
2.4.3.2 Water quality

The correct quality of water is highly important when preparing
coolant. Clear and clean water within the boundaries of the fol-
lowing analysis values should generally be used.
Analysis values
pH-value at 20 °C (68 °F) 6.5 - 8.5
Chlorine-ion content max. 100 mg/l
Sulphate ion content max. 100 mg/l
Water hardness (ion content of max. 3.56 mmol/l
calcium and magnesium )
max: 356 mg/l (ppm)
Germ degree: max. 20 °dH
English degree: max: 25 °eH
French degree: max: 35.6 °fH
Bacteria, fungi, yeasts not permitted
Information concerning the water quality can be obtained from the

waterworks.
If the fresh water analysis values are unknown, these must be
determined with the help of a water analysis.
If the values of the analysis deviate, the water must be treated
accordingly:
pH-value too low - Adding of caustic lye of soda or caustic
potash solution.
Water hardness too - Mix with soft, distilled or fully demineral-
high ized water
Chlorides and/or sul- - Mix with distilled or fully demineralized
phates too high water
NOTICE!
– Another analysis must be made after the fresh
water has been prepared.
2.4.3.3 Cooling system protection agent

As a protection against frost, corrosion and boiling, anti-freeze
agents must be used in any climatic conditions.
Coolant is prepared by adding an ethylene-glycol based anti-freeze
agent with corrosion inhibiting properties to the cooling water.
We therefore highly recommend using our BOMAG cooling system
protection agent.
BW 220 D-5 75
If our cooling system protection agent is not available for any

important reasons, you may, in exceptional cases, use products
that have been approved by the engine manufacturer.
The list of approved lubrication oils is also available on the

internet under the following link:
www.deutz.com
de SERVICE \ Maintenance \ Betriebsstoffe \ Kühlsys-
temschutz
en SERVICE \ Maintenance \ Operating Liquids \
Coolant
Products of the same product group (see Deutz Technical Circular

Cooling System Protection Agents) can be mixed with each other.
The BOMAG cooling system protection agent corresponds with
product group C.
NOTICE!
– Do not mix different coolants and additives of
any other kind.
– Before changing the product you must clean
the entire cooling system.
– Consult our customer service if in doubt.
– The cooling system protection agent must be
used all year round, to provide adequate corro-
sion protection.
The mixing ratio must not be below or exceed the following

value:
Cooling system Fresh water Protection against
protection agent cold down to
min. 35% 65% -22 °C (-8 °F)
40% 60% -28 °C (-18 °F)
45% 55% -35 °C (-31 °F)
max. 50% 50% -41 °C (-42 °F)
NOTICE!
– A proportion of more than 50% of cooling
system protection agent results in reduced
cooling power.
– The use of corrosion protection oils as cooling
system protection agents is not permitted.
76 BW 220 D-5
2.4.4 Hydraulic oil

2.4.4.1 Mineral oil based hydraulic oil
The hydraulic system is operated with hydraulic oil HV 46 (ISO)
with a kinematic viscosity of 46 mm2/s at 40 °C (104 °F) and
8 mm2/s at 100 °C (212 °F).
When refilling or changing oil, use only hydraulic oil type HVLP
according to DIN 51524, part 3, or hydraulic oil type HV according
to ISO 6743/4.
The viscosity index must be at least 150 (observe information of
manufacturer).
2.4.4.2 Bio-degradable hydraulic oil

The hydraulic system can also be operated with a synthetic ester
based biodegradable hydraulic oil.
The biodegradable hydraulic oil Panolin HLP Synth. 46 or
Plantohyd 46 S meets all the requirements of a mineral oil based
hydraulic oil according to DIN 51524.
In hydraulic systems filled with biodegradable hydraulic oil, always
use the same oil to top up and do not mix oil types.
When changing from mineral oil based hydraulic oil to an ester
based biologically degradable hydraulic oil, you should consult the
lubrication oil service of the oil manufacturer, or our customer
service for details.
NOTICE!
Danger of damage to the hydraulic system!
– After the changeover check the hydraulic oil fil-
ters increasingly for contamination.
– Have regular oil analyses performed regarding
the water content and mineral oil.
– Replace the hydraulic oil filter at the latest after
500 operating hours.
2.4.5 Gear oil SAE 75W-90

Use a fully synthetic gear oil in accordance with SAE 75W-90,
API GL5 with a kinematic viscosity of at least 16 mm2/s at 100 °C
(212 °F).
2.4.6 Gear oil SAE 80W-140

Use a fully synthetic gear oil in accordance with SAE 80W-140,
API GL5 with a kinematic viscosity of at least 20 mm2/s at 100 °C
(212 °F).
BW 220 D-5 77
It is a hypoid lubricant of highest quality class for transmissions

under extreme strain.
78 BW 220 D-5
Technical data – List of fuels and lubricants
2.5 List of fuels and lubricants

Assembly group Fuel or lubricant Spare parts Filling quantity
number
Summer Winter Observe the
level mark!
Engine oil SAE 10W-40 009 920 06 15.5 l
Specification: Ä Chapter 2.4.1 ‘Engine oil’ 20 l (4.1 gal us)
on page 72
SAE 15W-40
SAE 10W-30
SAE 30 SAE 10W
Fuel Diesel Winter diesel fuel 280 l
Specification: Ä Chapter 2.4.2 ‘Fuel’ (74 gal us)
on page 73
Coolant Mixture of water and anti-freeze agent 009 940 03 26 l
Specification: Ä Chapter 2.4.3 ‘Coolant’ 20 l (6.9 gal us)
on page 74
Hydraulic system Hydraulic oil (ISO), HVLP 46 009 930 09 75 l
Specification: Ä Chapter 2.4.4.1 ‘Mineral oil 20 l (20 gal us)
based hydraulic oil’ on page 77
or ester based biodegradable hydraulic oil
Specification: Ä Chapter 2.4.4.2 ‘Bio-degrad-
able hydraulic oil’ on page 77
Exciter housing Gear oil SAE 75W-90 009 925 05 1.6 l each
Specification: Ä Chapter 2.4.5 ‘Gear oil SAE 20 l (0.4 gal us)
75W-90’ on page 77
Drum drive reduction Gear oil SAE 80W-140 009 925 07 5l
gear
80W-140’ on page 77
Drive axle Gear oil SAE 80W-140 009 925 07 11 l
80W-140’ on page 77
Axle reduction gear Gear oil SAE 80W-140 009 925 07 1.9 l
80W-140’ on page 77
Wheel hubs Gear oil SAE 80W-140 009 925 07 1.4 l each
80W-140’ on page 77
Tyres Water + calcium chloride 295 l + 100 kg
(80 gal us +
220 lbs)
BW 220 D-5 79
Technical data – List of fuels and lubricants
Assembly group Fuel or lubricant Spare parts Filling quantity

number
Summer Winter Observe the
level mark!
or water + magnesium chloride 308 l + 87 kg
(81 gal us +
192 lbs)
Air conditioning Refrigerant R134a 1500 g
(3.3 lbs)
80 BW 220 D-5
Overview of machine
3 Overview of machine
BW 220 D-5 81
Overview of machine – General information
3.1 General information.................................................. 82

3.1.1 BCM 05.................................................................... 86
3.1.2 BCM start................................................................. 88
3.1.3 BCM net................................................................... 89
3.1.4 Economizer.............................................................. 90
3.1.5 Terrameter............................................................... 91
3.1.6 BOMAG Telematic................................................... 93
3.2 Electric systems....................................................... 95
3.3 Hydraulic system...................................................... 97
3.4 Machine assemblies................................................. 98
3.4.1 Diesel engine........................................................... 98
3.4.2 Drum........................................................................ 99
3.4.3 Air conditioning...................................................... 100
3.4.4 Auxiliary heating, AIRTRONIC............................... 101
3.1 General information
2
1
4 3
S-586-0455
Fig. 52: with attachment plates

1 Drum
2 Diesel engine
3 Central electrics
4 Articulated joint
82 BW 220 D-5
Simple servicing due to excellent

accessibility
Fig. 53
Smooth drum: BVC, D and DH

machines
Fig. 54
n Compaction of sand, gravel and crushed rock
n Tapered drum edges
n Optimum surface quality
BW 220 D-5 83
Padfoot shell optional equipment
Fig. 55
For the compaction of cohesive soils; the third of the circumference
shells are placed on the smooth drum and bolted together.
It is recommended to change the drive wheels

from diamond tread to tractor tread.
ECOMODE
The standard BOMAG "ECOMODE” ensures a clean result. Active
engine management provides power to the roller operator when
needed and reduces power when the application allows. Intelligent
sensors combined with a sophisticated control immediately detect
the actual power requirement and the engine speed is automati-
cally adjusted.
With conventional rollers, the hydrostatic drive of the vibration unit
depends on the diesel engine speed. As a result, the diesel engine
must be driven at “full load” to maintain the corresponding speed of
the exciter shaft. This is independent of whether the engine power
is actually needed at maximum speed or not. “ECOMODE”
reduces the speed of the diesel engine towards the optimum
engine torque. The drive pump of the vibration unit hydrostatic
drive now regulates the volume flow so that the speed of the
exciter shaft is not affected by it. The pump and engine always pro-
vide the “correct” speed of the vibration shaft for the closed circuit
of the vibration drive. If the diesel engine is actuated by increasing
the driving pressure, the engine speed will increase with simulta-
neous adjustment of the exciter shaft speed.
To summarise: “ECOMODE” allows the engine speed to be
reduced while full power is still available in the hydraulic system.
Fuel consumption and noise levels are reduced, vibration frequen-
cies and centrifugal forces remain unaffected.
84 BW 220 D-5
ECOSTOP
With the optional ECOSTOP the engine is shut down automatically
after a defined period of idle speed. This also reduces fuel con-
sumption and wear.
Additional modules
Fig. 56: BCM05, example of a single drum roller

1 PC or laptop
2 Printer
3 Print-outs
4 BCM 05mobile
5 CAN-USB communication
6 Output of measuring data in file format on any type of data
storage medium for transfer to third parties (e.g. client, con-
struction supervision, etc.)
Furthermore, the machine can also be extended with additional
modules. The technical requirements for surface covering compac-
tion control are achieved with BOMAG COMPACTION METER
(BCM) and GPS, the satellite-assisted location system.
BW 220 D-5 85
3.1.1 BCM 05
‘BCM 05’ is used for continuous and area covering compaction
control. The system documents the stiffness of the soil in MN/m2
(EVIB-value) in earth or asphalt compaction.
The EVIB-value is a physical measured value that correlates directly
with the plate-load test used in earth and road construction. It
expresses the correlation between the ground contact force and
the indentation of the roller drum.
Fig. 57
1 Office PC with BCM 05 office software
2 USB-stick for data transfer
3 Tablet-PC with touchscreen and BCM 05 mobile software
The machine is equipped with a tablet-PC (3) with ‘BCM 05
mobile’ software. During compaction, the display on the tablet-PC
informs the operator about the current position of the machine and
the number of passes that have already been driven.
With a USB-stick (2) the measured data can be transferred to an
Office-PC (1) for analysis and documentation with the software
‘BCM 05 office’ .
A report of the recorde3d measured data can be saved as a PDF
file or directly printed out.
86 BW 220 D-5
3.1.1.1 Network structure
Fig. 58
If more than one machines are working on a project, the measuring
data are recorded by various tablet-PCs (3) and then transferred to
the Office-PC (1). This PC is the Master-PC of the project.
When using further Office-PCs (2) one must make absolutely sure
that the measured data of a project are only transmitted to the
Master-PC.
3.1.1.2 Position detection

During a measurement, the measured data are assigned to the
corresponding measuring positions on the construction site.
‘BCM 05’ works with two different kinds of position detection.
This fundamental difference influences the representation and
evaluation of measured data.
Manual position detection for track Manual position detection requires a track bound working mode.
bound fields The construction site is in this case divided into fixed tracks.
The assignment of measured data and measuring positions is
accomplished by a distance transducer, which determines the posi-
tion of the machine within a track.
BW 220 D-5 87
Automatic position detection for In automatic position detection the assignment of measured data to
GPS fields measuring positions takes place with the help of an automatic posi-
tion detection system (e.g. a GPS-system).
In this case the machine is equipped with e.g. a GPS antenna.
Fig. 59
n To exactly 22 cm
n No local referencing station
The assignment of the individual measuring values to the meas-
uring position is accomplished with the help of an automatic posi-
tion acquisition system.
3.1.2 BCM start

‘BCM start’ documents the number of passes when compacting
soil or asphalt.
When compacting asphalt, the passes are not only documented
but also the compaction temperature if the machine is equipped
with a corresponding temperature sensor.
By means of a GPS receiver the system determines the machine's
position.
During compaction, the display on the tablet PC shows the oper-
ator the machine's current position and the number of performed
passes.
The resulting log of the recorded data can be saved as a PDF file
on a USB stick.
88 BW 220 D-5
3.1.3 BCM net

‘BCM net’ links up all rollers on a construction site involved in the
compaction process.
The individual measuring data and the position of the roller are
made available to all participants in the ‘BCM net’ group. The
tablet PC keeps each driver informed about his compaction work
and the work performed by other participants.
Fig. 60
1 BCM net Server
2 BCM net Client
The complete communication runs through a central node, the
‘BCM net’ server (1). Each group contains exactly one server. The
tablet PCs (2) with the ‘BCM 05 mobile’ or the ‘BCM start’ soft-
ware of the individual machines serve as clients.
Each machine sends its current position data as well as the deter-
mined measuring values to the server, which in turn distributes
these to all other machines. The server may, in addition to a client,
be located on a machine in the group.
The exchange of data can only take place when the client is within
the reach of the server. The reach is approximately 150 meters
around the server. It depends on both the environment and pos-
sibly existing interfering influences.
Should client and server become too far apart, the client can con-
tinue work separated from the group. In this time it is unable to
receive data from other clients and cannot transfer data to the
server.
Once the connection to the server has been restored, the saved
measuring values will be transmitted.
BW 220 D-5 89
3.1.4 Economizer
Fig. 61
The BOMAG ECONOMIZER, which is integrated in the central dis-
play, informs the driver about the optimal compaction results. Oper-
ation is very simple, because no set-up or calibration is required.
The ECONOMIZER automatically determines the compaction pro-
gress. A light strip informs the driver about the end of compaction,
in order to avoid over-compaction. A warning light also indicates
when there is a risk of overcompaction developing. Moreover, the
driver is also informed about the optimal speed.
90 BW 220 D-5
3.1.5 Terrameter
BOMAG TERRAMETER TERRAMETER is
available for all single drum rollers -5 and as
standard in single drum rollers with VARIOCON-
TROL.
Fig. 62
In earthworks, the stiffness of the material, measured with a pres-
sure plate, is often used as a criterion. However, load plates only
measure specific points and are expensive to use. TERRAMETER
has the technology to do far more. This measuring system allows
BOMAG single drum rollers to become rolling pressure plates: sur-
face covering, in real time.
TERRAMETER measures the level of stiffness E in MN/m². EVIB
correlates directly with the EV1 and EV2 values of the plate load
test. This means the driver not only sees the trend, but also a spe-
cific, absolute measuring value. The driver can directly work
towards the required stiffness level specified in the contract. .
The standard set values for DIN V2 of 45, 80, 100 and 120 MN/m²
are shown on the display as a compression ratio. This allows the
target achieved to be quickly displayed. Additionally, the driver is
notified by a red LED that compaction has not increased between
two passes.
HOW EXACTLY IS THE EVIB VALUE EVIB uses the interaction of the acceleration of the vibrating drum
CREATED? and the stiffness of the soil. In general, the soil stiffness will
increase as compaction increases. The principle corresponds with
a dynamic load plate.
BW 220 D-5 91
S-921-0388
Fig. 63
If the soil becomes stiffer, the drum acceleration will also increase.
The measuring sensors record this acceleration and from this
determine the effective contact force between the soil and drum
and, at the same time, the vibration amplitude of the drum. If the
contact force is then laid on top of the vibration amplitude of the
drum, this results in a loading and unloading curve for every revo-
lution of the exciter. The EVIB value corresponds with the increase
in load curve, as this correlates with the stiffness of the soil.
92 BW 220 D-5
3.1.6 BOMAG Telematic
S-921-0390
Fig. 64
BOMAG TELEMATIC is a fleet management system for the effi-
cient deployment of all machines. With BOMAG TELEMATIC the
machine operator can localise machines and record and save
operating states. The actual operating hours are documented.
BOMAG TELEMATIC is able to detect unauthorised use and theft
and simplify maintenance of the machine. The system consists of
machine-integrated hardware and an internet application. All data
is stored in a database. Access is individually determined for each
user and password protected on the internet.
BOMAG TELEMATIC START TELEMATIC START is available as an optional extra for self-pro-
pelled BOMAG machines – and BOMAG TELEMATIC START can
even be integrated into machines from other manufacturers! This
enables convenient management of mixed fleets.
The basic package offers the following functions
n Location tracking
n Geo-fence (an alarm signals when the machine leaves defined
areas)
n Monitoring of standing time (an alarm signals if the machine is
operated outside of defined times)
n Recording of operating hours
n Service and maintenance plan
BW 220 D-5 93
BOMAG TELEMATIC POWER TELEMATIC POWER is available as an optional extra for self-pro-
pelled BOMAG machines with electronic control, e.g. DH-4 single
drum rollers, pavers, planers, refuse compactors or MPH recyclers/
stabilizers. BOMAG TELEMATIC can also be installed in machines
from other manufacturers.
The POWER solution offers the following features in addition to
those from the basic package
n Calculation of total and average fuel consumption for any time
period
n Reports on utilisation of capacities and efficiency
n Idle running control
n Alarms in certain operational conditions (oil pressure, cooling
water, etc.)
94 BW 220 D-5
Overview of machine – Electric systems
3.2 Electric systems
4 5 6 7 8 9 10 11
3 12
13
14
2 15
16
1 17
18
19
20
31 30 29 28 27 26 25 24 23 22 21
S-586-0454
Fig. 65: (symbolic representation)

1 Operating console and monitoring module, A15
2 Monitor for reversing monitoring, P42
3 Working head lights, front left, E23
4 Tachograph (P09) and cabin operating console, A178
5 Front windscreen wiper motor, M04
6 Radio (A12) and printer (P11)
7 Working head lights, rear left, E27
8 Working head lights, front right, E25
9 Rear windscreen wiper motor, M05
10 Camera for reversing monitoring, P32
11 Working head lights, rear right, E28
12 Travel lever, S55
13 Control elements of driver’s seat
14 Air filter maintenance switch (B03) and ambient temperature sensor (B218)
15 Float switch for coolant compensation tank, B55
16 Fuse box for exhaust gas aftertreatment system; only for machines with exhaust classification Tier4f and
STAGE V
17 Warning buzzer for reverse travel, H14
18 Differential pressure switch for hydraulic oil filter, B21
BW 220 D-5 95
Overview of machine – Electric systems
20 Pressure sensor for travel pump, B234, B235, B236 and B237
21 Battery disconnecting switch, S30
22 Power board for SCR heating (U100), only machines with exhaust classification Tier4f and STAGE V
23 Fluid level sensor, R03
24 Battery, G01
25 Solenoid valve for brake, Y04
26 Warning horn, B11
27 Front windscreen washer motor, M06 and rear windscreen washer motor, M07
28 Central electrics, travel control (A34), engine control unit (A48), measuring technology control (A83), Tel-
ematic module (A124), cross-slope sensor (B57), diagnostics interfaces (X32) and (X34), Powerboard
and connector strip (X100 to X109)
29 Keyboard for anti-theft protection, A76
31 Wiring loom, cabin
96 BW 220 D-5
Overview of machine – Hydraulic system
3.3 Hydraulic system
Fig. 66
1 Drum drive motor
2 Steering valve
3 Hydraulic oil tank
4 Steering/charge pump
5 Travel pump for axle drive
6 Travel pump for drum drive
7 Vibration pump
8 Charge oil filter
9 Brake valve, Y04 & travel speed range selection for drum, Y30
10 Rear travel motor, with travel speed range selector Y31
11 Manifold block with thermostat
12 Steering cylinder
13 Vibration motor
BW 220 D-5 97
Overview of machine – Machine assemblies
3.4 Machine assemblies

3.4.1 Diesel engine........................................................... 98
3.4.2 Drum........................................................................ 99
3.4.3 Air conditioning...................................................... 100
3.4.4 Auxiliary heating, AIRTRONIC............................... 101
3.4.1 Diesel engine
S-586-0462
4 3
Fig. 67
1 Diesel engine
2 Fuel pre-filter with sensor for water separator (B124)
3 Main fuses
4 Central electrics, engine control unit (A48) and diagnostics interface of diesel engine (X32)
98 BW 220 D-5
3.4.2 Drum
Fig. 68: Sectional drawing of drum, BW216

1 Vibration motor
2 Exciter unit
3 Clutch
4 Travel gear
5 Travel motor
6 Drum shell
7 Rubber buffer
8 Rectangular rubber buffers
9 Travel bearings
BW 220 D-5 99
3.4.3 Air conditioning
3 2 1
S-586-0456

1 Compressor
2 Condenser
3 Dryer/collector
4 HKL module
Optional equipment
100 BW 220 D-5

3.4.4 Auxiliary heating, AIRTRONIC
2 3
1
S-586-0459

1 Heater unit, E30
2 Air filter
3 Timer (S28) and fuses (F320 and F321)
4 Fuel filter and pump for heating unit, Y14/M57
Optional equipment
BW 220 D-5 101

102 BW 220 D-5

Electric systems
4 Electric systems
BW 220 D-5 103

Electric systems – Basic principles
4.1 Basic principles...................................................... 104

4.1.1 Measuring technology............................................ 105
4.1.2 Understanding circuit diagrams............................. 110
4.1.3 Telemecanique switch............................................ 122
4.1.4 Deutsch connectors, DT and DTM series.............. 124
4.2 Overview of electric system.................................. 129
4.2.1 Central electrics..................................................... 131
4.2.2 Operator’s stand.................................................... 132
4.2.3 Wiring..................................................................... 133
4.2.4 CAN BUS overview................................................ 150
4.2.5 List of equipment................................................... 152
4.3 Starting the engine with jump leads..................... 161
4.4 Fuse assignment.................................................... 162
4.4.1 Notes on safety...................................................... 162
4.4.3 Main fuses............................................................. 163
4.4.4 Control console cabin............................................ 164
4.4.5 Auxiliary heating.................................................... 165
4.5 Central electrics...................................................... 166
4.5.1 Power board.......................................................... 167
4.6 Description of electrical components................... 173
4.6.1 Sensors and actuators........................................... 173
4.6.2 CPU control units and electrical modules.............. 178
4.6.3 Cabin operating console, A178.............................. 182
4.7 Training of electric system.................................... 184
4.7.1 Electrics training machine control.......................... 184
4.8 Inspection and maintenance work........................ 311
4.8.1 Maintenance Table................................................. 311
4.8.2 Every 500 operating hours..................................... 311
4.8.3 As required............................................................ 312
4.1 Basic principles

4.1.1 Measuring technology............................................ 105
4.1.2 Understanding circuit diagrams............................. 110
4.1.3 Telemecanique switch............................................ 122
4.1.4 Deutsch connectors, DT and DTM series.............. 124
104 BW 220 D-5

4.1.1 Measuring technology

Test lamp
NOTICE!
This type of tester must not be used for testing on
electronic components. The high power consump-
tion of the test lamp may destroy electronic compo-
nents in the control units.
Fig. 71: Test lamp
Voltage tester
It is used to perform simple voltage measurements. The tester con-
sists of two probes. The negative measuring line is connected to
ground; the positive measuring line is connected to the relevant
measuring point.
When voltage is applied, the corresponding LED lights up.
S-ELE-0044
Fig. 72: Voltage tester
BW 220 D-5 105

Multimeter
This tester is a multimeter and can be used to measure e.g. cur-
rent, voltage and resistance. Furthermore, depending on the
design you must carry out transistor and frequency tests.
In order to avoid damage:
n the range selector switch must be correctly set for the corre-
sponding measurement.
n the test cable must be plugged into the correct socket.
n the voltage type (AC/DC) must be set.
n In case of direct voltage the correct polarity must be assured.
n the measuring range should be chosen higher at the beginning
Fig. 73: Multimeter of the test.
n In order to avoid any influence on the circuitry to be measured,
the internal resistance of the voltage tester should be as high
as possible.
Resistance and continuity measurement with multimeter

The continuity tester of the multimeter can be used to measure
whether there is a connection between 2 measuring points.
Fig. 74
The following information should be observed when measuring

resistance and continuity:
n The component to be measured must not be connected to the
power supply during the measurement.
n At least one side of the component to be measured must be
disconnected from the circuitry, as otherwise the measuring
result may be influenced by parallel components.
n Polarity is of no significance.
Fig. 75
106 BW 220 D-5

Voltage and voltage drop measurement with multimeter

n Measurement at the voltage source measures the currently
available voltage.
n The meter is always connected parallel to consumer, compo-
nent or power source.
Fig. 76: Measuring voltage
n A measurement at the consumer measures the voltage drop at

this component.
Fig. 77: Voltage measurement
Current measurement with the multimeter

n The meter is connected in series with the consumer.
n During the measurement the current must be able to flow
through the meter, i.e. the electric circuit must be opened.
Fig. 78: Measuring current
BW 220 D-5 107

Advice
If the electric circuit is difficult to access and the internal resistance
of the consumer is known, the voltage may also be measured at
the consumer.
The current value can then be calculated with the help of Ohm's
law.
Fig. 79: Current measurement
Clip-on measuring instrument

The clip-on measuring instrument can be used to measure current,
voltage and resistance.
Fig. 80: Clip-on measuring instrument
n For measuring current the individual conductor must be fully

enclosed by the measuring tongs, the actual measurement
takes place without contact.
Fig. 81
108 BW 220 D-5

Magnet tester
The magnet tester is used to test solenoid valves and magnetic
coils.
The test lamp responds to the magnetic fields of A.C-voltage, D.C.-
voltage and permanent magnets.
n The component to be tested does not need to be removed.
n The magnetic coil can also be tested under a protective cap.
Fig. 82: Magnet tester
Power measurement
The electric power of a module within a circuit can be indirectly
determined (calculated) by separate measuring of current and
voltage.
However, there are also pure power meters with 4 connections
available. The power meter has a electro-dynamic measuring
mechanism. The current circuit must be opened for measuring.
Take care when performing power measurements: Voltage or cur-
rent path may already be overloaded during the measurement,
even though the end stop in the meter has not yet been reached.
Fig. 83
BW 220 D-5 109

4.1.2 Understanding circuit diagrams

4.1.2.1 Circuit diagrams
Circuit diagrams provide information on the logical, electrical func-
tions of BOMAG machines and currently do not provide any infor-
mation on how and in which order electrical components are wired
together, even if some directional wiring symbols are occasionally
used.
Wiring information is currently defined exclusively

in the corresponding wiring drawings or wiring
loom drawings.
A circuit diagram is indispensable for effective and systematic

trouble shooting in the vehicle wiring system. This diagram pro-
vides the following information:
n Number and type of individual elements in the examined elec-
tric circuit, such as plug connectors, fuses, switches, con-
sumers, relays, etc.
n The sequence in which current flows through the individual ele-
ments in the electric circuit.
n Connections between the examined electric circuit and other
circuits in the vehicle wiring system.
n Pin assignment of plug-in connections.
Structure of circuit diagram The circuit diagram consists of following individual parts:
n Cover sheet (with general information) Ä ‘Cover sheet’
on page 110
n Table of contents Ä ‘Table of contents’ on page 111
n Overview of structural symbols (only if the structural view is
used) Ä ‘Overview of structural symbols’ on page 111
n Overview of installation locations (only if the structural view is
used) Ä ‘Overview of installation locations’ on page 112
n Electric circuit documents for electrical engineering (functional
diagrams) Ä ‘Functional diagrams’ on page 113
n List of components for electrical engineering (without terminals
and plugs) Ä ‘List of components’ on page 114
n Overview of terminal strips (form type: terminal diagram)
Ä ‘Overview of terminal strips’ on page 115
n Overview of pins (form type: PLC diagram) Ä ‘Overview of
pins’ on page 116
n Overview of plugs (form type: plug diagram) Ä ‘Overview of
plugs’ on page 116
n Additional graphical information (e.g. CAN structure, overview
of central electrics and control boxes).
Cover sheet The cover sheet contains general information.
110 BW 220 D-5

S-ELE-0026
Fig. 84: Cover sheet
Table of contents The table of contents lists the individual functions.
S-ELE-0027
Fig. 85: Table of contents
Overview of structural symbols

Overview of structural symbols (only if the struc-
tural view is used).
The overview of structural symbols represents the structure of the

machine with respect to equipment, functions and installation loca-
tions as a summary. Structural symbols are mainly abbreviations
for machine parts/machines, functions and installation locations,
which were derived from designations in English.
BW 220 D-5 111

S-ELE-0028
Fig. 86: Overview of structural symbols

+BAT Battery box
+EBOX Electrics box
+MOT Engine and attachment parts
+SEAT Driver’s seat
+FRFR Front frame
+REFR Rear frame
+CONV Conveyor belt
+MIBO Milling box
+PUMP Pump module
+DRUM Drum
+DPL Driver’s stand
+ARC Dashboard
+ROPS Roll over protection structure
+ROOF Weather protection roof
+PLA Attachment plates
+HOOD Rotor hood
+CAB Cabin and attachment parts
+SPR Spraying module
+PUM Pump module
+RWT Reaction water tank
+FRA Frame
+LBOX Side-mounted driver’s stand, left
+RBOX Side-mounted driver’s stand, right
+SBOX Screed driver’s stand
+SCRD Screed
+ROOF Roof structure
Overview of installation locations

Overview of installation locations (only if the struc-
tural view is used).
112 BW 220 D-5

+FRFR
+DRUM +REFR
+PLA
+CAB
+ROPS
+DPL
+SEAT
+MOT
+ARC +PUMP
+BAT
+EBOX
0 1 2 3 4 5 6 7 8 9
Function Page from
Created == 7 98
Erstellt Layout mounting locations Funktion Blatt von
Checked
Geprüft
Übersicht Einbauorte S-ELE-0025 Higher-level function
Anlage
Mounting location
Einbauort
=
+ VIEW EPE / 000 / 00
Fig. 87: Installation locations with structural symbols

Overview of structural symbols Ä Fig. 86
Functional diagrams n The main reading direction is sheet by sheet, from top to
bottom and from left to right.
n All sheets are numbered successively.
n BOMAG uses the resolved type of representation. In this case
parts and components with different functions, which belong to
the same components (e.g. relay coil and relay contact), can
be represented on different sheets. Cross-references, which
refer to the sheet and current path, connect these partial com-
ponents.
BW 220 D-5 113

2 S15:11/=OPT/41.0
K61
4
3
5
5 6 7 8
S-ELE-0029
Fig. 88: Functional diagrams

1 Relay cross references are used to track signals, which need to be tracked for components with outgoing
contacts. A contact overview with information about the contact types of a relay and their positions in the
circuit diagram is additionally attached to the bottom of each relay coil. Example: (K61/9.6) indicates that
the relay coil on page 9 is found in current path 6.
2 Structural symbols example: +REFR Ä Fig. 86.
3 Potential cross references serve the purpose of tracking signals, which are transmitted from one func-
tional diagram to another. Potential cross-references may additionally have structural symbols assigned
to them. Example: → S15:11/=OPT/41.0 is continued to the right to page 41, current path 0. OPT stands
for option.
4 Contact overview of relay
5 Current paths are numbered successively from 0 to 9.
List of components The list of components is the first evaluation list that follows the
functional diagrams. This list contains all components used in the
circuit diagram, except terminal strips and plugs.
114 BW 220 D-5

S-ELE-0030
Fig. 89: List of components

An electric component is a part, assembly or device in an electrical
installation.
n Components are marked with a combination of letters and
numbers. The identification with letters follows the standard
DIN - EN 61346 T1-T2. A component identification (BMK) e.g.:
“S04” always describes the same component. In this context
the term “component” is always considered a function specific
assignment and does not represent a parts- or article number.
This ensures that the component with the designation “S04”
always refers to the “Brake switch”, irrespective of whether the
abbreviation is used in a circuit diagram for a single drum roller,
a tandem roller, a paver or a planer.
n The component identifications are alphabetically sorted in the
list of components. Each component has the corresponding
cross-references assigned, identifying where it can be found in
the circuit diagram, which installation location it is assigned to
and to which part of the system it belongs to. Moreover, the
functions (function text) and the technical characteristics are
also described.
Component identifications are used in both the

electrical and the hydraulic documentation and are
identical.
Overview of terminal strips The overview of terminal strips contains all terminal strips used in
the machine. Each terminal strip starts on a new page and can be
localized via the cross-reference in the circuit diagram.
BW 220 D-5 115

Terminal strip overview

Klemmleistenübersicht
WAGO
X1 WAGO
Mounting location
Einbauort
Device tag Page Path X1: 19-1 6 4 X1: 50 32 7 X1: 113 28 5 X1: 152 19 2 X1: 183 14 9
BMK Blatt Pfad
X1: 19-2 6 4 X1: 51 6 6 X1: 114 27 2 X1: 153 19 2 X1: 184 14 8
X1: 1-1 4 5 X1: 20-1 28 2 X1: 52 10 4 X1: 115 27 3 X1: 153 21 3 X1: 185 12 8
X1: 1-2 4 5 X1: 20-2 28 2 X1: 53 32 6 X1: 116 20 4 X1: 154 14 3 X1: 186 12 8
X1: 2-1 27 7 X1: 21-1 27 6 X1: 54 4 5 X1: 117 27 7 X1: 154 14 5 X1: 187 12 5
X1: 2-2 27 7 X1: 21-2 27 6 X1: 54 34 0 X1: 118 6 8 X1: 154 19 3 X1: 188 12 6
X1: 3-1 26 5 X1: 22-1 6 3 X1: 55 10 8 X1: 119 27 7 X1: 155 19 4 X1: 189 20 2
X1: 3-2 26 5 X1: 22-2 6 3 X1: 55 33 4 X1: 121 15 6 X1: 156 7 9 X1: 190 20 1
X1: 4-1 28 1 X1: 23-1 30 6 X1: 61-1 15 9 X1: 122 15 6 X1: 156 12 5 X1: 191 21 3
X1: 4-2 28 1 X1: 23-2 30 6 X1: 61-2 15 9 X1: 123 15 6 X1: 156 20 1 X1: 192 21 4
X1: 5-1 27 0 X1: 24-1 6 6 X1: 62-1 15 8 X1: 124 17 2 X1: 157 12 8 X1: 193 21 5
X1: 5-2 27 0 X1: 24-2 6 6 X1: 62-2 15 8 X1: 125 21 0 X1: 157 28 0 X1: 195 18 2
X1: 6-1 6 8 X1: 25-1 6 5 X1: 63-1 15 8 X1: 126 27 8 X1: 157 28 8 X1: 196 14 4
X1: 6-2 6 8 X1: 25-2 6 5 X1: 63-2 15 8 X1: 127 20 5 X1: 159 17 6 X1: 197 14 3
X1: 7-1 26 4 X1: 26-1 6 1 X1: 64-1 15 8 X1: 128 13 3 X1: 160 17 7 X1: 205 12 2
X1: 7-2 26 4 X1: 26-2 6 1 X1: 64-2 15 8 X1: 128 27 8 X1: 161 14 6 X1: 206 12 1
X1: 8-1 26 3 X1: 27-1 6 2 X1: 65-1 15 7 X1: 129 17 2 X1: 162 7 8 X1: 207 12 2
X1: 8-2 26 3 X1: 27-2 6 2 X1: 65-2 15 7 X1: 130 20 5 X1: 163 7 8 X1: 208 12 1
X1: 9-1 5 4 X1: 31 4 4 X1: 71-1 4 3 X1: 131 27 6 X1: 164 11 3 X1: 209 12 0
X1: 9-2 5 4 X1: 32 4 4 X1: 71-2 4 3 X1: 132 27 6 X1: 165 11 3 X1: 210 12 1
X1: 10-1 5 3 X1: 33 11 5 X1: 72-1 6 9 X1: 133 28 4 X1: 166 4 3 X1: 211 26 3
X1: 10-2 5 3 X1: 34 11 6 X1: 72-2 6 9 X1: 134 28 5 X1: 167 30 7 X1: 212 26 4
X1: 11-1 5 4 X1: 35 11 3 X1: 73-1 4 8 X1: 135 27 2 X1: 168 7 6 X1: 213 26 3
X1: 11-2 5 4 X1: 36 11 4 X1: 73-2 4 8 X1: 136 27 3 X1: 169 4 7 X1: 214 26 4
X1: 12-1 5 1 X1: 37 28 2 X1: 76-1 30 6 X1: 137 18 4 X1: 170 4 8 X1: 215 17 2
X1: 12-2 5 1 X1: 38 28 2 X1: 76-2 30 6 X1: 138 18 5 X1: 171 15 6 X1: 215 18 7
X1: 13-1 4 8 X1: 39 15 8 X1: 103 15 5 X1: 139 27 6 X1: 172 15 5 X1: 216 18 6
X1: 13-2 4 8 X1: 40 15 4 X1: 104 15 6 X1: 139 37 4 X1: 173 15 4 X1: 216 21 9
X1: 14-1 5 5 X1: 41 6 3 X1: 105 15 5 X1: 140 27 6 X1: 174 15 2 X1: 217 17 2
X1: 14-2 5 5 X1: 42 6 3 X1: 106 18 3 X1: 141 13 1 X1: 175 14 8 X1: 219 17 1
X1: 15-1 21 1 X1: 43 13 1 X1: 107 18 3 X1: 142 13 2 X1: 176 14 9 X1: 219 17 3
X1: 15-2 21 1 X1: 44 14 9 X1: 109 6 8 X1: 144 13 1 X1: 177 13 5 X1: 220 21 9
X1: 16-1 27 2 X1: 45 14 8 X1: 109 20 4 X1: 149 5 1 X1: 178 13 5 X1: 221 21 7
X1: 16-2 27 2 X1: 46 24 2 X1: 109 27 0 X1: 151 19 1 X1: 179 15 6 X1: 222 21 7
X1: 17-1 27 3 X1: 47 12 8 X1: 110 27 0 X1: 151 21 5 X1: 180 15 5 X1: 231 27 6
X1: 17-2 27 3 X1: 48 12 8 X1: 111 27 1 X1: 152 14 4 X1: 181 15 4 X1: 232 27 6
X1: 18-1 6 5 X1: 49 27 1 X1: 112 28 3 X1: 152 18 2 X1: 182 15 2 X1: 233 28 2
X1: 18-2 6 5
0 1 2 3 4 5 6 7 8 9
Higher-level function Page from
Created = 46 65
Erstellt Terminal strip overview X1 Anlage
Function
==
Blatt von
Funktion
Checked
Geprüft Klemmleistenübersicht X1 S-ELE-0031 Mounting location
Einbauort + EPE/ 000 / 00
Fig. 90: Overview of terminal strips
Overview of pins The overview of pins Ä Fig. 91 informs about the type of inputs
and outputs of the components used in the machine Ä Fig. 89, as
well as their signals and potentials.
Pin overview
Pin Übersicht
Travel lever
S55 Fahrhebel
Plug Pin Page Path Description
Stecker Kontakt Blatt Pfad Beschreibung Signal Signal
X23 1 14 6 Power supply (8...32V) Power supply Stromversorgung

X23 2 14 5 Ground Ground Masse
X23 3 29 9 BTS signal "Brake catch" BTS brake BTS Bremse
X23 4 BTS signal "warning horn"
(prepared)
X23 5 29 3 Output voltage supply Supply analog selectors Versorgung Analoge Wahlschalter
"+5V"
X23 6 16 4 CAN bus high
X23 7 16 5 CAN bus low CAN low CAN low
X23 8 29 2 Ground / 0V / reference Ground analog selectors Masse Analoge Wahlschalter
to PIN 5
X23 9 14 6 Adressing 1 Ground Masse
X23 10 14 7 Adressing 2 -"- -"-
X23 11 29 1 Analog IN 1 Switch, speed range selector 2 Schalter Fahrstufen 2
X23 12 29 4 Analog IN 2 Frequency adjustment plates Frequenzverstellung Anbauplatten
X24 1 29 7 Digital IN 1 Switch, vibration low/off (on/off) Schalter Vibration klein/aus (an/aus)
X24 2 29 8 Digital IN 2 Switch, vibration off/high Schalter Vibration aus/groß
X24 3 29 6 Digital IN 3 Floating position plates Schwimmstellung Anbauplatten
X24 4 29 5 Digital IN 4 Vibration plates Vibration Anbauplatten
X24 5 Digital IN 5
X24 6 Digital IN 6
X24 7 Output supply voltage
+Ub
X24 8 Output supply voltage
"ground" (0V)
0 1 2 3 4 5 6 7 8 9
Function Page from
Created == 74 98
Erstellt Pin overview S55 Funktion
Higher-level function
=
Blatt von
Checked
Geprüft
Pin Übersicht S55 S-ELE-0032 Anlage
Mounting location
Einbauort + PINO EPE / 000 / 00
Fig. 91: Overview of pins, S55
Overview of plugs The plug diagram is at the end of the list evaluations. The plug dia-
gram contains all plugs used in the machine. The list is sorted in
numerical order. Behind each connector designation is a reference
to the installation location, a function text and information about the
plug type used. For each individual connector pin used, a note is
given where the PIN is shown in the circuit diagram.
116 BW 220 D-5

Plug overview
Steckerübersicht
Plug Mounting location Plug Mounting location Plug Mounting location Plug Mounting location
Stecker -X0.A Einbauort +EBOX Stecker -X0.C Einbauort +EBOX Stecker -X1.B Einbauort +EBOX Stecker -X2.A Einbauort +EBOX
Function text Plug, supply potential 30 Function text Plug, supply potential 30 before battery disconnect switch Function text Plug, access harness engine controller Function text Plug, access harness rear frame
Funktionstext Stecker Versorgung Potential 30 Funktionstext Stecker Versorgung Potential 30 vor Batterietrennschalter Funktionstext Stecker Anschluß Kabelbaum Motorsteuergerät Funktionstext Stecker Anschluß Kabelbaum Hinterrahmen
Plug type Plug type Plug type Plug type
Amphenol RADSOK® 8mm Amphenol RADSOK® 3,6mm AMP Junior Power Timer 18 pole blue AMP Junior Power Timer 15 pole green
Steckertyp Steckertyp Steckertyp Steckertyp
Wire harness Wire harness Wire harness Wire harness
Kabelbaum Kabelbaum Kabelbaum EMR 1
Kabelbaum 1
Contact
Contact
Contact
Contact
Kontakt
Kontakt
Kontakt
Kontakt
16 13
Page Path Page Path Page Path 18 12 9 3 Page Path 15 9 3
Blatt Pfad Blatt Pfad Blatt Pfad Blatt Pfad

30 8 4 1 10 8 1 20 2 1 28 4
2 20 2 2 32 6
Plug Mounting location Plug Mounting location 3 3
Stecker -X0.A Einbauort +EBOX Stecker -X1.A Einbauort +EBOX 4 4 28 5
Function text Plug, supply potential 30 Function text Plug, access harness engine 5 5
Funktionstext Stecker Versorgung Potential 30 Funktionstext Stecker Anschluß Kabelbaum Motor 6 6
Plug type
Amphenol RADSOK® 8mm
Plug type
AMP Junior Power Timer 9 pole blue
7 7 31 7
Steckertyp Steckertyp 8 8
Wire harness Wire harness 9 20 5 9
Kabelbaum Kabelbaum Motor 1
10 20 7 10 30 2
Contact
Contact
Kontakt
Kontakt
7
Page Path Page Path 9 6 3 11 11

Blatt Pfad Blatt Pfad 12 20 6 12 28 4
1 8 5 1 13 20 7 13
2 14 20 4 14 28 5
Plug Mounting location 3 15 20 7 15 27 8
Stecker -X0.B Einbauort +EBOX 4 16 20 5
Function text Plug, supply ground 5 48 1 17 Plug Mounting location
Funktionstext Stecker Versorgung Masse 18 20 8 Stecker -X2.A Einbauort +EBOX
6
Function text Plug, access harness rear frame
Plug type
7 8 6
Steckertyp Plug Mounting location Funktionstext Stecker Anschluß Kabelbaum Hinterrahmen
8 18 8 -X1.B +EBOX
Stecker Einbauort Plug type
Wire harness 9 18 8 AMP Junior Power Timer 15 pole green
Function text Plug, access harness engine controller Steckertyp
Kabelbaum
Contact
Kontakt
Funktionstext Stecker Anschluß Kabelbaum Motorsteuergerät Wire harness
Page Path Plug Mounting location
-X1.A +EBOX Plug type Kabelbaum
Contact
Kontakt
Blatt Pfad Stecker Einbauort AMP Junior Power Timer 18 pole blue
Steckertyp Page Path
Function text Plug, access harness engine
31 8 6 Wire harness Blatt Pfad
Funktionstext Stecker Anschluß Kabelbaum Motor
Kabelbaum
Contact
Kontakt
Plug Mounting location Plug type
1 28 4
Stecker -X0.B Einbauort +EBOX Steckertyp Page Path 2 32 6
Wire harness Blatt Pfad 3
Function text Plug, supply ground
Kabelbaum 1 20 2 4 28 5
Contact
Kontakt
Funktionstext Stecker Versorgung Masse
Plug type Page Path 2 20 2 5
Amphenol RADSOK® 6mm Blatt Pfad 3 20 2 6
Steckertyp
Wire harness 1 9 2 4 20 7 7 31 7
Kabelbaum 2 9 2 5 20 2 8
Contact
Kontakt
Page Path 3 18 6 6 20 3 9 28 5
Blatt Pfad 4 20 5 7 20 8 10 30 2
5 48 1 8 20 3 11
1 8 6 9 20 5 12 28 4
6 18 6
7 8 6 10 20 7 13 28 5
Plug Mounting location
Stecker -X0.C +EBOX 8 18 8 11 20 6 14 28 5
Einbauort
9 18 8 12 20 6 15 27 8
Function text Plug, supply potential 30 before battery disconnect switch
Funktionstext Stecker Versorgung Potential 30 vor Batterietrennschalter
13 20 7
14 20 4
Plug type
Steckertyp
Amphenol RADSOK® 3,6mm 15 20 7
16 20 5
Wire harness
17 20 5
Kabelbaum
Contact
Kontakt
18 20 8
Page Path
Blatt Pfad
30 10 8
0 1 2 3 4 5 6 7 8 9
Function Page from
Created == 75 98
Erstellt Plug overview Funktion
=
Blatt von
Anlage
Checked
Geprüft
Steckerübersicht Mounting location
Einbauort + PLGO EPE / 000 / 00
Fig. 92: Overview of plugs
4.1.2.2 Circuit symbols in E-Plan

Circuit symbol Circuit symbols are standardized representations for electrical
appliances. They serve the purpose of a simplified representation
of complete systems, from which, however, the function can be
clearly identified. This standardization is in compliance with the
globally valid regulations of the IEC (International Electrical Com-
mission). The standardization serves the purpose of global under-
standing and fault free connection of appliances, especially in
vehicle repairs. Since the wiring diagram is intended to show only
the most essential aspects, the circuit symbol only shows as much
of the function, as is needed for easy recognition and for the avoid-
ance of mistakes.
Fig. 93: For example: Circuit symbol

1 Current source
2 Conductor
3 Switches
4 Ground
5 Filament lamp
6 Filament lamp with two luminous elements
7 Voltmeter
8 Ammeter
9 Resistance
BW 220 D-5 117

10 Fuse
11 Terminal strip
12 Plugs
Different symbols are used to simplify the differentiation of terminal
strips 11 Ä Fig. 93 and plugs (12) in a wiring diagram.
Plugs are mainly used to connect two wiring looms

or to connect a wiring loom with a component with
cable connection and mating plug.
Representation of electric devices Electronic devices and components are increasingly used in the
construction equipment industry. Controls with software, control
elements (e.g. joystics and man / machine interfaces, such as e.g.
screens, LC-Displays) are frequently used to represent and control
machine functions. The internal construction of such components
is in most cases protected or just too complex to be illustrated in
the wiring diagram within the context of the actual machine func-
tion. There are two different ways to simplify the representation of
such devices in the diagram.
Black-Box representation
Fig. 94: Example: Central lubrication system

The Black-Box representation shows the device as a Box with the
connections required for the machine function. Connections which
are not needed do not need to be represented.
The Blackbox representation is mainly used if there is no differenti-
ated information (e.g. signals from pins) available from the sub-
supplier.
118 BW 220 D-5

Identification of externally supplied

documentation
Fig. 95: Example: Identification of externally supplied documenta-

tion
In industrial technology of today it is quite common to integrate
externally supplied electric sub-systems into the projecting of
machines. These systems may be composed of various compo-
nents and wirings. For easier differentiation of BOMAG designation
and manufacturer identification the latter appears under the
BOMAG designation with a text frame and a reduced character
height.
PLC box representation (-A66)
Fig. 96: PLC box representation

The PLC box representation of connecting pins uses a table with
associated connecting plugs, which are used in connection with the
machine functions. The table symbols can be arranged in a line, if
necessary. Connections which are not used do not need to be rep-
resented. The PLC box representation enables the representation
of further reaching functional descriptions to the individual compo-
nent connections.
The PLC box representation is mainly used for controls with
BOMAG software, or for electronic devices which were specified
accordingly, and where information on the assignment of signals is
available.
Identification of similar, adjacent circuit symbols
In circuit diagrams, symbols of the same type are often arranged in
series or close to each other. In such cases it is common practice
to reduce the identification on the subsequent symbol to the cri-
teria, which are different from the previous symbol on the left.
BW 220 D-5 119

For example:-X0 36 and -X0 37. In the example illustrated here the
component identification "-X0" for the left plug symbol is also valid
for the right plug symbol.
Electric circuit symbols
Designation Meaning Example

A n System n Control unit
n Assembly group n Electronic controller
n Subassembly n Computer
n Modules
n ...
B n Converter of non-electrical quantities into elec- n Speed sensor
trical quantities and vice versa n Pressure sensor
n ...
C n Condenser n Capacitors of all sorts
D n Binary element n Integrated circuits
n Accumulators
E n Different electrical equipment n Lights
n Head lights
n ...
F n Safety system n Fuses
n Current protection circuit
n Polarity protection device
G n Power supply n Battery
n Generator
H n Control, detection and signalling devices n Control lights
n Warning buzzer
K n Relay n Flasher encoder
n Contactor n Plug-in relay
L n Inductance n Choke coil
n Coils
n Windings
M n Engine n Fan motor
n Windscreen wiper motor
n Starter
N n Governor n Electronic or electric gov-
n Amplifier ernor
P n Measuring instrument n Tachometer

n Thermometer
n Oil pressure gauge
R n Resistance n Heating resistance
n Potentiometer
n NTC resistor
120 BW 220 D-5

Designation Meaning Example

S n Switch n Switches and buttons of all
sorts
T n Transformer n Ignition coil
n Ignition transformer
U n Converter n DC converter
V n Semiconductor n Diodes
n Transistor
n Thyristor
X n Terminal n Terminal strips
n Plug n Distributor connector
n Plug-in connections n Plug
n Couplings of all sorts
Y n Electrically operated mechanism n Control solenoid valves
n Proportional solenoid
valves
Z n Electric filter n Suppressor
n Suppression filter
4.1.2.3 Identification of switch blocks

Switches of modular design
Fig. 97
F Direction
BW 220 D-5 121

n For normally open contacts the contact symbols _3/_4 are

used.
n For normally closed contacts the contact symbols _1/_2 are
used.
In combination with the contact block numbering described above
each individual connection is clearly defined.
Example:
The contact block marked with 4 is called 43/44, if it is a normally
open contact and 41/42, if it is a normally closed contact.
open contact and 21/22 , if it is a normally closed contact.
4.1.3 Telemecanique switch

Dismantling
Fig. 98
1. Lift up the interlock (5).
122 BW 220 D-5

2. Fold down the switch block (4).

3. Loosen the screw (1).
Fig. 99: Folding down the switch

block
4. Lift up the interlock (2) and pull out the front element (3).
Fig. 100: Pulling out the front element
Assembly
Fig. 101: Assembly

1. Insert the front element (3) into the bore in the control panel.
BW 220 D-5 123

2. Clip the fastening adapter (6) onto the front element (3).
Watch the marks on front element and fas-

tening flange.
3. Tighten the screw (1) with a tightening torque of 0.6 Nm.
Fig. 102: Observe the marks.
4. Clip on the switch block (4).
Hook in the switch block at the bottom first.
Fig. 103: Install the switch block
4.1.4 Deutsch connectors, DT and DTM series

General
NOTICE!
Do not crimp more than one lead per pin or per
socket.
Sockets and pins must not be soldered to leads,
they may only be crimped (see special tools for
electrics).
Fig. 104: Crimp connections When connecting sockets and plugs these must
engage with a noticeable click when both halves
interlock.
The plug connection should not be separable
(without loosening the interlock).
124 BW 220 D-5

DT contacts
Fig. 105: DT series

DT and DTM plug connectors have a wedge which holds the pins
and sockets in place. The wedge can be removed and replaced
without having to cut through the wires.
Removing the DT contacts
1 2 3
S-ELE-0040
Fig. 106: Removing the DT contacts

1. Pull out the wedge using long-nose pliers.
2. Pull the cable lightly and unlock the snap-fit hook with a
screwdriver.
3. Pull the contact out of the plug.
Use the same method when assembling the

socket.
In this case the interlock disassembly tool
serves as an aid to remove the wedges.
BW 220 D-5 125

Installing the DT contacts
1 1.1 1.2
2
S-ELE-0041
Fig. 107: Installing the DT contacts

1. Insert the contact through the grommet until locks into place.
2. Insert the wedge in the direction of the arrow.

socket.
Pull test
The pull test ensures that the wire has been cor-
rectly squeezed into the terminal and the contact
has locked correctly into the housing.
1. Conduct a pull test on each wire; each terminal and each

connection must easily withstand a withdrawal force of 45 N.
126 BW 220 D-5

DTM contacts
Fig. 108: DTM series

DT and DTM plug connectors have a wedge which holds the pins
and sockets in place. The wedge can be removed and replaced
without having to cut through the wires.
Removing the DTM contacts
1 2 3
S-ELE-0042
Fig. 109: Removing the DTM contacts

1. Pull out the wedge (lock) using long-nose pliers.
2. Pull the cable lightly and unlock the snap-fit hook with a
screwdriver.
3. Pull the contact out of the plug.

socket.
In this case the interlock disassembly tool
serves as an aid to remove the wedges.
BW 220 D-5 127

Installing the DTM contacts
1 1.1 1.2
S-ELE-0043
Fig. 110: Installing the DTM contacts

1. Insert the contact through the grommet until locks into place.
2. Insert the wedge until it locks into place.

socket.
Pull test
The pull test ensures that the wire has been cor-
rectly squeezed into the terminal and the contact
has locked correctly into the housing.
1. Conduct a pull test on each wire; each terminal and each

connection must easily withstand a withdrawal force of 45 N.
128 BW 220 D-5

Electric systems – Overview of electric system
4.2 Overview of electric system

4.2.2 Operator’s stand.................................................... 132
4.2.3 Wiring..................................................................... 133
4.2.4 CAN BUS overview................................................ 150
4.2.5 List of equipment................................................... 152
4 5 6 7 8 9 10 11
3 12
13
14
2 15
16
1 17
18
19
20
31 30 29 28 27 26 25 24 23 22 21
S-586-0454

1 Operating console and monitoring module, A15
2 Monitor for reversing monitoring, P42
3 Working head lights, front left, E23
4 Tachograph (P09) and cabin operating console, A178
5 Front windscreen wiper motor, M04
6 Radio (A12) and printer (P11)
7 Working head lights, rear left, E27
8 Working head lights, front right, E25
9 Rear windscreen wiper motor, M05
10 Camera for reversing monitoring, P32
11 Working head lights, rear right, E28
BW 220 D-5 129

12 Travel lever, S55

13 Control elements of driver’s seat
14 Air filter maintenance switch (B03) and ambient temperature sensor (B218)
15 Float switch for coolant compensation tank, B55
16 Fuse box for exhaust gas aftertreatment system; only for machines with exhaust classification Tier4f and
STAGE V
17 Warning buzzer for reverse travel, H14
20 Pressure sensor for travel pump, B234, B235, B236 and B237
21 Battery disconnecting switch, S30
22 Power board for SCR heating (U100), only machines with exhaust classification Tier4f and STAGE V
23 Fluid level sensor, R03
24 Battery, G01
25 Solenoid valve for brake, Y04
27 Front windscreen washer motor, M06 and rear windscreen washer motor, M07
28 Central electrics, travel control (A34), engine control unit (A48), measuring technology control (A83), Tel-
ematic module (A124), cross-slope sensor (B57), diagnostics interfaces (X32) and (X34), Powerboard
and connector strip (X100 to X109)
29 Keyboard for anti-theft protection, A76
130 BW 220 D-5

4.2.1 Central electrics
6
5
4
3 7
2
1 X32
X100 - X109 A124
A161
X34
A162
B57
8
A34
A48
9
X45
A83
10
11
S-586-0467
Fig. 112: Central electrics

1 Travel control, A34
2 Cross-slope sensor, B57
3 Diagnostics interface BOMAG, X34
4 Diagnostics interface Deutz, X32
5 Connector strip X100 to X109
6 Telematic module, A124
7 Module for CAN gateway, A161
9 Powerboard with folding function for better troubleshooting
10 Engine control unit, A48
10 Measuring technology control, A83
BW 220 D-5 131

4.2.2 Operator’s stand
6 1
2 3 4 5 7 12
MIN EC
O MAX
13
14
11 10 9 8
15
S-586-0484
Fig. 113
1 [A15] Instrument cluster
2 [S01] Emergency stop switch
3 [S09] Rotary switch for amplitude pre-selection, not on BVC machines
4 [S26] Rotary switch for working lights (optional equipment)
5 [S299] Button for regeneration, only on machines with exhaust classification STAGE V
6 [S299] Rotary button for regeneration, only on machines with exhaust classification Tier 4f
7 [S127] Rotary switch for engine speed
8 [S37] Rotary switch for direction indicators (optional equipment)
9 [S154] Rotary switch for hazard light system (optional equipment)
10 [S15] Rotary switch for lighting system (optional equipment)
11 [S42] Rotary switch for travel speed ranges
12 [S00] Starter switch
13 [S55] Travel lever
14 [S107] Rotary switch for BVC, only on BVC machines
15 [S09] Rotary switch for vibration, only on BVC machines
132 BW 220 D-5

4.2.3 Wiring
A15
X33
S127
X26
X24
2
S299 X87
X99
S35 S107
S42
S01 S09
S36
S64
S55
S00
H07 X23
X14
X82 M06
M07
XS
X10
B11
B11
X79
GND
1 X4.B
X102
X4.A
X4.D
X6.B
X6.C
X102
X7.A
S-586-0228
Fig. 114
1 Wiring loom, instruments
2 Wiring loom, seat console
BW 220 D-5 133

X78
B55
G02
X72
2 B124
X72
X73
X67
1 OPTION
OPTION
M35-Winterpaket
Kompressor Klimaanlage M35-Winter package
Compressor air-conditioning
Y15
X12
B218
B03
X68
OPTION
Druckschalter Klimaanlage
Pressure switch air conditioning
GND
-X0.B X1A
X101
X108
3
S-586-0450
Fig. 115
1 Wiring loom, engine
2 Wiring loom, adapter
3 Wiring loom, ground
134 BW 220 D-5

X25 Y07
nicht benötigt X30
not required
1 Y08
H14
Y16
Y17
X81
X11
2 Y04
Y30
X69
X80
B21
nicht benötigt
not required
´B11.1
´B11.2
Y31
180° X2A
B60
X2B
X103
_
GND
S-586-0249
Fig. 116
1 Wiring loom, pump installation
2 Wiring loom, adapter warning horn
BW 220 D-5 135

F95:1
F164 150 A S30:4

nicht belegt
F48 not used
F164:1
F00 125 A
F95 30 A S30:3
1
G02
M01:30
180° 4
X0C X0A
S-586-0231
Fig. 117
1 Wiring loom, charge line
2 Wiring loom, starter
3 Wiring loom, main battery switch <> main battery fuse
4 Wiring loom, charge system
136 BW 220 D-5

2 -G03
-G01
+G03
+G01
3
1
- 4
S30:3
S-586-0232
Fig. 118
1 Wiring loom, battery box <> fuses
2 Wiring loom, battery (-)
3 Wiring loom, battery (-)
4 Wiring loom, battery (+)
5 Wiring loom, ground engine <> ground frame
BW 220 D-5 137

A
X1.B
GND
X108 X41
X32 X48
A
1
X45
S-586-0451
Fig. 119
1 Wiring loom, EMR
138 BW 220 D-5

X104
B59
Y30
S-586-0235
Fig. 120
1 Wiring loom, front frame
BW 220 D-5 139

1 X50
X94 X202 X31.3

X201 X31.2
X85 X200 X31.1
X83
E28
R80-1 X4.E X8.B

2 X8.A
X65
B51R
R80-2
E25 X1.4 E27
X1.5
XA12.B
X203
X66 B51L
E32
E23
S-586-0242
Fig. 121
2 Wiring loom, cabin internal
140 BW 220 D-5

AZ 12 tachograph with connection

A12 Option
1
X205
P09
A16
S-586-0236
Fig. 122
1 Wiring loom, radio / tachograph
E21 radio
A12
A12:A
A12:B
X205 1
S-586-0237
Fig. 123
1 Wiring loom, radio adapter <> control console
BW 220 D-5 141

E66 BOMAG Telematic Power

X6D
1 A124
A138
S-586-0238
Fig. 124
1 Wiring loom, Telematic
142 BW 220 D-5

FS27 Electric anti-theft protection
X7B
180°
A67
X16
S-586-0239
Fig. 125
1 Wiring loom, immobilizer
BW 220 D-5 143

K2 heating (optional equipment)
F320
F321
XS28
X207
X76
X76
M57
X7.C
S-587-0009
Fig. 126
M57 Fuel pump for heater unit
144 BW 220 D-5

VM31 Bracket and cable BCM/GPS
X95A
1 A87
X91
2 3
X210
X96A
X211
X204
X93
X85
X90
S-586-0243
Fig. 127
1 Interface CAN-USB
2 Wiring loom BCM, Supply + CAN
3 Wiring loom GPS Power
BW 220 D-5 145

VM33 BOMAG terrameter

X5.E
GND
180°
X107 A83
X88
2
X21
B171
X20
B62
S-586-0241
Fig. 128
1 Wiring loom, measuring computer
2 Wiring loom, acceleration transducer
146 BW 220 D-5

VM20 Economizer
X109f
X109m
GND
2 180°
1 X5E3
XA161
X5E3
XA103
A103
180°
X39
X39
B84
S-586-0463
Fig. 129
1 Wiring loom, transducer for Economizer
2 Wiring loom, Economizer
BW 220 D-5 147

VM38 measuring technology inter-

face X400
X110
X7.C.2
A162
X5.E.2
X7.C.2
X5.E.2
2
S-586-0452
Fig. 130
1 Wiring loom, measuring technology interface
2 Wiring, measuring technology interface
148 BW 220 D-5

M35 winter package
XR79
X67
R79
S-586-0453
Fig. 131
1 Wiring loom, adapter for fuel pre-heater
2 Fuel heater
BW 220 D-5 149

4.2.4 CAN BUS overview
A87
P15
CAN 4
X400
A67
A161 A162
A162
A178
A161
CAN 3
A103
CAN 1
A15
A83
X34
A124
S55
A175
CAN 2
A177
A48
A34
A48
X32
S-586-0449
Fig. 132: CAN bus

A15 Monitoring module
A34 Travel control
150 BW 220 D-5

A48 ECU engine control unit, not available in BW177D-5 (Kubota engine, exhaust classification Tier3a)
A67 Keyboard anti-theft protection
A83 Measuring technology control
A87 USB CAN interface BCM
A103 ECONOMIZER module
A124 ECU BOMAG TELEMATIC
A161 Module for CAN gateway
A175 Electronics for Morey Telematic
A177 ECU ZTR Telematic
A178 Module for cabin operating console
P15 BCM05
S55 Travel lever
X32 Diagnostics interface for engine control unit, not available in BW177D-5 (Kubota engine, exhaust clas-
sification Tier3a)
X34 Diagnostics interface for ESX machine control
X400 Interface for measuring technology
At the end of the eighties, CAN-Bus, Controller Area Network

was created by Bosch for applications in the automotive industry.
The objectives of this development was to ensure real-time, reli-
able and cheap communication between control units, such as
gearbox and engine control unit, but also less time-critical functions
in the area of convenience electronics, such as air-conditioning.
Why CAN? n Connection of control units to realise complex functions.
n Reduction of effort when installing cables and plug-in connec-
tions.
n Better possibilities for diagnostics (central diagnostics socket).
Features of CAN
It is a serial communication interface. The individual bits are trans-
ferred one at a time; only 2 lines are required.
CAN lines are twisted together 30 to 40 times per metre. Electro-
magnetic interferences always occur simultaneously in both lines,
which makes it easier for the software to filter out any interference
signals.
A unified colour assignment does not exist. Both wires may have
different colours, depending on the manufacturer.
At Bomag, a standard has been defined for the wires. Ä Fig. 133
Fig. 133 n Wire (+)
= cable colour blue
n Wire (-)
= cable colour yellow
Measuring at the CAN Signals transmitted through the bus line can generally not be
measured with simple measuring instruments. Testing is therefore
quite complicated for the user. Only the correct line connections
can be tested by means of a continuity test. For the fitter or user to
recognize faults or retrieve information from the BUS, BOMAG
connects display modules to the BUS.
BW 220 D-5 151

Termination At the end of each line there should be a terminating resistance of

120 Ohm. For an individual CAN bus device on a stub line, this
functions just like a single 60 Ohm resistor, which is installed at the
branch location.
4.2.5 List of equipment
Component identifications are used in both the

electrical and the hydraulic documentation and are
identical.
Ä ‘List of components’ on page 114
Operating Function text Technical character-

equipment istics
A02 Direction indicator module 12 V
A12 Radio module 12 V
A34 Travel control
A48 Engine control unit EMR3 (EDC 16)
A67 Keyboard
A93 GPS Receiver
A108 Heating/air conditioning unit
A138 Aerial for BOMAG Telematic
B03 Air filter service switch
B11.1 Warning horn max. 3.5 A
152 BW 220 D-5


equipment istics
B21 Differential pressure switch for hydraulic oil filter
B51.L Radio loudspeaker
B51.R Radio loudspeaker
B55 Float switch in coolant compensation tank
B57 Cross-slope sensor speed range selection 0.5 to 4.5 V
B59 Rotary speed sensor for drum speed
B60 Rotary speed sensor for axle speed
B62 Acceleration transducer
B84 Acceleration sensor, left
B88 EMR engine oil pressure
B93 Sensor for fuel rail pressure
B97 Sensor slewing motor
B104 Pressure switch for air conditioning
B113 Coolant temperature sensor
B114 Engine speed sensor
B124 Water separator sensor, fuel
B130 Engine speed sensor
B133 Sensor for charge air pressure and temperature
B145 Pressure sensor for fuel
B171 Acceleration transducer
B234 Pressure sensor travel pump for axle MA
B235 Pressure sensor travel pump for axle MB
B236 Pressure sensor travel pump for drum MA
B237 Pressure sensor travel pump for drum MA
B312 Sensor for height adjustment of plates 4 to 20 mA
B313 Sensor for lateral adjustment of plates 4 to 20 mA
D2.1 Control light for relay K32 Green
D05 Control light for relay K05 Green
BW 220 D-5 153


equipment istics
Dx Control light for fuse test Green
E08 Direction indicator, front left 21 W
E09 Direction indicator, rear left 21 W
E10 Direction indicator, front right 21 W
E11 Direction indicator, rear right 21 W
E12 Parking light, left 5W
E13 Tail light, left LED
E14 Parking light, right 5W
E15 Tail light, right LED
E16 Head lights, left 55 W
E17 Head lights, right 55 W
E23 Working head lights, front left 12 V, 55 W
E25 Working head lights, front right 12 V, 55 W
E27 Working head lights, rear left 12 V, 55 W
E28 Working head lights, rear right 12 V, 55 W
E29 Cabin light
E30 Heating unit 12 V
E32 Flashing beacon 12 V / 70 W
E72 Illumination of control switch
E159 Heating for driver's seat 12 V / 6.85 A
F00 Main fuse for battery 125 A
F05 Fuse for socket 20 A
154 BW 220 D-5


equipment istics
F07 Fuse for hazard light 10 A
F08 Fuse for direction indicator 10 A
F09 Fuse for parking and tail light, left 10 A
F10 Fuse for parking and tail light, right 10 A
F11 Fuse for front working head lights, left 15 A
F13 Fuse for starter switch 15 A
F17 Fuse for radio 5A
F19 Fuse for working head lights, front left 15 A
F22 Fuse for working head lights, rear 15 A
F23 Fuse for warning horns 15 A
F24 Fuse for monitoring module 10 A
F27 Fuse for wiper and washer, front 15 A
F28 Fuse for wiper and washer, rear 15 A
F29 Fuse for suspended seat compressor 15 A
F39 Main fuse for cabin 80 A
F40 Fuse for cabin heater 30 A
F48 Fuse for pre-heating system 125 A
F67 Fuse for control (potential 30) 15 A
F68 Fuse for potential 30 15 A
F84 Fuse for control (contact 54) 10 A
F91 Fuse for sensors 5A
F95 Fuse for engine control unit 30 A
F103 Fuse for potential 15 15 A
F122 Fuse for engine control unit 10 A
F124 Fuse for fuel pre-heater 25 A
F129 Fuse MD+ 3A
F143 Fuse for rear windscreen heating 20 A
F150 Fuse for GPS receiver 5A
F157 Fuse for magnetic switch starter motor 30 A
F164 Fuse for B+ charge line 150 A
F169 Fuse for starting current 5A
BW 220 D-5 155


equipment istics
F243 Fuse for BOMAG Telematic (potential 30) 7.5 A
F244 Fuse for BOMAG Telematic (potential 15) 5A
F264 Fuse for BCM05 10 A
F266 Fuse for radio/tachograph 10 A
F268 Fuse for fuel pump 20 A
F271 Fuse for BCM-Net 10 A
F272 Fuse for controller of cabin operating console 5A
F279 Spare fuse 15 A
F320 Fuse, timer for optional heater (potential 30) 5A
F321 Fuse, timer for optional heater (potential 15) 5A
Fx Fuse holder for fuse test
FM1 Fuse for sensors 1A
FM2 Fuse for sensors 1A
G01 Battery 12 V / 88 Ah
G02 Generator 14 V / 70 A
G03 Battery 12 V / 88 Ah
H06 Control light for hazard light 12 V
H07 Warning buzzer for malfunctions 70 mA
H14 Warning buzzer for reverse travel 300 mA
K05 Relay for start current 12 V / 20 A
K06 Relay for rear working head lights 12 V / 30 A
K09 Relay for air conditioning 12 V / 20 A
K11 Relay for potential 30 to 15 12 V
K13 Relay for warning horn 12 V / 20 A
K14 Pre-heating relay 12 V
K16 Relay for working head lights, front 12 V / 20 A
K20 Relay for front windscreen wipers 12 V / 20 A
K21 Relay for rear windscreen wipers 12 V / 20 A
K22 Relay for engine shut-down solenoid actuator 12 V / 20 A
K32 Relay for cabin 12 V / 20 A
K38 Relay for starter control 12 V / 40 A
K41 Disconnecting relay 12 V / 20 A
K43 Relay for vibration 12 V / 20 A
156 BW 220 D-5


equipment istics
K48 Relay for travel lever “0” position 12 V / 20 A
K61 Relay for charge control 12 V / 20 A
K141 Relay for rear windscreen heating 12 V / 20 A
K145 Relay for starter solenoid actuator 12 V / 40 A
K189 Brake relay 12 V / 10 A
K209 Relay for fuel pump 12 V / 30 A
M01 Starter
M04 Windscreen wiper motor, front 4.7 A
M05 Windscreen wiper motor, rear 4.7 A
M06 Windscreen washer motor, front 3.5 A
M07 Windscreen washer motor, rear 3.5 A
M10 Compressor of air cushioned seat 12V / < 9A
M57 Fuel pump for heating unit
P09 Tachograph
P11 Printer
P15 BCM05
P32 Camera, reversing monitoring
P42 Monitor, reversing monitoring
P43 Operating hour meter for plates
R03 Fuel level sensor 66 Ω / 64.2 Ω
R10 Parallel resistor 22 Ω / 22 W
R19 Heating flange 167 A
R20 Terminating resistor CAN 120 Ω
R23 Terminating resistor CAN 121 Ω/0.6 W
BW 220 D-5 157


equipment istics
R40 Resistance 18.2 Ω/0.6 W
R79 Fuel pre-heating 200 W
R80 Rear windscreen heating approx. 11 A
S00 Engine start switch
S01 Emergency stop switch
S06 Seat contact switches
S09 Switch front vibration
S14 Switch for hazard light system
S15 Switch for StVZO lighting
S25 Switch for operator’s seat heating
S26 Switch for working lights
S28 Timer
S29 Switch for air suspended seat
S30 Battery isolator switch 250 A
S35 Switch for vibration low / high
S36 Vibration switch
S37 Switch for direction indicator
S42 Travel stage switch 4...20 mA / 0...5 V
S55 Switch for travel control lever
S107 Switch for amplitude setting 4-20 mA
S127 Switch for engine speed
S139 Potentiometer, frequency setting for attachment plates
S439 Switch for amplitude limitation
T14 Aerial for BOMAG TELEMATIC
T21 Radio aerial
V01 Diode S5G-E3
V02 Diode SF 64
V03 Diode SF 64
V04 Diode SF 64
V05 Diode SF 64
V06 Diode SF 64
V07 Diode S1M
158 BW 220 D-5


equipment istics
V08 Diode S1M
V09 Diode S1M
V10 Diode S1M
Y04 Brake solenoid valve 2.41 A
Y07 Solenoid valve for front vibration, high 640-1580 mA
Y08 Solenoid valve for front vibration, small 640-1580 mA
Y15 Magnetic clutch for air conditioning compressor 3.5 A
Y16 Solenoid valve for travel direction forward 640-1580 mA
Y17 Solenoid valve for travel direction backward 640-1580 mA
Y30 Solenoid valve for drum travel speed range 1.05 A
Y31 Solenoid valve for axle travel speed range 1.05 A
Y60 Solenoid valve for floating position
Y72 Solenoid valve for travel direction forward 640-1580 mA
Y73 Solenoid valve for travel direction backward 640-1580 mA
Y98 Solenoid valve, vibration pump for plates 400-1200 mA
Y102 Solenoid valve for floating position
Y122 Solenoid valve, plates up
Y123 Solenoid valve, plates down
Y137 Solenoid valve for EMR locked
Y140 Solenoid valve exciter up 400-1200 mA
Y141 Solenoid valve exciter down 400-1200 mA
Y142 Solenoid valve, shift plates to the left
Y143 Solenoid valve, shift plates to the right
Y144 Solenoid valve, plates floating position
Y145 Solenoid valve, plates (priority)
Y147 Injector A1
Y148 Injector A2
Y149 Injector A3
Y166 Injector A4
Y169 Injector A6
Y170 Injector A5
Y378 Solenoid valve for dozer blade priority
BW 220 D-5 159


equipment istics
Y379 Solenoid valve for dozer blade up
Y380 Solenoid valve for dozer blade down
160 BW 220 D-5

Electric systems – Starting the engine with jump leads
4.3 Starting the engine with jump leads
NOTICE!
A wrong connection will cause severe damage
in the electric system.
– Bridge the machine only with a 12 Volt auxiliary
battery.
1. Connect the plus pole of the external battery first with the
plus pole of the vehicle battery using the first jump lead.
2. Then connect the second battery cable first to the minus pole
of the current supplying auxiliary battery and then to engine
or chassis ground, as far away from the battery as possible.
3. Start the engine.
NOTICE!
Danger of damage to the electronic system!
If no powerful consuming device is switched on,
Fig. 134
voltage peaks may occur when separating the con-
necting cables between the batteries, which could
damage electrical components.
4. Once the engine is running switch on a powerful consumer

(working light, etc.).
5. After starting disconnect the negative poles first and the posi-
tive poles after.
6. Switch off the consumer.
BW 220 D-5 161

Electric systems – Fuse assignment
4.4 Fuse assignment

4.4.1 Notes on safety
WARNING!
Danger of injury by fire in the machine!
– Do not use fuses with higher ampere ratings
and do not bridge fuses.
4.4.2 Central electrics

Fuse Amperage Designation
F05 20 A 12-V socket
F07 10 A Hazard light
F08 10 A Direction indicators
F09 10 A Parking and tail light, left
F10 10 A Parking and tail light, right
F11 15 A Head lights, front
F13 15 A Starter switch
F19 15 A Working head lights, front
F22 15 A Working head lights, rear
F23 15 A Warning horn
F24 10 A Instrument cluster
F29 15 A Compressor - air suspended seat, seat heating
F39 80 A Main fuse for cabin
F40 30 A Heating, air conditioning, fan
F67 15 A Control (potential 30)
F68 15 A Reserve (potential 30)
F84 10 A Control (contact 54)
F91 5A Sensors
F122 10 A Engine control unit
F124 25 A Fuel pre-heating
F129 3A BOMAG TELEMATIC (MD+)
F157 30 A Starter
162 BW 220 D-5


F169 5A Start current
F243 7.5 A BOMAG TELEMATIC (potential 30)
F244 5A BOMAG TELEMATIC (potential 15)
F268 20 A Fuel pump
F320 5A Timer for optional heater (potential 30)
FM1 1A Sensors
FM2 1A Sensors
4.4.3 Main fuses

The main fuse box is located in the engine compartment.
Fig. 135

F164 150 A (B+) charge line
F00 125 A Main fuse (potential 30)
Fig. 136

F48 125 A Preheating system
BW 220 D-5 163

4.4.4 Control console cabin
Fig. 137
Position Fuse Amperage Designation

1 F17 5A Radio
2 F264 10 A BCM
3 F271 10 A BCM net
4 F150 5A GPS
5 F266 10 A Radio/Tachograph
6 F143 20 A Rear windscreen heating
7 F28 15 A Rear windscreen wiper
8 F27 15 A Front windscreen wiper
9 F279 15 A Spare
10 F272 5A Control console cabin
164 BW 220 D-5

4.4.5 Auxiliary heating
B-586-0424
Fig. 138

F320 5A Timer for auxiliary heating (potential 30)
BW 220 D-5 165

Electric systems – Central electrics
4.5 Central electrics
6
5
4
3 7
2
1 X32
X100 - X109 A124
A161
X34
A162
B57
8
A34
A48
9
X45
A83
10
11
S-586-0467

166 BW 220 D-5

Connector strip
X105
X107
X109 X110
X104
X106
X108
X103
X101
X102
X100
S-586-0468
Fig. 140
4.5.1 Power board

Solid press-fit technology for high-
current applications NOTICE!
Processing
– During assembly, installation and use, twisting
and warping of the assembly must not occur
under any circumstances.
– A printed circuit board must never be
machined, adjusted or manipulated in any
other way with sharp-edged or metallic tools;
neither may objects such as tools, screws, etc.,
be placed on a printed circuit board, as this
might damage the insulating solder resist and
conductor tracks.
– Fuses may only be replaced and not repaired
or bridged.
– Conductive contamination of the assembly or
contact with aggressive media (greases, oils,
cleaning agents, conductive dust, fertilizers,
etc.) must be avoided at all costs.
– The power board may only be put into opera-
tion after it has been installed.
BW 220 D-5 167

S-ELE-0039
Fig. 141: Example figure of solid press-fit technology

In press-fit technology, a connection is made between the plated-
through sleeve of a printed circuit board and the contact pin, e.g. of
a plug connector. The result is a powerful, gas-tight electrical con-
nection between pin and sleeve, which also has an extremely low
electrical resistance. This makes the solid press-fit technology par-
ticularly suitable for use in the high-current range and in harsh
environmental conditions.
This has the following advantages:
n Particularly quick connection with the wiring loom of the vehicle
n Possibility of combining high-current and signal lines
n Highest possible avoidance of connecting and wiring faults
n Gain in space due to the possibility of compact design (e.g. by
placement from both sides) as well as weight reduction
n Increased reliability and prolonged lifetime of the overall
system
n Clear display of switching states by means of LEDs (simple
diagnostics)
168 BW 220 D-5

S-586-0312
Fig. 142: Plug side

X0A Supply potential 30
X0B Supply GND
X0C Supply potential 30 before battery
K43/K78
30A
S-586-0313 F148/F25 F103/F41
Fig. 143: Top side

R10 Dropping resistor for generator excitation
+30 Potential 30, battery
X8B Potential 31, GND
X8A Potential 30
Fuse test Test base for fuses
BW 220 D-5 169

On each relay is a green control LED which is activated parallel to

the coil. This indicates if the coil is energised.
K38
K41
K13
K145
K05
K61
K22
K209
K16
K43
K78 K09
K06
A02
K11
K48
S-538-0055
Fig. 144: Installed relays

A01 Flasher encoder
K05 Relay for start current
K06 Relay for working head lights
K09 Relay for air conditioning
K11 Relay for potential 30 to 15
K13 Relay for warning horn
K16 Relay for working head lights, front
K22 Relay for engine solenoid
170 BW 220 D-5

K38 Relay for starter control

K41 Disconnecting relay
K43 Vibration relay for single drum roller
K48 Relay for travel lever “0” position
K61 Relay for charge control
K78 Relay for emulsion pump for BW 11 RH-5
K145 Relay for starter solenoid actuator
FM2 F19
FM1 F22
F243
F39
F157
F23 F268
F68
F11
F13 F84
F09 F67
F10 F07 F146
F124
F40
F91
F103 / F41
F08
F05
F244
F29
F24
F169 F122
F148 / F25 S-538-0056
Fig. 145: Installed fuses

1 Fuse test cap
BW 220 D-5 171

Test base for fuses

The printed circuit board is equipped with a fuse test socket (fuse
test). When plugging in an intact fuse, the LED "DX" lights up.
Fig. 146: Pictogram
172 BW 220 D-5

Electric systems – Description of electrical components
4.6 Description of electrical components

4.6.1 Sensors and actuators........................................... 173
4.6.2 CPU control units and electrical modules.............. 178
4.6.3 Cabin operating console, A178.............................. 182
4.6.1 Sensors and actuators

4.6.1.1 Acceleration transducer, B62 & B171................. 173
4.6.1.2 Differential pressure switch for hydraulic oil filter,
B21..................................................................... 174
4.6.1.3 Air filter vacuum switch, B03............................... 175
4.6.1.4 Sensor, water in fuel, B124................................. 176
4.6.1.5 Float switch coolant tank, B55............................ 176
4.6.1.6 Level sensor in diesel tank (R03)....................... 177
4.6.1.7 Charge control light............................................. 177
4.6.1.1 Acceleration transducer, B62 & B171
Fig. 147
BVC machines and machines with E-VIB meter are equipped with
two piezo-electric acceleration transducers, which are mounted to
the drum.
BW 220 D-5 173

During operation these transducers transmit the acceleration sig-

nals to the measuring ESX.
The function of the piezo electric acceleration transducer is based
on the self-charging effect of quartz crystals under mechanical load
(pressure, tension, torsion) in vertical direction to the polar axes,
which was discovered in 1880 by J. and P. Curie.
The piezoelectric acceleration sensor comprises two basic compo-

nents:
n Piezoelectric material
n Seismic mass
Once side of the piezo disc is connected with the seismic mass,
the other one with a rigid carrier. When this combination is set to
oscillate, the seismic (sluggish) mass transfers a force to the piezo
disc. According to Newton's Law the resultant force is the product
of acceleration and mass. The piezoelectric effect generates a
charge (u) on the electrodes, which is proportional to the force and
Fig. 148 thus also to the acceleration (a).
1 Seismic mass (m)
2 Piezoelectric material
3 Acceleration (a)
4.6.1.2 Differential pressure switch for hydraulic oil filter, B21

The differential pressure switch switches to ground at a pressure
differential of Δp 3.6 bar.
Hydraulic oil filter warning light: The switching condition is
detected by the ESX-control (A34) and forwarded to the instrument
cluster (A15) via the CAN bus connection.
Designation Note
Hydraulic oil Lights up if the hydraulic oil filter is
filter warning blocked. Warning buzzer sounds. The
light engine is shut down after approx. 2
minutes.
Check the hydraulic system and
Fig. 149
replace the hydraulic oil filter.
174 BW 220 D-5

4.6.1.3 Air filter vacuum switch, B03

At a vacuum of > 50 mbar the vacuum switch (1) will switch to
ground.
Air filter warning light: The switching condition is detected by the
ESX-control (A34) and forwarded to the instrument cluster (A15)
via the CAN bus connection.
Designation Note
Air filter Lights up if the air filter is blocked.
warning light
Clean or replace the air filter.
Fig. 150
BW 220 D-5 175

4.6.1.4 Sensor, water in fuel, B124

The sensor data are detected by the EMR control (A48) and
passed on to the instrument cluster (A15) via the CAN-bus connec-
tion.
Designation Note
Water in fuel Lights up when the water content in
warning light the fuel pre-filter reaches the sensor
contacts. The warning buzzer
sounds.
Clean the water separator.
Fig. 151
4.6.1.5 Float switch coolant tank, B55

In case of a too low coolant level the float switch will switch to
ground.
Coolant level warning light: The switching condition is detected
by the ESX-control (A34) and forwarded to the instrument cluster
(A15) via the-CAN bus connection.
Designation Note
B55
Coolant level Lights up if the coolant level is too
warning light low. The engine is shut down after a
short while.
Check coolant level, check cooling
system for leaks, repair if necessary.
S-921-0202
Fig. 152
176 BW 220 D-5

4.6.1.6 Level sensor in diesel tank (R03)

The sensor inside the tank is equipped with a float, which drops or
rises with the fuel level. Contact springs mounted on the float
thereby slide along two resistor wires arranged parallel to the
movement of the float and generate a resistance value, which is
proportionate to the fluid filling level. The corresponding resistance
value is measured by an electric meter and displayed as fluid level
value.
Fig. 153: R03
Nominal values:
n Tank empty, 64.2 Ω
n Tank full, 0.5 Ω
If no level switch is connected or the cable is broken, no fuel level
will be displayed.
4.6.1.7 Charge control light

Charge control light: The switching condition on the generator
terminal (D+) is detected by the ESX control (A34) and forwarded
to the instrument cluster via the CAN bus connection.
Designation Note
Charge control Lights up if the battery is not being
light charged.
Check V-belt, if necessary repair the
generator.
Fig. 154
The control lamp lights up if a ground signal is

applied to the generator terminal (D+).
The relay K61 on the Powerboard also switches if
a ground signal is applied to the generator terminal
(D+). The LED (D61) on the relay base lights up.
BW 220 D-5 177

4.6.2 CPU control units and electrical modules

Control units (ECU = electronic control unit or ECM = electronic
control module) are electronic modules which are mainly installed
in places where something needs to be controlled or regulated.
Control units are used in many electronic sectors in the automotive
industry, as well as for controlling machines, plants and other tech-
nical processes.
Control units generally work according to the IPO model. IPO
stands for input-process-output. Sensors are available for the
input. They determine a physical parameter like e.g. speed, pres-
sure, temperature etc. This value is then compared with a calcu-
lated or fixed nominal value that has been entered into the control
unit. If the measured value does not match the stored value, the
control unit regulates the physical process by means of actuators,
so that the measured actual values match the nominal values
again. This means that the actuators correct the running process.
In modern vehicles, control units are connected to each other via
system buses (CAN bus). The units exchange information
throughout the vehicle’s system, such as the operating states and
other relevant data. Furthermore, the on-board diagnostics or the
diagnostic system of the vehicle are connected by means of these
buses (and possible K-lines). Furthermore, external diagnostic
devices (alternatively normal personal computers or laptops with a
matching interface) can communicate with the control units. In this
case, the system will be prompted to find out whether the constant
self tests of the control unit have revealed and registered any faults
in the system or on the connected sensors.
Travel control (A34) and measuring

technology control (A83)
Fig. 155
The freely programmable control unit is an independently-working
measuring- and control device for managing the sensors and
actuators. It can process multiple independent or connected tasks
in real time.
All inputs and outputs are protected against overvoltage and short
circuits and are diagnosable.
178 BW 220 D-5

A sturdy aluminium die cast housing (protection class IP 65, opt. IP

67, with a GORE-TEX ® membrane for pressure compensation)
not only ensures high protection against electromagnetic interfer-
ences, but also provides reliable protection against mechanical
stress.
Component description of engine

control unit, A48
Fig. 156
Designation Technical data

Nominal voltage 12 and 24 V DC
Operating voltage 9 - 32 V, engine start up to 6 V possible
Main relay Integrated
Plug Vehicle side: 94 pins
Engine side: 60 pins
The ECU controls:

n Injection quantity
n Injection timing
n Injection rate (number of injections)
n Injection pressure (rail pressure)
n Exhaust gas aftertreatment system
The ECU is also equipped with:
n Fault log
n Diagnostic function
BW 220 D-5 179

Replacing the control unit Each control unit is clearly designated to the engine, in accordance
with the respective application. In case of a replacement the con-
trol 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).
The Deutz part-number specified on the EMR-con-

trol unit is the part number without software spe-
cific for the engine. The correct part number can
be found in the BOMAG spare parts catalogue.
Module for CAN gateway, A161 and

A162
S-870-0191
Fig. 157
A gateway is an electronic device that enables the connection of
different network technologies.
The CAN gateway is a compact device for automotive applications.
It can be used for a whole range of applications thanks to its small
size and easy installation.
180 BW 220 D-5

4.6.2.1 Electronic module for air conditioning, A108
Fig. 158
1 Switch for fresh air (S44)
2 Rotary switch for air conditioning
3 Cabin fan (M09)
B104 Pressure switch for air conditioning
Y15 Solenoid valve for air conditioning compressor
BW 220 D-5 181

4.6.3 Cabin operating console, A178
X202
K20
K21 K32
K141
D2.1
X206
D2.3 X204
D2.4 D2.2 X203
X201 31
X205 X200 30
S-921-0201
Fig. 159
K20 Relay for front windscreen wipers
K21 Relay for rear windscreen wipers
K32 Relay for cabin
K141 Relay for rear windscreen heating
X200 Potential 30, power supply
X201 Potential 31, ground
X202 Connection of power board
X203 Connection for cabin equipment
X204 Connection BCM and printer
X205 Connection radio and tachograph
X206 Connection of optional headlights
182 BW 220 D-5

Fig. 160
Push button assignment

Pos. Designation Note
1 Side lights/additional illumination left Optional equipment
2-7 not used
8 Side lights/additional illumination right Optional equipment
9 Rear windscreen wiper Interval/on/off
10 Washer nozzles for rear windscreen
11 Rear windscreen heating The rear windscreen heating is switched
off after three minutes.
12 Rear working lights
13 Cabin light
14 Front working lights
15 Flashing beacon
16 Washer nozzles for front windscreen
17 Front windscreen wiper Interval/on/off
BW 220 D-5 183

Electric systems – Training of electric system
4.7 Training of electric system

4.7.1 Electrics training machine control
184 BW 220 D-5

Service Training
Electrics
Single Drum Rollers – 5
Version 1.06
Version/Status: V1.06 / 14.09.20 Page 1 of 77

Author: Brand / EE
BW 220 D-5 185

Service Training SDR -5
Table of contents
1 Confirmation of changes ...............................................................................................................6

1.1 Document ..............................................................................................................................6
1.2 Software.................................................................................................................................7
Displayed monitoring activities with fault reactions ........................................................................13
2 Known faults .................................................................................................................................14
3 The diagnostics system...............................................................................................................15
3.1 Display functions ................................................................................................................15
3.2 General facts and operation ..............................................................................................16
3.2.1 4-button travel lever .........................................................................................................16
3.2.1.1 Calling up service mode............................................................................................... 16
3.2.1.2 Entering input codes .................................................................................................... 16
3.2.2 7-, 8- or 9-button travel lever ............................................................................................17
3.2.2.1 Calling up service mode............................................................................................... 18
3.2.2.2 Entering input codes .................................................................................................... 18
3.3 Querying firmware version ................................................................................................19

3.3.1 Meaning of the firmware number......................................................................................19
4 Fault log – displaying and deleting ............................................................................................20
4.1 Showing logged faults .......................................................................................................20
4.1.1 Code 700 with two-colour display .....................................................................................20
4.1.2 Code 700 with multi-coloured display ...............................................................................20
4.1.3 Switch off the “show stored faults” function: .....................................................................21
4.1.4 Deleting all stored faults ...................................................................................................21
4.2 Delete engine control unit fault log ..................................................................................22
4.2.1 Deleting logged engine faults ...........................................................................................22
4.2.2 Deleting active engine faults ............................................................................................22
5 Settings and queries ....................................................................................................................23
5.1 Setting the machine type ...................................................................................................23
5.1.1 BW145 D/DH/PDH ...........................................................................................................23
5.1.2 BW177 D/DH/PDH/BVC ...................................................................................................24
5.1.3 BW197 DH .......................................................................................................................24
5.1.4 BW211 D/PD/DH/PDH .....................................................................................................25
5.1.5 BW212 D/PD/DH..............................................................................................................25
5.1.6 BW213 D/DH/PDH/BVC ...................................................................................................26
5.1.7 BW214 D ..........................................................................................................................26
5.1.8 BW216 D/PD/DH/PDH .....................................................................................................27
5.1.9 BW219 D/PD/DH/PDH/BVC .............................................................................................27
5.1.10 BW226 DH/PDH/BVC/DI/RC............................................................................................28
5.1.11 Procedure for initial commissioning of a control ...............................................................29
5.1.11.1 4-button travel lever ..................................................................................................... 29
5.1.11.2 7-, 8- or 9-button travel lever ........................................................................................ 29
5.1.12 Procedure for changing a machine type ...........................................................................29
5.2 Driving against the closed brake ......................................................................................30
5.3 Automatic detection of surge currents in travel system (information code 1090) ......31
5.3.1 Procedure.........................................................................................................................32
5.4 Display of coil current on the travel pump ......................................................................33
5.4.1 Procedure.........................................................................................................................33

Author: Brand / EE
186 BW 220 D-5

5.5 Display of pressure on the travel pump ...........................................................................34

5.5.1 Procedure for DH/PDH/BVC/DI/RC machines .................................................................34
5.5.2 Procedure BW145/177 D-machines .................................................................................35
5.6 Display of pressure on the vibration pump .....................................................................35
5.6.1 Procedure BW145/177 D-machines .................................................................................35
5.7 Ports BW145/177/197 DH/PDH/BVC ..................................................................................36
5.8 Ports BW145/177 D .............................................................................................................37
5.9 Ports BW211-226 DH/PDH/BVC/DI/RC ..............................................................................38
5.10 Activating / deactivating the pressure override ..............................................................39
5.10.1 Procedure.........................................................................................................................39
5.11 Calibrating the speed detection (calibration of wheel diameter) ..................................40
5.11.1 Procedure.........................................................................................................................40
5.11.2 Explanation ......................................................................................................................40
5.12 Show pulses per 10 metres ...............................................................................................41
5.12.1 Procedure.........................................................................................................................41
5.13 Showing the speed of the rotary speed sensor in m/min ..............................................41
5.13.1 Procedure.........................................................................................................................41
5.14 Showing the speed of the rotary speed sensor in km/h (as of software version V4.06) ..41
5.14.1 Procedure.........................................................................................................................41
5.15 Showing the pulses of the rotary speed sensor .............................................................42
5.15.1 Procedure.........................................................................................................................42
5.16 Showing the direction signal of the rotary speed sensor ..............................................42
5.16.1 Procedure.........................................................................................................................42
5.17 Showing the travel speed range .......................................................................................42
5.17.1 Procedure.........................................................................................................................42
5.18 Setting the vibration frequency ........................................................................................43
5.18.1 Procedure.........................................................................................................................43
5.19 Activating/deactivating the cabin .....................................................................................44
5.19.1 Procedure.........................................................................................................................44
5.20 Setting the serial number (information code 4019) ........................................................45
5.20.1 Procedure with 4-button travel lever.................................................................................45
5.20.2 Procedure with 7-, 8- or 9-button travel lever ...................................................................45
5.21 Activating/deactivating the measuring technology ........................................................46
5.21.1 Procedure.........................................................................................................................46
5.22 Activating/deactivating the printer ...................................................................................46
5.22.1 Procedure.........................................................................................................................46
5.23 Checking the position of the Vario exciter ......................................................................47
5.23.1 Procedure.........................................................................................................................47
5.24 Carrying out the acceleration transducer position test (information code 4071)........48
5.24.1 Procedure.........................................................................................................................48
5.25 Activating ECONOMIZER ...................................................................................................49
5.25.1 Procedure.........................................................................................................................49
5.26 Carrying out calibration of ECONOMIZER (information code 4081) .............................49
5.26.1 Procedure.........................................................................................................................49

Author: Brand / EE
BW 220 D-5 187

5.27 Reading out counter for “Regeneration suppressed” ....................................................50

5.27.1 Procedure.........................................................................................................................50
5.28 Deleting counter for “Regeneration suppressed” ..........................................................50
5.28.1 Procedure.........................................................................................................................50
5.29 Activating/deactivating the dozer blade...........................................................................51
5.29.1 Procedure.........................................................................................................................51
5.30 Activating/deactivating the attachment plates ................................................................52
5.30.1 Procedure.........................................................................................................................52
5.31 Activating/deactivating the reversing lock with lowered attachment plates ...............52
5.31.1 Procedure.........................................................................................................................52
5.32 Adjusting the plates despite missing sensors ................................................................53
5.32.1 Procedure.........................................................................................................................53
5.33 Setting the cross-slope sensor (information code 1265) ...............................................54
5.33.1 Procedure.........................................................................................................................54
5.34 Displaying the cross slope ................................................................................................54
5.34.1 Procedure.........................................................................................................................54
5.35 Flushing the double pumps hydrostatically ....................................................................55
5.35.1 Procedure.........................................................................................................................55
5.36 Testing double pumps individually ..................................................................................56
5.36.1 Procedure.........................................................................................................................56
5.37 Setting the coolant filling level sensor.............................................................................57
5.37.1 Procedure.........................................................................................................................57
5.38 The “Water in fuel” sensor shuts down the engine ........................................................57
5.38.1 Procedure.........................................................................................................................57
5.39 Performing the EOL test (information code 5180) ..........................................................58
5.39.1 Procedure.........................................................................................................................58
6 Other explanations .......................................................................................................................59
6.1 Extended machine functions.............................................................................................59
6.1.1 Hydraulicoil filter monitoring .............................................................................................59
7 Replacement of components ......................................................................................................60
7.1 How to proceed when replacing components?...............................................................60
7.2 Replacement of an ESX control ........................................................................................60
7.3 Replacement of a travel pump / axle drive motor / drum drive motor ..........................60
7.4 Replacement of a vibration pump / vibration motor .......................................................60
7.5 Component replacement without adjustment procedure ..............................................61
8 Description of the signals on the ESX control ..........................................................................62
9 Description of signals on the travel lever ..................................................................................68
10 Descriptions of signals on the display ......................................................................................70
11 Fault codes of the ESX control ...................................................................................................72
12 Input codes of the ESX control ...................................................................................................73
13 History ...........................................................................................................................................73
14 Terminology in connection with ESX .........................................................................................74

Author: Brand / EE
188 BW 220 D-5


Author: Brand / EE
BW 220 D-5 189

1 Confirmation of changes
1.1 Document
This document applies for all single drum rollers of generation “5”
(BW145-226 D/PD/DH/PDH/BVC/DI/RC).
No. Date Description of changes resp.

1.00 23.06.2015 Version 1.00 for single drum rollers -5 created. Brand
1.01 22.11.2016 Functional supplements. Brand

Author: Brand / EE
190 BW 220 D-5

1.2 Software
Vers. Date Description of changes resp.

V 2.00 20/11/2013  D-machines without pressure sensors. Brand
V 2.01 06/02/2014  Communication of travel control – measuring technology Brand
adjusted.
 Travel ramps for DH machines adjusted.
V 2.02 25/02/2014  Surge current limits in travel system adjusted. Brand
V 2.03 11/03/2014  BW197 DH released. Brand
 Teaching process for surge currents optimized.
V 2.04 21/05/2014  Option “ECOstop” added. Brand
 Option “Immobilizer” added.
V 2.05 03/06/2014  Limits of travel speed range switch Brand
(DH/PDH/BVC machines) adjusted.
V 2.06 26/06/2014  Limits of travel speed range switch (D machines) Brand
adjusted.
 Manual setting of vibration frequency added.
V 2.07 28/07/2014  BW145 PDH released. Brand
 BW177 PDH released.
 Vibration frequency limits adjusted.
V 2.08 03/09/2014  Fault “Delete fault log” rectified. Brand
V 2.09 08/09/2014  Fault “Shutdown time with ECOstop” rectified. Brand
V 2.10 09/10/2014  Fault “Pulses per 10m for measuring technology” rectified. Brand
V 2.11 11/12/2014  Fault monitoring for speed sensor added. Brand
 Engine speed for “Driving against closed brake” adjusted.
V 2.12 28/01/2015  Fault 9170 rectified. Brand
 Vibration frequencies for BW145 D/DH/PDH adjusted.
V 2.13 09/03/2015  Fault in communication with measuring technology Brand
rectified.
V 2.14 04/05/2015  Input of serial number revised. Brand
V 2.15 12/05/2015  Input code “Vibration also at high travel speed” added. Brand
V 2.16 01/06/2015 Immobilizer fault rectified. Brand
V 2.17 09/07/2015  Counter for “Regeneration suppressed” added. Brand
 Display of last page when starting the machine type.
 Individual operation of double pumps added.
V 2.18 28/07/2015 Fault “Selection of machine type” rectified. Brand
V 2.19 11/12/2015  Fault in teaching process “Pulses per 10 m” rectified. Brand
 Change of regeneration switch/button added.
V 2.20 22/11/2016  Parameter “Engine speed at low idle” for BW145/177 D Brand
adjusted.
 Option “VM38” added.
 Statistics module added.
V 2.21 13/02/2018  Fault in display of operating hours for Kubota engines Brand
rectified.

Author: Brand / EE
BW 220 D-5 191


V 3.00 04/05/2015 First software for series. Brand
V 3.01 19/06/2015  BW211 D/PD/DH/PDH released. Brand
 BW212 D/PD/DH released.
 BW213 D/BVC released.
 BW214 D released.
 BW216 D/PD released.
 BW219 DH/PDH released.
V 3.02 22/07/2015  BW213 DH/PDH released. Brand
 BW226 DH/PDH/BVC/DI/RC released.
 BW211 D/PD/DH/PDH vibration frequency adjusted.
 BW212 D/PD/DH vibration frequency adjusted.
 BW213 D/BVC vibration frequency adjusted.
 BW213 DH/PDH/BVC min. idle speed adjusted.
 BW216 D/PD min. idle speed adjusted.
V 3.03 06/08/2015  BW216 DH/PDH released. Brand
V 3.05 21/10/2015  BW219 BVC released. Fondel
 Fault 9170 rectified.
 Fault in teaching procedure “Pulses per 10 metres” Brand
rectified.
V 3.06 11/12/2015  BW219 D/PD released. Brand
 BW226 BVC Tier 3 released.
 BW226 DI Tier 3 released.
 BW177 D (Kubota Tier 4f) released.
 Procedure EOL-Test revised.
 Driving in reverse with plates lowered deactivated.
 Mode for adjustable coolant filling level sensor
implemented.
V 3.07 15/02/2016  BW177 D/DH/PDH Tier 3 released. Brand
 BW211 D Tier 3 released.
 BW213 DH/PDH Tier3 released.
 Input codes “Water separator shuts down engine” added.
 Frequency adjustment added.
 Fault DEF warning lamp rectified.
V 3.08 01/03/2016  BW177 DH/PDH/BVC released. Brand
 BW197 DH released.
 BW226 DH/PDH/BVC max. travel speed changed to 9 km/h.
V 3.09 14/04/2016  BW145 DH released. Brand
 Operation of plate assembly extended.
V 3.10 02/05/2016  BW226 PDH Tier 3 added Brand
V 3.11  BW213 D Tier 3 released. Brand
 BW213 BVC Tier 3 released.
 Option “VM38” added.
 Test “Position acceleration transducer” added.
 Test “Travel pump test” added (only for DH/BVC
machines).
 Information code “Serial no. not set” added.
 Information code “Cross-slope sensor not adjusted”
added (only for DH/BVC machines).
 Max. travel speed with lowered plates limited.
V 3.12 01/06/2016  BW216 D/PD Tier 3 released. Brand
 BW219 DH/PDH Tier 3 released.
V 3.13 28/06/2016  BW219 D/PD Tier 3 released. Brand
 BW226 DH/PDH Tier 3 released.

Author: Brand / EE
192 BW 220 D-5


V 3.14 09/08/2016  Fault “Communication machine on test stand” rectified. Brand
 Engine speed low idle for TCD6.1 adjusted.
 Emergency stop function adjusted.
 Saving parameters on the display added.
V 3.15 15/11/2016  Fault “Vibration at standstill” rectified. Brand
 BW211 PD Tier 3 released.
V 3.16 16/11/2016  Parameter fault ECOstop on Tier 3 machines rectified. Brand
V 3.17 08/06/2017  Plates held in top position. Brand
V 3.18 04/08/2017  Fault “Backward travel with lowered plates” rectified. Brand
V 3.19 08/08/2017  Input code “Display of backward travel with lowered Brand
plates activated” added.
V 3.20 20/10/2017  Fault in regeneration switch/button rectified. Brand
The software V3.xx has been replaced by the software V5.yy and will not be further maintained.
If a machine still has software V3.xx, the version V3.20 has to be installed first and then version
V5.yy.

Author: Brand / EE
BW 220 D-5 193


V 4.00 14/12/2016  Pressure override BW145/177 D via software. Brand
 Vibration revised.
V 4.01 16/01/2017  BW145 D released. Brand
 BW177 D released.
 Fault frequency adjustment rectified.
V 4.02 19/01/2017  Fault in travel lever (1005 ) rectified. Brand
 Fault in display of travel speed ranges rectified.
V4.03 20/02/2017  BW177 D Tier 3 released. Brand
 Test of acceleration transducer in BVC machines added.
 Fault in high-pressure measurement for attachment plates
rectified.
 Fault in display for BW177 D/DH/PDH Tier 3 rectified.
V 4.04 28/02/2017  Fault in display of imperial units system rectified. Brand
V 4.05 21/03/2017  Parameter for pressure override adjusted. Brand
V 4.06 02/05/2017  Input codes “1104” and “1114” added (travel speed in Brand
km/h).
 Electric pressure override adjusted.
V 4.07 09/05/2017  Fault “Pressure sensor plausibility” rectified. Brand

V 4.08 30/05/2017  BW177 parameter for pressure override adjusted. Brand
 New version of cabin module implemented.
 Fault “Regeneration counter suppressed” rectified.
V 4.09 14/06/2017  Fault “Travel lever doesn’t work” rectified. Brand
V 4.10 08/08/2017  Fault “Backward travel with lowered plates” rectified. Brand
V 4.11 12/10/2017  BOMAG diagnostics implemented. Brand
 Fault “Pressure sensor plausibility” for BW145-197
rectified.
V 4.12 19/10/2017  Fault in regeneration switch/button rectified. Brand
V 4.13 24/10/2017  Fault “Teach surge currents” rectified. Brand
 Fault “Teach pulses per 10 metres” rectified.
V 4.14 28/11/2017  Fault “Test acceleration transducer” rectified. Brand
 Fault “ECONOMZIER calibration” rectified.
V 4.15 14/12/2017  Coolant filling level sensor changeover for Deutz TCD3.6 Brand
and TCD4.1.
 Fault “Display of operating hours” for Kubota engines
rectified.
V 4.16 01/02/2018  Cross slope indicator [%] added to display Brand
(DH/BVC machines).
 Fault “Vibration signal in measuring technology control”
rectified.
If a machine still has software V4.xx, then version V 5.yy can simply be installed.

Author: Brand / EE
194 BW 220 D-5


V 5.00 26/01/2018  Cross slope indicator [%] added to display Brand
(DH/BVC machines).
 Fault “Vibration signal in measuring technology control”
rectified.
 Deutz TCD2012 L06 (150kW) implemented.
V 5.01 06/03/2018  Communication check between travel control and engine Brand
control unit added.
 Fault “ECONOMIZER calibration not saved” rectified.
V 5.02 25/05/2018  BW219 D Tier 3 released. Brand
 BW226 DH Tier 3 released.
 Deutz TCD2012 L04 (103kW) implemented.
 Display of operating hours per input code added.
V 5.03 05/06/2018  Input codes “pressure override” added. Brand
 Driving without travel speed range switch permitted
(max. 1 km/h).
 Maximum engine speed when driving uphill and vibration
is switched on (only on D/PD machines).
If a machine still has software V5.xx, then version V 6.yy can simply be installed.

Author: Brand / EE
BW 220 D-5 195


V 6.00 17/08/2018  New hardware (control BMESX2). Brand
V 6.01 18/10/2018  BW219 DH Tier 3 released. Brand
 BW226 DH Tier 3 released.
 BW226 DI Tier 3 released.
 BW145/177 prebuy added.
V 6.02 25/10/2018  D+ signal debounced. Brand
V 6.03 12/11/2018  Parameters for vibration adjusted. Brand
 Dozer blade adjusted.
V 6.04 18/12/2018  Kubota diesel engine stage V added.
 New display (colour display) added.
 New travel levers (4 or 9 buttons) added.
 New regeneration button (push button) added.
V 6.05 15/01/2019  Variocontrol and Economizer added to the colour display.
 Fault when setting the serial number rectified.
V 6.06 06/02/2019  Overview page on colour display activated.
 Button for floating position of dozer blade and attachment
plates adjusted.
 Fault input code 4040 rectified.
 Fault in Economizer surge information rectified.
 Fault in background illumination of colour display rectified.
 Fault in floating position of attachment plates rectified.
 Fault in activation of VM38 in VM20 rectified.
V 6.07 11/02/2019  Fault in colour display (Signet 24- 29) rectified.
V 6.08 25/02/2019  Function to delete fault log via BOMAG diagnostics
added.
 BW216/219 D/PD improved gradeability implemented.
 Fault in ECOstop activation rectified.
 Fault in travel speed range switch rectified.
 Fault in Kubota engine communication (fault code 5023)
rectified.
 Fault in immobilizer (input code 7091) rectified.
 Fault in frequency adjustment (input code 3052 or 3053)
rectified.

Author: Brand / EE
196 BW 220 D-5

Displayed monitoring activities with fault reactions
Reaction Symbol on fault Warning Warning Engine stop

indicator
Code output Code output Code output
Signal without buzzer with buzzer with buzzer
Fault in exhaust gas

aftertreatment
5161 5153 5154

Exhaust gas
aftertreatment 5155
5156
High exhaust gas
5161
temperature
Engine oil pressure

5100 5101
(from EMR) 5112 5112
Coolant temperature
5100 5101
(from EMR) 5116 5116
5024 5025
Coolant filling level
after 5 s after 10 s
5026 5027
Engine air filter
after 5 s after 2 min.
Hydraulic oil filter

(ATTENTION! Delay in
5500 5501
acceleration time. See after 5 s after 2 min.
6.1.1)
5028 5029
Water separator in after 5 s after 2 min.
fuel filter
(Standard
not active)
1300
Seat contact
1330
Arm rest

Author: Brand / EE
BW 220 D-5 197

2 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:
Fault 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.

Author: Brand / EE
198 BW 220 D-5

3 The diagnostics system

The machine is equipped with a diagnostics system consisting of display unit (LCD) and button-type
input unit (in this case the travel lever) to report machine faults, display measuring values and to set
parameters.
3.1 Display functions
The field t on the LCD display shows the following diagnostic readings:
Type of indication Flashing Flashing “d” Comment

warning
triangle
Fault message
* *
Warning
* *
Note
* *
Display and measuring Values ranging from
values 0 0 0 0 - 9 9 9 9 to be called up via
input codes
Parameter setting Values ranging from
0 0 0 0 - 9 9 9 9 to be called up via
input codes
Negative display values are identified by a “minus sign”.
If several faults are detected, the displayed fault codes will change in a 3 second cycle.
Version/Status: V1.06 / 14.09.20 Functions of ESX Control Page 15 of 77

Author: Brand / EE
BW 220 D-5 199

3.2 General facts and operation
The following chapter describes the operation of the display via travel lever buttons.
3.2.1 4-button travel lever
The 4-button travel lever is as follows:
Button assignment:
1: Horn (orange button)

2: Vibration on/off (red button)
3: Info 1 (yellow button F1)

3.2.1.1 Calling up service mode

For this purpose the display must be switched over to service mode via input mode. This is
accomplished via the two yellow info buttons “INFO 1” and “INFO 2” on the back of the travel lever.
Navigating in input- and service mode is also accomplished via the two yellow info buttons.
The travel lever should be in locked braking position in order to activate input mode!
By simultaneously pressing both info buttons (for approx. 3 seconds) the input mode is activated.
3.2.1.2 Entering input codes

Input mode starts with flashing of the left digit. There is the option here of switching to service mode
using access code “ 9 9 9 9 ” . The “INFO 1” button is used to increase (briefly press the button) or
reduce (press the button for approx. 3 seconds) the values at the relevant position. By pressing the
“INFO 2” button briefly, the next (right) digit can be selected. Once the last right hand digit has been
entered, the code will be transferred to the control by briefly pressing the “INFO 2” button once again.
To go back one position to the left, the “INFO 2” button must be pressed longer (approx. 3 seconds).
If the access code has been entered correctly, the “spanner” icon is displayed and the first input digit
flashes again. Individual operating states of the machine can now be requested by transferring the
input code to the control (as described above).
By pressing both INFO buttons again for approx. 3 seconds, another input code can be entered. The
service mode is quit by entering code “ 0 0 0 0 ” or by switching the ignition off.
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 display, which remains in service mode and continues to
display the operating values requested last.

Author: Brand / EE
200 BW 220 D-5

3.2.2 7-, 8- or 9-button travel lever

The 7-button travel lever is as follows:
Button assignment:
1: Horn / button– (green button)

2: Left button (blue button)
4: + button (green button)
5: Right button (blue button)

Here the assignment on the 8-button travel lever:
Button assignment:

2: – button (green button)

As a conclusion the 9-button travel lever:
Button assignment:
1: Floating position (blue button)

3: – button (green button)


Author: Brand / EE
BW 220 D-5 201

3.2.2.1 Calling up service mode

For this purpose the display must be switched over to service mode via input mode. This is
accomplished via the two yellow info buttons “INFO 1” and “INFO 2” on the back of the travel lever.
Navigating in input- and service mode is accomplished via the green or blue buttons respectively.
The travel lever should be in locked braking position in order to activate input mode!
By simultaneously pressing both info buttons (for approx. 3 seconds) the input mode is activated.
3.2.2.2 Entering input codes

Input mode starts with flashing of the left digit. There is the option here of switching to service mode
using access code “ 9 9 9 9 ” . The green buttons can be used to increase or reduce the values of the
corresponding digit. By pressing the right hand blue button, the next (right) digit can be selected. 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. To go back one position to the left, the left hand blue button must
be pressed.
If the access code has been entered correctly, the “spanner” icon is displayed and the first input digit
flashes again. Individual operating states of the machine can now be requested by transferring the
input code to the control (as described above).
By pressing both INFO buttons again for approx. 3 seconds, another input code can be entered. The
service mode is quit by entering code “ 0 0 0 0 ” or by switching the ignition off.
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 display, which remains in service mode and continues to
display the operating values requested last.

Author: Brand / EE
202 BW 220 D-5

3.3 Querying firmware version
The firmware or software version of the travel control can be displayed using input code “ 0 5 5 5 ”
(see appendix with input codes).
3.3.1 Meaning of the firmware number
The firmware version is displayed in the following layout:
V[Version].[Revision]
For example: A firmware version with the number V4.59 contains the following information:
- Version = 4
- Revision = 59
Version number:
Any change to the version number requires a change in the part number of the control.
Exchanging controls with different part numbers is not intended.
When flashing a fimware, make sure that it “matches” the control to be flashed (part number blank).
Revision number:
Any change in revision number indicates a change of the firmware while the part number remains
unchanged. The firmware is downwards compatible to firmware versions with the same version
number.

Author: Brand / EE
BW 220 D-5 203

4 Fault log – displaying and deleting

4.1 Showing logged faults
There are two possibilities of displaying the logged faults:
4.1.1 Code 700 with two-colour display
• Enter code number “ 0 7 0 0 ” (WITHOUT service code “ 9 9 9 9 ” ). This code number enables
the “show stored faults” function.
The faults stored in the ESX are displayed in flashing mode. If several faults are stored, these are
successively displayed in cycles of 3 seconds. After the last fault has been displayed, the first fault will
appear again. If no fault is stored, “- - - - - ” is shown on the display.
4.1.2 Code 700 with multi-coloured display
• Enter code number “ 0 7 0 0 ” (WITHOUT service code “ 9 9 9 9 ” ). This code number enables
The faults stored in the ESX are displayed in the centre of the
display. If several faults are stored, these are successively
displayed in cycles of 3 seconds. Below the red triangle, the index
of the displayed fault and the total number of faults is shown. After
the last fault has been displayed, the first fault will appear again.
In the image on the top right this would mean:

The fault 1234 (“DTC”) would have occurred once (“OC”); the last
time being at operating hour 738 (“HLO”). Also, the fault would be
the 99th of 99 faults in total.
If no fault is stored, an indicator with a green tick mark appears on

the display (see image below right).

Author: Brand / EE
204 BW 220 D-5

4.1.3 Switch off the “show stored faults” function:
To switch off the function “Show stored faults”, proceed as follows:
• Enter code number “ 0 7 0 1 ” (WITHOUT service code “ 9 9 9 9 ” ). This code number disables
4.1.4 Deleting all stored faults

This function is only valid from software version 1.10!
Execute the “delete all stored faults” function:

• The engine must not be running!
• Enter code number “ 0 7 1 0 ” (!WITHOUT service code 9999).
• Switch the ignition off and on again.
All stored faults are now deleted.
The stored faults can only be deleted when the engine is not running.
i Note

Author: Brand / EE
BW 220 D-5 205

4.2 Delete engine control unit fault log

4.2.1 Deleting logged engine faults
Execute the function “Delete all logged faults in engine control unit”:
• Service code “ 9 9 9 9 ” .
• Enter code number “ 0 7 6 0 ” .
All stored engine faults are now deleted.
4.2.2 Deleting active engine faults

Execute the function “Delete all logged faults in engine control unit”:
• Service code “ 9 9 9 9 ” .
• Enter code number “ 0 7 6 1 ” .
All active engine faults are now deleted.

Author: Brand / EE
206 BW 220 D-5

5 Settings and queries

5.1 Setting the machine type
Since the same control software is used for all single drum rollers of generation 5 (with electronically
controlled engines), the control must be matched to the machine in which it is actually installed (setting
the machine type).
This is necessary during commissioning as well as in case of a spare parts replacement.
This type setting is necessary, because different machine types/variants can have different parameter
sets, e.g. different wheel or axle drive motors (different numbers of pulses) or electrically different
hydraulic components (valve spools), or may be equipped with attachment plates or other optional
equipment.
For simple checking of the currently set machine type simply enter the code “ 0 7 2 0 ” .
EXAMPLE: Machine code for BW 213 D: 7223
• Parameters can only be configured when the engine is not running!

i Note
• This function can only be activated/deactivated when the travel lever
is locked in the brake gate. ( Input mode).
The following machine types can be adjusted:
5.1.1 BW145 D/DH/PDH
Exhaust First Last Machine

Machine classification serial number serial number code
Standard - - - 7200
Tier 4 final 101 586 00 1001 101 586 00 1121

Tier 4 final 101 586 54 1001 101 586 54 XXXX
BW145 D Tier 4 final 101 586 77 1001 101 586 77 XXXX 7261
Tier 4 final 101 587 28 1001 101 587 28 XXXX
StageV 101 587 05 1001 101 587 05 XXXX
Tier 4 final 101 586 01 1001 101 586 01 XXXX

BW145 DH Tier 4 final 101 586 78 1001 101 586 78 XXXX 7263
Stage V 101 587 07 1001 101 587 07 XXXX
Tier 4 final 101 586 02 1001 101 586 02 XXXX

BW145 PDH Tier 4 final 101 586 79 1001 101 586 79 XXXX 7264
Stage V 101 587 08 1001 101 587 08 XXXX

Author: Brand / EE
BW 220 D-5 207

5.1.2 BW177 D/DH/PDH/BVC

Standard - - - 7200
Tier 3 101 586 50 1001 101 586 50 XXXX 7285

Tier 4 final 101 586 03 1001 101 586 03 1387
Tier 4 final 101 586 49 1001 101 586 49 XXXX
BW177 D
Tier 4 final 101 586 80 1001 101 586 80 XXXX 7265
Tier 4 final 101 587 29 1001 101 587 29 XXXX
Stage V 101 587 06 1001 101 587 06 XXXX
Tier 3 101 586 51 1001 101 586 51 XXXX 7287

Tier 4 final 101 586 04 1001 101 586 04 XXXX
BW177 DH
Tier 4 final 101 586 81 1001 101 586 81 XXXX 7267
Stage V 101 587 09 1001 101 587 09 XXXX
Tier 3 101 586 52 1001 101 586 52 XXXX 7288

Tier 4 final 101 586 05 1001 101 586 05 XXXX
BW177 PDH
Tier 4 final 101 586 82 1001 101 586 82 XXXX 7268
Stage V 101 587 10 1001 101 587 10 XXXX
Tier 4 final 101 586 06 1001 101 586 06 XXXX

BW177 BVC Tier 4 final 101 586 83 1001 101 586 83 XXXX 7270
Stage V 101 587 11 1001 101 587 11 XXXX
5.1.3 BW197 DH

Standard - - - 7200
BW197 DH Tier 4 final 101 586 07 1001 101 586 07 XXXX 7269

Author: Brand / EE
208 BW 220 D-5

5.1.4 BW211 D/PD/DH/PDH

Machine type classification serial number serial number code
Standard - - - 7200
101 586 47 1001 101 586 47 XXXX

Tier 3 7202
101 586 69 1001 101 586 69 XXXX
BW211 D
Tier 4 final 101 586 08 1001 101 586 08 XXXX
7201
Stage V 101 587 12 1001 101 587 12 XXXX
101 586 60 1001 101 586 60 XXXX

Tier 3 7217
101 586 70 1001 101 586 70 XXXX
BW211 PD
Tier 4 final 101 586 10 1001 101 586 10 XXXX
7203
Stage V 101 587 13 1001 101 587 13 XXXX
Tier 4 final 101 586 09 1001 101 586 09 XXXX

BW211 DH 7220
Stage V 101 587 14 1001 101 587 14 XXXX
Tier 4 final 101 586 11 1001 101 586 11 XXXX

BW211 PDH 7221
Stage V 101 587 15 1001 101 587 15 XXXX
5.1.5 BW212 D/PD/DH

Standard - - - 7200
BW212 D Tier 4 final 101 586 12 1001 101 586 12 XXXX

7204
Stage V 101 587 16 1001 101 587 16 XXXX
BW212 PD Tier 4 final 101 586 14 1001 101 586 14 XXXX

7205
Stage V 101 587 17 1001 101 587 17 XXXX
BW212 DH Tier 4 final 101 586 13 1001 101 586 13 XXXX

7222
Stage V 101 587 18 1001 101 587 18 XXXX

Author: Brand / EE
BW 220 D-5 209

5.1.6 BW213 D/DH/PDH/BVC

Standard - - - 7200
101 586 48 1001 101 586 48 XXXX

Tier 3 7207
101 586 71 1001 101 586 71 XXXX
BW213 D
Tier 4 final 101 586 15 1001 101 586 15 XXXX
7206
Stage V 101 587 19 1001 101 587 19 XXXX
101 586 17 1001 101 586 17 XXXX

Tier 3 7224
101 586 72 1001 101 586 72 XXXX
BW213 DH
Tier 4 final 101 586 16 1001 101 586 16 XXXX
7223
Stage V 101 586 86 1001 101 586 86 XXXX
BW213 DH with Tier 4 final 101 586 22 1001 101 586 22 XXXX
7227
plates Stage V 101 586 89 1001 101 586 89 XXXX
101 586 19 1001 101 586 19 XXXX

Tier 3 7226
101 586 73 1001 101 586 73 XXXX
BW213 PDH
Tier 4 final 101 586 18 1001 101 586 18 XXXX
7225
Stage V 101 586 87 1001 101 586 87 XXXX
101 586 21 1001 101 586 21 XXXX

Tier 3 7251
101 586 74 1001 101 586 74 XXXX
BW213 BVC
Tier 4 final 101 586 20 1001 101 586 20 XXXX
7250
Stage V 101 586 88 1001 101 586 88 XXXX
BW213 BVC with Tier 4 final 101 586 23 1001 101 586 23 XXXX
7252
plates Stage V 101 586 90 1001 101 586 90 XXXX
5.1.7 BW214 D

Standard - - - 7200
Tier 4 final 101 586 24 1001 101 586 24 XXXX

BW214 D 7208
Stage V 101 587 20 1001 101 587 20 XXXX

Author: Brand / EE
210 BW 220 D-5

5.1.8 BW216 D/PD/DH/PDH
Exhaust First Last

Machine type classification serial number serial number Code
101 586 26 1001 101 586 26 XXXX

Tier 3 7210
101 586 75 1001 101 586 75 XXXX
BW216 D
Tier 4 final 101 586 25 1001 101 586 25 XXXX
7209
Stage V 101 586 91 1001 101 586 91 XXXX
101 586 29 1001 101 586 29 XXXX

Tier 3 7212
101 586 76 1001 101 586 76 XXXX
BW216 PD
Tier 4 final 101 586 28 1001 101 586 28 XXXX
7211
Stage V 101 586 92 1001 101 586 92 XXXX
Tier 4 final 101 586 27 1001 101 586 27 XXXX

BW216 DH 7228
Stage V 101 586 93 1001 101 586 93 XXXX
Tier 4 final 101 586 30 1001 101 586 30 XXXX

BW216 PDH 7229
Stage V 101 586 94 1001 101 586 94 XXXX
5.1.9 BW219 D/PD/DH/PDH/BVC
Exhaust First Last

101 586 32 1001 101 586 32 XXXX

Tier 3 7214
101 586 61 1001 101 586 61 XXXX
BW219 D Tier 4 final 101 586 31 1001 101 586 31 XXXX
Tier 4 final 101 587 32 1001 101 587 32 XXXX 7213
Stage V 101 586 95 1001 101 586 95 XXXX
101 586 36 1001 101 586 36 XXXX

Tier 3 7216
101 586 62 1001 101 586 62 XXXX
BW219 PD
Tier 4 final 101 586 35 1001 101 586 35 XXXX
7215
Stage V 101 586 96 1001 101 586 96 XXXX
101 586 34 1001 101 586 34 XXXX

Tier 3 7231
101 586 63 1001 101 586 63 XXXX
BW219 DH Tier 4 final 101 586 33 1001 101 586 33 XXXX
Tier 4 final 101 587 33 1001 101 587 33 XXXX 7230
Stage V 101 586 97 1001 101 586 97 XXXX
101 586 38 1001 101 586 38 XXXX

Tier 3 7233
101 586 64 1001 101 586 64 XXXX
BW219 PDH Tier 4 final 101 586 37 1001 101 586 37 XXXX
Tier 4 final 101 587 34 1001 101 587 34 XXXX 7232
Stage V 101 586 98 1001 101 586 98 XXXX
Tier 4 final 101 586 39 1001 101 586 39 XXXX

BW219 BVC 7253
Stage V 101 586 99 1001 101 586 99 XXXX

Author: Brand / EE
BW 220 D-5 211

5.1.10 BW226 DH/PDH/BVC/DI/RC
Exhaust First Last

101 586 41 1001 101 586 41 XXXX

Tier 3 7235
101 586 65 1001 101 586 65 XXXX
BW226 DH
Tier 4 final 101 586 40 1001 101 586 40 XXXX 7234
Stage V 101 587 00 1001 101 587 00 XXXX
p
101 586 59 1001 101 586 59 XXXX
Tier 3 7237
101 586 66 1001 101 586 66 XXXX
BW226 PDH
Tier 4 final 101 586 42 1001 101 586 42 XXXX
7236
Stage V 101 587 01 1001 101 587 01 XXXX
101 586 44 1001 101 586 44 XXXX

Tier 3 7255
101 586 67 1001 101 586 67 XXXX
BW226 BVC
Tier 4 final 101 586 43 1001 101 586 43 XXXX
7254
Stage V 101 587 02 1001 101 587 02 XXXX
101 586 53 1001 101 586 53 XXXX

Tier 3 7257
101 586 68 1001 101 586 68 XXXX
BW226 DI Tier 4 final 101 586 45 1001 101 586 45 XXXX
Tier 4 final 101 587 30 1001 101 587 30 XXXX 7256
Stage V 101 587 03 1001 101 587 03 XXXX
Tier 3 101 587 23 1001 101 587 23 XXXX 7259

Tier 4 final 101 586 46 1001 101 586 46 XXXX
BW226 RC
Tier 4 final 101 587 31 1001 101 587 31 XXXX 7258
Stage V 101 587 04 1001 101 587 04 XXXX

Author: Brand / EE
212 BW 220 D-5

5.1.11 Procedure for initial commissioning of a control
• The control has been installed in the machine.

• Switch the ignition on. After switching on, the inscription “ C O D E ” is displayed for approx.
3 seconds. After this the display changes and shows code “ 7 2 0 0 ” .
5.1.11.1 4-button travel lever

• Use the INFO 1 button to select the correct machine type code from the listed codes.
• Confirm the selection with the INFO 2 button.
• After a short while (< 10 seconds), the new parameters are loaded, in accordance with the set
machine type. 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.
5.1.11.2 7-, 8- or 9-button travel lever

• Use the green buttons to select the correct machine type code from the listed codes.
• Confirm the selection with the right hand blue button.
5.1.12 Procedure for changing a machine type
• Enter code number “ 9 9 9 9 ” (activation of service mode).

• Enter code number “ 7 0 1 0 ” . This code number activates the function “set machine type”.
• The display module now permanently shows the code “ 7 2 0 0 ” .
• According to the tables above, select and confirm the machine code (like described in chapter
5.1.11.1 or 5.1.11.2). After confirming, the control switches automatically off and on again.
A machine must not be operated with incorrect type settings, as the

i Note proper functioning of the control system is otherwise not guaranteed!
New controls are delivered with a default machine type setting “ 7 2 0 0 ” .

This does not enable driving or steering of the machine. It only serves the
purpose of commissioning.

Author: Brand / EE
BW 220 D-5 213

5.2 Driving against the closed brake

After entering code number “ 0 5 0 0 ” , the brake will not be released. If the travel lever is disengaged
from the brake gate and moved in any travel direction, the travel pumps will be triggered according to
the chosen travel direction. At the same time, the pressure in the hydraulic travel circuit is shown on
the display. The brake control light in the LCD display remains activated.
In order to terminate this function and to release the brake 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 “ O K ” is
displayed as confirmation for 5 seconds. After this the code needs to be entered again.
This function can only be activated/deactivated when the travel lever is

i Note locked in the brake gate. ( Input mode).

Author: Brand / EE
214 BW 220 D-5

5.3 Automatic detection of surge currents in travel system (information code

1090)
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 of the travel pump or the complete travel pump has been replaced or 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 of the travel pump in small steps, starting from 580mA.
After each current increase the system waits for 3 seconds. If a considerable axle or drum movement
is measured during the waiting time, the surge current is reached. In order to enhance the measuring
result this measurement is performed several times. The mean value of the measured values
represents the final surge current. This surge current is automatically stored and is valid from the next
start of the machine.
Before the measurement, always 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.
Caution! First set the machine to input mode (code “ 9 9 9 9 ” ). Make absolutely sure that the speed
sensors work correctly. For function testing, enter the code number “ 1 1 1 6 ” (sensor on axle,
available on all machines) or the code number “ 1 1 0 6 ” (sensor on drum, DH/BVC machines only)
into the display module. This code can be used to display the number of 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 speed sensor must first be restored to its proper condition, as otherwise the movement of the
machine will not be detected. (See also: “Resetting the surge currents in the travel system”)
During the measurement the machine will move when the surge current is
! Danger reached!
Do not leave the machine while the measurement is in progress!
Please take notice of the emergency stop button to be able to quickly shut
down the machine if this is required.
During the measurement, watch your environment and interrupt the

measurement if people come too close to the machine!
To stop the machine reset the travel lever to neutral position!

Author: Brand / EE
BW 220 D-5 215

5.3.1 Procedure
• 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 code number “ 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 perform the following steps. From this point
the machine can no longer be operated with the travel lever! The travel lever will only
function again after the teach function has been completed or the machine has been
restarted.
• 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 1091
• After the input of the above code number, the display shows “ F O R W ” . Shifting the travel lever
forwards 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 in forward 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.
• During the measurement the actual current is displayed (display value = current in mA).
• After completion of the measurement 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 taught 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 machine start-up.
• The teach function can be aborted at any time by means of the emergency stop or the ignition
switch.

Author: Brand / EE
216 BW 220 D-5

5.4 Display of coil current on the travel pump
5.4.1 Procedure
Input Description
• 9999 Switch on service mode.
• 1050 Display of coil current for drum travel pump forward in mA
(only for DH/PDH/BVC/DI/RC-machines).
or
• 1060 Display of coil current for drum travel pump reverse in mA
(only for DH/PDH/BVC/DI/RC-machines).
or
• 1070 Display of coil current for travel pump axle forward in mA (all machines).
or
• 1080 Display of coil current for travel pump axle reverse in mA (all machines).
• The display now shows the chosen current in mA.

Author: Brand / EE
BW 220 D-5 217

5.5 Display of pressure on the travel pump
5.5.1 Procedure for DH/PDH/BVC/DI/RC machines
Input Description
• 1270 Display of pressure on travel pump axle in bar. Pressure sensor, B234.
Up to V6.xx
BW145-177 DH/PDH/BVC Axle forward
BW211-226 DH/PDH/BVC/DI/RC Axle forward
From V7.00
BW145-177 DH/PDH/BVC Axle reverse
BW211-226 DH/PDH/BVC/DI/RC Axle forward
or
• 1274 Display of pressure on travel pump axle in bar. Pressure sensor, B235.
Up to V6.xx
BW145-177 DH/PDH/BVC Axle reverse
BW211-226 DH/PDH/BVC/DI/RC Axle reverse
From V7.00
BW145-177 DH/PDH/BVC Axle forward
BW211-226 DH/PDH/BVC/DI/RC Axle reverse
or
• 1280 Display of pressure on drum travel pump in bar. Pressure sensor, B236.
Up to V6.xx
BW145-177 DH/PDH/BVC Drum forward
BW211-226 DH/PDH/BVC/DI/RC Drum reverse
From V7.00
BW145-177 DH/PDH/BVC Drum forward
BW211-226 DH/PDH/BVC/DI/RC Drum reverse
or
• 1284 Display of pressure on drum travel pump in bar. Pressure sensor, B237.
Up to V6.xx
BW145-177 DH/PDH/BVC Drum reverse
BW211-226 DH/PDH/BVC/DI/RC Drum forward
From V7.00
BW145-177 DH/PDH/BVC Drum reverse
BW211-226 DH/PDH/BVC/DI/RC Drum forward
• The display now shows the chosen travel pressure in bar.

Author: Brand / EE
218 BW 220 D-5

Procedure BW145/177 D-machines
Input Description
• 1270 Display of pressure on travel pump forward in bar.
Pressure sensor, B234
or
• 1274 Display of pressure on travel pump reverse in bar.
• The display now shows the chosen travel pressure in bar.
5.6 Display of pressure on the vibration pump
5.6.1 Procedure BW145/177 D-machines
Input Description
• 3280 Display of pressure on vibration pump low amplitude in bar.
or
• 3284 Display of pressure on vibration pump high amplitude in bar.
• The display now shows the chosen vibration pressure in bar.

Author: Brand / EE
BW 220 D-5 219

5.7 Ports BW145/177/197 DH/PDH/BVC
Y16
X56 Y72
Y17
X57 Drum travel
pump
Y73
Travel
pump axle
X55
X58
Up to software version V6.xx:
BW145/177/197 DH/PDH/BVC
Plug Sensor Fault Input codes
X55 B234 1220, 1221 or 1222 1270, 1271, 1272 or 1273
X56 B235 1210, 1211 or 1212 1274, 1275, 1276 or 1277
X57 B236 1230, 1231 or 1232 1280, 1281, 1282 or 1283
X58 B237 1240, 1241 or 1242 1284, 1285, 1286 or 1287
From software version V7.00:

BW145/177/197 DH/PDH/BVC
X55 B234 1210, 1211 or 1212 1270, 1271, 1272 or 1273
X56 B235 1220, 1221 or 1222 1274, 1275, 1276 or 1277
X57 B236 1230, 1231 or 1232 1280, 1281, 1282 or 1283
X58 B237 1240, 1241 or 1242 1284, 1285, 1286 or 1287

Author: Brand / EE
220 BW 220 D-5

5.8 Ports BW145/177 D
Y16
X56 Y07
Y17
X57 Vibration
pump
Y08
Travel
pump axle
X55
X58
BW145/177 D
X55 B234 1220, 1221 or 1222 1270, 1271, 1272 or 1273
X56 B235 1210, 1211 or 1212 1274, 1275, 1276 or 1277
X57 B236 3230, 3231 or 3232 3280, 3281, 3282 or 3283
X58 B237 3240, 3241 or 3242 3284, 3285, 3286 or 3287

BW145/177 D
X55 B234 1210, 1211 or 1212 1270, 1271, 1272 or 1273
X56 B235 1220, 1221 or 1222 1274, 1275, 1276 or 1277
X57 B236 3230, 3231 or 3232 3280, 3281, 3282 or 3283
X58 B237 3240, 3241 or 3242 3284, 3285, 3286 or 3287

Author: Brand / EE
BW 220 D-5 221

5.9 Ports BW211-226 DH/PDH/BVC/DI/RC
X55
X57
Vibration
pump
Y16
Y73
Y07
Y17
Y72
X56
pump axle
Y08
X58
Drum travel
Travel
pump

BW211-226 DH/PDH/BVC/DI/RC
X55 B234 1210, 1211 or 1212 1270, 1271, 1272 or 1273
X56 B235 1220, 1221 or 1222 1274, 1275, 1276 or 1277
X57 B236 1240, 1241 or 1242 1280, 1281, 1282 or 1283
X58 B237 1230, 1231 or 1232 1284, 1285, 1286 or 1287

BW211-226 DH/PDH/BVC/DI/RC
X55 B234 1210, 1211 or 1212 1270, 1271, 1272 or 1273
X56 B235 1220, 1221 or 1222 1274, 1275, 1276 or 1277
X57 B236 1230, 1231 or 1232 1280, 1281, 1282 or 1283
X58 B237 1240, 1241 or 1242 1284, 1285, 1286 or 1287

Author: Brand / EE
222 BW 220 D-5

5.10 Activating / deactivating the pressure override
The travel pumps of the small single drum rollers BW145/177/197 do not have a pressure override.
For this reason, the travel control takes over this function. Machines with the software versions V 2.xx
or V 3.yy have a hydraulic pressure override and therefore, if necessary, the electric pressure override
must be deactivated when updating the travel control to V 5.zz.
5.10.1 Procedure
Only switch the ignition on, do NOT start the machine!
i Note The function is only available on BW145/177/197 D/DH/PDH/BVC!
Input Description
• 8811 “Activate / deactivate pressure override” function.
• 8812 Start “Activate pressure override” function.
or
• 8813 Start “Deactivate pressure override” function.
• The display shows for 5 seconds “ O K ” .
• Use code 8 8 1 0 to check, whether the pressure override is active (0 – active; 1 – not active).

Author: Brand / EE
BW 220 D-5 223

5.11 Calibrating the speed detection (calibration of wheel diameter)
5.11.1 Procedure
Input Description
• 1160 Allow function “Calibrate the speed detection”.
• 1161 Start function “Calibrate the speed detection” for a 5 m distance.
or 1 1 6 2 for 10m distance
• The display shows: “ F O R W ” : Move the travel lever forward (or back).
• 1168 Load original value.
• 1169 Save the values.
5.11.2 Explanation
The function “Calibrate speed detection” offers the possibility to calibrate the internal calibration
value of the speed detection.
For this purpose the input code “ 1 1 6 0 ” (enable function) and “ 1 1 6 1 - 1 1 6 5 ” (start the
respective function) can be used to select a distance, which is then travelled with the machine
(as exactly as possible).
During travel a numeric value is displayed.
The measurement is subsequently saved by means of the input code “ 1 1 6 9 ” and is now a valid
criterion for the speed detection.
With the input code “ 1 1 6 8 ” it is also possible to adjust the basic values (“ 1 1 6 0 ” -> “ 1 1 6 8 ” ).
Caution! If the speed detection is extremely falsified because of operating

i Note errors, this can lead to uncomfortable travel behaviour.

Author: Brand / EE
224 BW 220 D-5

5.12 Show pulses per 10 metres
5.12.1 Procedure

• 1110 Show pulses per 10 metres on the axle.
or
• 1100 Show pulses per 10 metres on the drum (only for DH/PDH/BVC machines).
• The display now shows a value, which represents the pulses per 10 metres on the axle or the
drum.
The pulses per 10 metres is a fixed value that does not change while travelling. (See chapter 5.11)
5.13 Showing the speed of the rotary speed sensor in m/min
5.13.1 Procedure

• 1115 Show the speed of the rotary speed sensor on the axle.
or
• 1105 Show the speed of the rotary speed sensor on the drum (only for DH/PDH/BVC
machines).
• The display shows the current speed in m/min.
With the machine at standstill the speed is 0. Once the machine is travelling, values unequal 0 will be
displayed.
5.14 Showing the speed of the rotary speed sensor in km/h (as of software
version V4.06)
5.14.1 Procedure

• 1114 Show the speed of the rotary speed sensor on the axle.
or
• 1104 Show the speed of the rotary speed sensor on the drum (only for DH/PDH/BVC
machines).
• The display shows the current speed in km/h.
With the machine at standstill the speed is 0. Once the machine is travelling, values unequal 0 will be
displayed.

Author: Brand / EE
BW 220 D-5 225

5.15 Showing the pulses of the rotary speed sensor
5.15.1 Procedure

• 1116 Show the pulses of the rotary speed sensor on the axle.
or
• 1106 Show the pulses of the rotary speed sensor on the drum (only for DH/PDH/BVC
machines).
• The display now shows the pulses of the axle or drum.
With the machine at standstill the displayed value will not change. When the machine is driving,
the value will increase continuously.
5.16 Showing the direction signal of the rotary speed sensor
5.16.1 Procedure

• 1117 Show the direction of rotation of the rotary speed sensor on the axle.
or
• 1107 Show the direction of rotation of the rotary speed sensor on the drum (only for
DH/PDH/BVC machines).
• The display now shows the direction of rotation of the sensor on the axle or on the drum
(0: reverse, 1: forward).
For the direction of rotation signal to be displayed correctly, the machine must be moved for a few
metres.
5.17 Showing the travel speed range
5.17.1 Procedure

• 1040 Show the travel speed range.
• The display now shows the set travel speed range of the machine (D/PD-machines 1-5;
DH/PDH/BVC/DI/RC-machines 1-12).

Author: Brand / EE
226 BW 220 D-5

5.18 Setting the vibration frequency
Since the vibration motor is not equipped with a frequency sensor, both the high and low amplitudes
must be checked with an external measuring instrument and corrected, if necessary.
The drum of the machine must be standing on a rubber mat for adjusting
i Note the vibration frequency! During the input the diesel engine of the machine
must be running and the speed pre-selection must not be positioned at
“minimum idle speed“!
5.18.1 Procedure
• Start the diesel engine.

• Pre-select low or high amplitude with Low High
the vibration switch. amplitude amplitude
Machine [Hz] [Hz]
• Press the red button on the travel lever
to start vibration.
• Measure the vibration frequency with an BW145 D/DH/PDH 35 31
external measuring instrument.
BW177 D/DH/PDH 32 29
• 9 9 9 9 Switch on service mode.
BW177 BVC 28
• 3 0 5 0 Enable function “Set vibration
frequency”.
BW197 DH 32 29
• 3 0 5 2 Set vibration frequency at low
amplitude. BW211 D/PD/DH/PDH 34 30
or
• 3 0 5 3 Set vibration frequency at high BW212 D/PD/DH 34 30
amplitude.
• The display now shows a 4-digit value, BW213 D/DH/PDH 34 30
which, however, does not represent the BW213 BVC 28
vibration frequency. This value can now
be changed with the green buttons
BW214 D 36 30
(7-, 8- or 9-button travel lever) or with
the yellow buttons (4-button travel
lever). Checking the vibration frequency BW216 D/PD/DH/PDH 36 30
requires the use of an external
measuring instrument. BW219 D/PD/DH/PDH 26 26
• When the correct frequency has been BW219 BVC 26
reached, the value can be stored by
pressing the right blue button (7-, 8- or BW226 DH/PDH 26 26
9-button travel lever) or with the orange BW226 BVC/DI/RC 26
button (4-button travel lever).
• Repeat this procedure for the low or high amplitude.
• Once both frequencies have been set, vibration can be switched off with the red button on the
travel lever.

Author: Brand / EE
BW 220 D-5 227

5.19 Activating/deactivating the cabin
If the machine is NOT equipped with a cabin, this should be deactivated in

i Note the software. Only switch the ignition on, do NOT start the machine!
On machines of generation -5 the software always assumes that there is a cabin. If a machine has no
cabin, the fault 9 1 0 9 appears on the display and the cabin needs to be deactivated.
5.19.1 Procedure
Input Description
• 8821 Enable function “Activate or deactivate cabin”.
• 8822 Activate the cabin.
or
• 8823 Deactivate the cabin.
• Use code 8 8 2 0 to check, whether the cabin is active (0 – ROPS; 1 – cabin).

Author: Brand / EE
228 BW 220 D-5

5.20 Setting the serial number (information code 4019)
• On the machines the serial number must be set, if this is not done, the information code “4 0 1 9 ”
will appear. The serial number consists of 4 blocks (101 586 03 1001). If necessary, the last three
blocks can be changed. The first block cannot be changed.
Only switch the ignition on, do NOT start the machine!

i Note
5.20.1 Procedure with 4-button travel lever
Input Description
• 4010 Enable the function “Adjust serial number”.
• 4011 Adjust the serial number.
• The display now shows the value “ 1 0 0 1 ” which can be edited with the two yellow buttons.
• If the correct serial number was adjusted, the number can be confirmed with the orange button.
The display shows for 5 seconds “ O K ” .
• With the help of the input code “ 4 0 1 9 ” , the complete serial number can be shown on the
display.
• With codes “ 4 0 1 2 ” , “ 4 0 1 3 ” or “ 4 0 1 4 ” , the other three blocks of the serial number can
also be adjusted. However, this should only be made, if they do not contain the correct value.
5.20.2 Procedure with 7-, 8- or 9-button travel lever
Input Description
• 4010 Enable the function “Adjust serial number”.
• 4011 Adjust the serial number.
• The display now shows the value “ 1 0 0 1 ” which can be edited with the two green buttons.
• If the correct serial number was adjusted, the number can be taken on with the right blue button.
The display shows for 5 seconds “ O K ” .
• With the help of the input code “ 4 0 1 9 ” , the complete serial number can be shown on the
display.
• With codes “ 4 0 1 2 ” , “ 4 0 1 3 ” or “ 4 0 1 4 ” , the other three blocks of the serial number can
also be adjusted. However, this should only be made, if they do not contain the correct value.

Author: Brand / EE
BW 220 D-5 229

5.21 Activating/deactivating the measuring technology
During the input, the diesel engine of the machine should not be running!
i Note Any change to the setting of the measuring technology will only become
effective after switching the ignition off and back on again!
If the machine is equipped with measuring technology, it most certainly needs to be activated.
This also applies for a possibly installed printer.
5.21.1 Procedure
Input Description
• 3011 Enable function “Activate or deactivate measuring technology”.
• 3012 Activate the measuring technology.
or
• 3013 Deactivate the measuring technology.
• Use code 3 0 1 0 to check, whether the measuring technology is active.
5.22 Activating/deactivating the printer
i Note Any change to the setting of the printer will only become effective after
switching the ignition off and back on again!
5.22.1 Procedure
Input Description
• 3016 Enable function “Activate or deactivate printer”.
• 3017 Activate the printer.
or
• 3018 Deactivate the printer.
• Use code 3 0 1 5 to check, whether the printer is active.

Author: Brand / EE
230 BW 220 D-5

5.23 Checking the position of the Vario exciter
For checking the Vario exciter, the exciter can be swivelled to different positions using the selector
switch in simulation mode. The following codes must be entered to activate this mode:
5.23.1 Procedure
Input Description

• 4040 Start Vario exciter simulation mode.
• The display now shows the voltage of the exciter potentiometer (0425 = 4.25 V).
• Operate the BVC rotary switch to change the position of the exciter.
• The displayed voltage should change as described in the table.
Switch Simulated Manual Indicated

position travel stage on
direction display
a Forward 6 230
b Forward 5 306
c Forward 4 337
d Forward 3 363
e Forward 2 389
f Horizontal 1 425
g Horizontal 1 425
h Backward 2 468
i Backward 3 495
j Backward 4 520
k Backward 5 554
l Backward 6 627

Author: Brand / EE
BW 220 D-5 231

5.24 Carrying out the acceleration transducer position test (information code
4071)
During the acceleration transducer check, the sensors can be checked to ensure they are correctly
connected.
5.24.1 Procedure
Input Description
• 9999 Activate service mode.
• 4071 Enable initiate position test.
• 4072 Initiate position test.
• The Vario exciter now automatically swivels into a position.
• Vibration starts.
• The display shows “O K ” or “E R R O R ” after a max. 20 seconds.
• “O K ” – transducers are correctly connected.
• “E R R O R ” – transducers are incorrectly connected.
• Switch vibration off again.
• If the test was successful, the information code 4 0 7 1 will no longer be displayed.

Author: Brand / EE
232 BW 220 D-5

5.25 Activating ECONOMIZER

i Note Any change to the setting of the ECONOMIZER will only become effective
after switching the ignition off and back on again!
This “VM20” option can be activated for all machines except for BVC machines. On machines with
VM33 (Terrameter), VM20 cannot be activated either.
5.25.1 Procedure
Input Description
• 3011 Enable ECONOMIZER activation.
• 3014 Activate ECONOMIZER.
• The display shows the text “O K ” for approx. 5 seconds.
• After switching the ignition off and on again, the “VM20” option will be activated. This is very easy
to check because a new display page has now been activated in the middle of the display (can be
checked with the lower yellow button on the travel lever).
5.26 Carrying out calibration of ECONOMIZER (information code 4081)
For machines with the “VM20” option, the option has to be calibrated, if hardware has been replaced
on the ECONOMIZER or the information code 4 0 8 1 appears on the display.
5.26.1 Procedure
Input Description
• Make sure the drum is standing on air cushions or rubber mats.
• 4081 Enable initiation of ECONOMIZER calibration.
• 4082 Initiate ECONOMIZER calibration.
• The display now shows “V I B ”.
• Start vibration at low amplitude.
• The display shows “O F F ” after a max. 60 seconds.
• Switch the vibration off.
• The display now shows “V I B ” again.
• Start vibration at high amplitude.
• The display shows “O F F ” after a max. 60 seconds.

Author: Brand / EE
BW 220 D-5 233

5.27 Reading out counter for “Regeneration suppressed”
The machine is equipped with a counter to display the number of times the regeneration has been
suppressed.
5.27.1 Procedure
Input Description
• 5151 Read out regeneration suppression counter.
• The display now shows the number of times the regeneration has been suppressed.
5.28 Deleting counter for “Regeneration suppressed”
5.28.1 Procedure
Input Description
• 5152 Enable “ Delete regeneration suppression counter” function.
• 5153 Delete regeneration suppression counter (set to “0”).

Author: Brand / EE
234 BW 220 D-5

5.29 Activating/deactivating the dozer blade
i Note Any change to the setting of the dozer blade will only become effective
after switching the ignition off and back on again!
5.29.1 Procedure
Input Description
• 3021 Enable function “Activate or deactivate dozer blade”.
• 3022 Activate the dozer blade.
or
• 3023 Deactivate the dozer blade
• The display shows the text “ O K ” for approx. 5 seconds.
• After the ignition has been switched off and on again, the dozer blade is active or no longer active.
• 3 0 2 0 This input code can be used to check the status of the dozer blade (0: not active;
1: active).

Author: Brand / EE
BW 220 D-5 235

5.30 Activating/deactivating the attachment plates
i Note Any change to the setting of the attachment plates will only become
effective after switching the ignition off and back on again!
5.30.1 Procedure
Input Description
• 3061 Enable function “Activate or deactivate attachment plates”.
• 3062 Activate the attachment plates.
or
• 3063 Deactivate the attachment plates
• After the ignition has been switched off and on again, the attachment plates are active or no
longer active.
• 3 0 6 0 This input code can be used to check the status of the attachment plates (0: not active;
1: active).
5.31 Activating/deactivating the reversing lock with lowered attachment

plates
On machines with attachment plates reversing with lowered plates is locked or deactivated as
standard. With the following procedure, reversing can be enabled.
5.31.1 Procedure
Input Description
• 3077 Enable function “Activate or deactivate reversing with lowered attachment plates”.
• 3078 Activate function to reverse with lowered attachment plates.
or
• 3079 Deactivate function to reverse with lowered attachment plates
• Reversing with lowered attachment plates is either possible or locked after switching the ignition
off and on again.

Author: Brand / EE
236 BW 220 D-5

5.32 Adjusting the plates despite missing sensors

Should one or two path measuring systems for the attachment plates fail, adjustments to the plates
are still required. The following procedure allows adjustments to be made.
5.32.1 Procedure
Input Description
• 3075 Enable adjustment of the attachment plates.
• Now the attachment plates can be adjusted for an ignition change.

Author: Brand / EE
BW 220 D-5 237

5.33 Setting the cross-slope sensor (information code 1265)

If the cross-slope sensor has not been adjusted yet, the information code “1 2 6 5 ” will appear on the
display. Only DG/PDH/BVC/DI/RC machines have a cross-slope sensor.
i Note The machine must stand on level ground to adjust the cross slope!
5.33.1 Procedure
Input Description
• Machine must stand on a level surface (no gradient or slope)
• 1265 Enable the function “Adjust cross-slope sensor”.
• 1266 Adjust the cross-slope sensor (set to “0”).
5.34 Displaying the cross slope
5.34.1 Procedure
Input Description
• 1261 Display of cross slope in %.

Author: Brand / EE
238 BW 220 D-5

5.35 Flushing the double pumps hydrostatically
On machines with double pump drive (DH/PDH/BVC), the axle and drum will always rotate
simultaneously. However, sometimes it may be necessary to just drive axle or drum individually, e.g.
to flush a hydrostatic circuit. This can be accomplished by entering the input codes below.
However, the selected drive will in this case rotate with reduced speed.
During the input, the diesel engine of the machine should be running!
i Note After switching the ignition off and on again, the function will be
deactivated again!
This function is only available on machines with double pump system

i Note (DH/PDH/BVC/DI/RC)!
5.35.1 Procedure
Input Description
• 1180 Enable function “Drum operation”.
• 1181 Start drum operation.
• The drum can now be driven by means of the travel lever.
or
Input Description
• 1190 Enable function “Axle operation”.
• 1191 Start axle operation.
• The axle can now be driven by means of the travel lever.
If the machine is used in “Drum operation” or “Axle operation”, the

i Note machine must be lifted off the ground at the corresponding drive. If the
machine is moved on the ground, the display will show a fault and the
engine will be shut down!

Author: Brand / EE
BW 220 D-5 239

5.36 Testing double pumps individually
On machines with double pump drive (DH/PDH/BVC), the axle and drum will always rotate
simultaneously. However, sometimes it may be necessary to just drive axle or drum individually, e.g.
to test the electric and hydraulic connections. This can be accomplished by entering the input codes
below.
During the input, the diesel engine of the machine should be running!
i Note After switching the ignition off and on again, the function will be
deactivated again!
This function is only available on machines with double pump system

i Note (DH/PDH/BVC/DI/RC)!
5.36.1 Procedure
Input Description
• 1095 Enable function “Individual operation”.
• 1096 Start drum operation.
or
• 1097 Start axle operation.
• The drum or axle can now be driven by means of the travel lever.
If the machine is used in “Drum” or “Axle mode”, the machine must not
i Note be permanently operated in this mode, as otherwise damage to the
machine cannot be ruled out!

Author: Brand / EE
240 BW 220 D-5

5.37 Setting the coolant filling level sensor
The machines are fitted with two different coolant filling level sensors. One is a normally closed type,
the other one is a normally open type. The machine can work with both variants, but may need to be
adjusted to the matching sensor.
i Note During the input, the diesel engine of the machine should not be running!
5.37.1 Procedure
Input Description
• 5041 Enable function “Set coolant filling level sensor”.
• 5042 Set the coolant filling level sensor as a normally open contact (old version).
or
• 5043 Set the coolant filling level sensor as normally closed contact (new version).
• Code 5 0 4 0 can be used to check which sensor is currently set
(0 or 1 – normally open; 2 – normally closed).
5.38 The “Water in fuel” sensor shuts down the engine
The machines are equipped with a sensor that checks if there is water in the fuel. Under normal
conditions, an audible warning signals this problem. There are users who want to have the engine
shut down after a certain time (2 minutes), if water is detected in the fuel. This can be set with the
following input codes:
i Note During the input, the diesel engine of the machine should not be running!
5.38.1 Procedure
Input Description
• 5055 Enable function “Water in fuel”.
• 5056 The “Water in fuel” sensor can shut down the engine.
or
• 5057 The “Water in fuel” sensor cannot shut down the engine.

Author: Brand / EE
BW 220 D-5 241

5.39 Performing the EOL test (information code 5180)
For all machines with SCR system (AdBlue system), an end-of-line test is to be performed. This is
indicated by the reference code “5 1 8 0 ”.
5.39.1 Procedure
Input Description
• Switch the ignition on and start the engine.
• Before the EOL test can be started, the coolant temperature must be higher than 45 °C and the
travel lever must be in the brake gate (all other conditions are to be met after approx. 2 minutes at
low idling speed).
• 5180 Enable EOL test.
• 5181 Start EOL test.
• The regeneration button must subsequently be moved to the right.
• The display shows “E O L ”, as long as the test is running (between 5 and 10 minutes). The engine
speed is additionally increased automatically.
• Once the EOL test has been successfully completed, the display will show the information
“D O N E ” for approx. 10 seconds and the information code “5 1 8 0 ” is no longer displayed.
• During the EOL test, there must not be any other active load on the machine!

Author: Brand / EE
242 BW 220 D-5

6 Other explanations
6.1 Extended machine functions
6.1.1 Hydraulicoil filter monitoring
In case of low temperatures, the differential pressure switch for monitoring the hydraulic oil filter may
respond just after the engine has been started.
This actually does not indicate a contaminated filter, but represents a system-related triggering of the
differential pressure switch caused by the viscosity characteristics of the cold hydraulic oil.
Here a monitoring delay of 5 minutes has been set.
This delay is in effect each time the engine is started and prevents a fault evaluation during this time
(engine shut-down).
Please note: Triggering of the differential pressure switch is always indicated (lamp).

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7 Replacement of components
7.1 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 vibration 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 and ESX control. These tolerances apply to both mechanical
and electrical functions and are unavoidable for manufacturing reasons.
To enable simple and quick adjustment procedures expensive tools have deliberately been excluded.
All that is needed is this manual and a bit of time. By following the described procedure, it is possible
to put 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 no previous knowledge. Even an
incorrectly or incompletely conducted teaching procedure can be repeated without any issues as often
as necessary. At first glance, performing this adjustment work on every machine may seem a bit
complicated, but this procedure enables the operation of all machines with the same operating
software. Ultimately, this will considerably increase the spare parts availability.
7.2 Replacement of an ESX control

Since the control stores all machine teaching values, each teaching procedure must be performed with
the new control after a replacement.
IMPORTANT: Before performing one of the following steps, first set the
i Note corresponding machine type (see chapter 5.1)!
When changing the machine type all previously made adjustments will be lost.
Now the teach functions must be executed.
• D or DH
• Automatic detection of surge currents in the travel system (see chapter 5.3).
• Setting the vibration frequencies (see chapter 5.18).
• On BVC
• Setting the vibration frequency (see chapter 5.18).
• Perform acceleration transducer test (see chapter 5.24).
7.3 Replacement of a travel pump / axle drive motor / drum drive motor
7.4 Replacement of a vibration pump / vibration motor

• Setting the vibration frequency(ies) (see chapter 5.18).

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7.5 Component replacement without adjustment procedure
Which components can be replaced without a subsequent adjustment procedure?
• Display
• Joystick
• Diesel engine
• All switches in the dashboard
A final function test of the complete machine is highly recommended.

i Note

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Service Training WZ –5 Description of Signals on the ESX Control
8 Description of the signals on the ESX control

Notes:
Wherever the value of 12V is mentioned in the following text, it refers to the current battery voltage
under due consideration of voltage drops in the lines.
ESX Signal description Nominal values (voltage/current)

terminal
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 travel motor axle Y31 active, i.e. min. displacement approx. 12 V
Digital output (max. 2.5 A) inactive, i.e. max. displacement  0V
X35:3 Output travel motor drum Y30 active, i.e. min. displacement approx. 12 V
Digital output (max. 2.5 A) inactive, i.e. max. displacement  0V
X35:4 Interface RS 232 RxD, not used for normal operation. Communication Measurement not possible!
interface for parameter changes
X35:5 Interface RS 232 RxD, not used for normal operation. Communication Measurement not possible!
X35:6 Input hydraulic pressure travel pump circuit axle forward B234 0 bar  approx. 4 mA
Analogue input (current input 4 mA..20 mA) from pressure sensor on travel 600 bar approx. 20 mA
pump.(only on DH machines)
X35:7 Input hydraulic pressure travel pump circuit axle reverse B235 0 bar  approx. 4 mA
pump.(only on DH machines)
X35:8 Input sensor for height adjustment of plates B312
Analogue input (current input 4 mA..20 mA) from height-way measuring
system for attachment plates. (only on machines with attachment plates)
X35:9 Input D+-signal active approx. 12 V
Analogue input (voltage input 0..12 V) inactive  0V
X35:10 Input Release vibration pump for plates
Digital input active low.
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terminal
X35:11 Output floating position of dozer blade Y102 active, i.e. floating position switched on approx. 12 V
or inactive, i.e. floating position switched off  0V
Output floating position of attachment plates Y60
Digital output (max. 2.5 A)
(only on machines with dozer blade or attachment plates)
X35:12 Input axle speed B60 Signal changes between approx. 0 V and 12 V, when machine is moving.
Frequency input active low (0-7.5 kHz) Frequency with travel speed m/min
Machine type:
XX m/min approx. XX Hz
Machine type:
Machine type:
X35:13 Input direction of rotation axle B60 Rotary direction forward approx. 12 V
Digital input active high Rotary direction reverse  0V
X35:14 Input BTS brake (from travel lever) Brake released approx. 12 V
Digital input active high Brake applied  0V
X35:15 Input seat contact switch S06 Seat actuated  0V
Digital input active high Seat not actuated  ?V
X35:16 Input arm rest switch B146 Arm rest actuated  0V
Digital input active high Arm rest not actuated  ?V
(only BW145/177/197)
X35:17 Input rotary direction of drum B60 Rotary direction forward approx. 12 V
Digital input active high Rotary direction reverse  0V
(only on DH machines)
X35:18 Input engine oil pressure switch B06
Digital input active low
(only BW177 D/DH/PDH with Tier 3 engines)
X35:19 Input coolant temperature switch B53

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terminal
X35:20 Output drum travel pump forward Y72 Forward travel active  600-1800 mA
PWM power output (max. 4 A) Forward travel inactive  0 mA
X35:21 Output drum travel pump reverse Y73 Reverse travel active  600-1800 mA
PWM power output (max. 4 A) Reverse travel inactive  0 mA
X35:22 Output solenoid valve vibration pump for plates Y98 Vibration of attachment plates active  400-1200 mA
PWM power output (max. 4 A)
(only on machines with attachment plates)
X35:23 Voltage supply for sensors Nominal voltage = 8.5 V
Without this voltage the control cannot work correctly and will switch to Permissible range: approx. 7.65-9.35 V
override state (limp home function) This voltage must be measured against AGND.
X35:24 Output relay engine shut-down solenoid active, i.e. engine shut down  approx. 12 V
Digital output (max. 2.5 A) inactive, i.e. engine not shut down  0V
X35:25 Output relay warning horn active, i.e. warning horn switched on  approx. 12 V
Digital output (max. 2.5 A) inactive, i.e. warning horn not switched on  0V
X35:26 Interface CAN-Bus 1 Wire - is used for communication with MESX, ESX,
Measurement not possible!
the cabin module and with the immobilizer.
X35:27 Interface CAN-Bus 1 Wire + is used for communication with MESX, ESX,
X35:28 Input potential terminal 15 Control switched on approx. 12 V
Digital input active high Control switched off  approx. 2 V
This signal must be present so that the control can work.
X35:29 Input hydraulic pressure travel pump circuit drum forward B236 0 bar  approx. 4 mA
pump
X35:30 Input hydraulic pressure travel pump circuit drum reverse B237 0 bar  approx. 4 mA
pump (only on DH machines)
X35:31 Input sensor for height adjustment of plates B313
Analogue input (current input 4-20 mA) from side way measuring system
for attachment plates.

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terminal
X35:32 Input cross-slope sensor B57
(only on DH/BVC machines)
X35:33 Interface CAN-Bus 2 Wire - is used for communication with the travel lever
and the engine EMR.
X35:34 Not used
X35:35 Input drum speed B59 Signal changes between approx. 0 V and 12 V, when machine is moving.
Frequency input active low (0-7.5 kHz) Frequency with travel speed m/min
(only on DH machines) Machine type:
Machine type:
Machine type:
X35:36 Input fuel water separator sensor, B124
X35:37 Input differential pressure switch hydraulic oil filter, B21
X35:38 Input air filter pressure switch B03
X35:39 Input coolant float switch B55
X35:40 Input engine speed sensor B92
Frequency input active low (0-7.5 kHz)
X35:41 Input pre-heating relay, K14 active approx. 12 V
Digital input active high inactive  0V

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terminal
X35:42 Output levelling blade up Y379 active, i.e. levelling blade/plates up approx. 12 V
or inactive, i.e. levelling blade/plates not up  0V
Output plates up Y122
X35:43 Output levelling blade down Y380 active, i.e. levelling blade/plates down approx. 12 V
or inactive, i.e. levelling blade/plates not down  0V
Output plates down Y123
X35:44 Output Relay engine speed K114 active, i.e. max. idle speed approx. 12 V
Digital output (max. 4 A) inactive, i.e. min. idle speed  0V
X35:45 Output floating position of attachment plates 2 Y144 active, i.e. floating position switched on approx. 12 V
Digital output (max. 2.5 A) inactive, i.e. floating position switched off  0V
X35:46 Output travel pump axle forward Y16 Forward travel active  600-1800 mA
PWM power output (max. 4 A) Forward travel inactive  0 mA
X35:47 Output travel pump axle reverse Y17 Reverse travel active  600-1800 mA
PWM power output (max. 4 A) Reverse travel inactive  0 mA
X35:48 Output amplitude switch-over active, i.e. high amplitude  approx. 12 V
Digital output (max. 2.5 A) Inactive, i.e. low amplitude  0V
(not on BVC machines)
X35:49 Output Vibration pump Ports BW145/177/197 DH/PDH/BVC
PWM power output (max. 4 A) Vibration active  400-1200 mA
Vibration inactive 0 mA
On all machines
Vibration active  600-1200 mA
Vibration inactive 0 mA
X35:50 Output plates left Y142 active, i.e. move plates to the left approx. 12 V
Digital output (max. 5 A) inactive, i.e. do not move plates to the left  0V
X35:51 Output plates right Y143 active, i.e. move plates to the right approx. 12 V
Digital output (max. 5 A) inactive, i.e. do not move plates to the right  0V

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terminal
X35:52 Input self-latching relay, K35 active, i.e. self-latching on approx. 12 V
Digital input active high inactive, i.e. self-latching off  0V
X35:53 Interface CAN-Bus 2 Wire + is used for communication with the travel
lever and the engine EMR.
X35:54 Voltage supply for electronics (permanent voltage) Control running approx. 12 V
Control not running  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 warning buzzer, H14 Warning buzzer active approx. 12 V
Digital output (max. 4 A) Warning buzzer inactive  0V
X35:62 Output levelling blade priority Y378 active approx. 12 V
or inactive  0V
Output plates priority Y145
X35:63 Output operating hour meter plates, P43 active approx. 12 V
Digital output (max. 2.5 A) inactive  0V
X35:64 Output brake Y04 Open brake approx. 12 V
PWM power output (max. 4 A) Close brake  0V
X35:65 Ground connection approx. 0 V

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Service Training WZ -5 Description of Signals on the Travel Lever
9 Description of signals on the travel lever

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

Travel
lever
X23:1 Voltage supply (permanent voltage) Electronics working approx. 12 V
Electronics not working  0V
X23:2 Ground connection 0V (measured against ground)
X23:3 Output BTS brake Brake opens approx. 12 V
Digital output (max. 4 A) Brake closes  0V
X23:4 Not used
X23:5 Output voltage supply for additional analogue evaluations Nominal voltage = approx. 5,0 V
This output supplies the 12-stage travel speed range switch. This voltage Permissible range: approx. 4.8-5.2 V
is required to connect and evaluate further analogue 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 analogue approx. 0 V measured against ground (terminal 31)
evaluations
Reference to PIN X23:5
X23:9 Node address addressing 1 Connection to machine ground (0 V)
X23:10 Node address addressing 2 Connection to machine ground (0 V)
X23:11 Input travel speed range switch The voltage signal changes with the adjusted travel speed range
Analogue input Travel speed range min.  ?? V
Travel speed range max.  ?? V
X23:12 Not used ---
X24:1 Input low amplitude Low amplitude active approx. 12 V
Digital input active high Low amplitude inactive  0V
X24:2 Input high amplitude High amplitude active approx. 12 V
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Service Training WZ -5 Description of Signals on the Travel Lever

Travel
lever
Digital input active high High amplitude inactive  0V
X24:3 Not used
X24:4 Not used
X24:5 Not used
X24:6 Not used
X24:7 Output voltage supply for additional digital evaluations Voltage supply active approx. 12 V
This output supplies the amplitude selector switch. This voltage is Voltage supply inactive  0V
required to connect and evaluate further digital switches to the travel
lever.
X24:8 Output voltage supply ground potential 0 V (measured against ground)
In connection with PIN X24:7, this output enables the control of additional
components (relays, displays, etc.)
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Service Training WZ -5 Description of Signals on the Display
10 Descriptions of signals on the display

Notes:
Wherever the value of 12 V is mentioned in the following text, it refers to the current battery voltage

Display
X33:1 Not used
X33:2 Input tank sensor R03 The signal changes with the filling level in the fuel tank.
Resistance input 0-140 Ohm
X33:3 Output warning buzzer, H07 Warning buzzer active approx. 12 V
Digital output (max. 1.5 A) Warning buzzer inactive  0V
X33:4 Output Vibration Telematic A124 Vibration active approx. 12 V
Digital output (max. 1.5 A) Vibration inactive  0V
X33:5 Input lighting S15 Lighting switched on approx. 12 V
Digital input active high Lighting switched off  0V
X33:6 Interface RS232 RxD, not used for normal operation. Communication Measurement not possible!
X33:7 Interface RS232 TxD, not used for normal operation. Communication Measurement not possible!
X33:8 Input indicator relay Indicator active approx. 12 V
Digital input active high Indicator inactive  0V
X33:9 Input engine speed low idle S120 Low idle active approx. 12 V
Digital input active high Low idle inactive  0V
X33:10 Input engine speed high idle S120 High idle active approx. 12 V
Digital input active high High idle inactive  0V
X33:11 Input suppress regeneration S299 Suppress regeneration active approx. 12 V
Digital input active high Suppress regeneration inactive  0V
(only machines with Tier 4f engines)
X33:12 Input request regeneration S299 High idle active approx. 12 V
Digital input active high High idle inactive  0V
(only machines with Tier 4f engines)
X33:13 Not used
X33:14 Not used
X33:15 Not used
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Service Training WZ -5 Description of Signals on the Display

Display
X33:16 Not used
X33:17 Not used
X33:18 Not used
X33:19 Not used
X33:20 Not used
X33:21 Interface CAN-Bus 1 Wire + is used for communication with MESX, ESX, Measurement not possible!
X33:22 Interface CAN-Bus 1 Wire - is used for communication with MESX, ESX, Measurement not possible!
X33:23 Not used
X33:24 Not used
X33:25 Ground connection 0 V (measured against ground)
X33:26 Voltage supply (permanent voltage “ignition on”) Electronics working approx. 12 V
Electronics not working  0V
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Service Training WZ -5
11 Fault codes of the ESX control
Fault reaction Description of fault reaction
1 Warning.
Fault code is displayed.
2 Warning.
The fault code is displayed and an audible signal occurs.
3 Impairment of function.
The faulty function is overridden by a limp home function.
4 Fault in a partial function.

The faulty function cannot be overridden by a limp home function. After the fault occurs, the machine is stopped.
The machine can still be driven to a limited extent, but must be repaired by the service department as soon as possible.
5 Serious fault in a partial function -> the diesel engine is shut down.
The faulty function cannot be overridden by a limp home function.
The machine is no longer able to drive, e.g. because parts of the travel system are defective.
6 Fatal fault -> the control and the diesel engine are shut down.
Fault code is displayed and the signal lamp in the monitoring module is constantly lit up. NO audible signal occurs.
Note: Faults with fault reaction 1 and 2 are only warning messages and are NOT saved in the fault log!
See list of fault codes.
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12 Input codes of the ESX control

See list of input codes.
13 History

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14 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 causes 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

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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 states are permitted within a certain range. E.g. room temperature
0° to 40°, current 4mA to 20mA; voltage 0V to 8.5V; resistance 100 Ω to 300Ω; valve 0% to
100% opened (proportional valve)

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Control system
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, etc.) must be known.
Disturbance
variable (z)
Input (w) Output (y)

Control Distance
system
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.
Disturbance
variable (z)
Input (w) Output (y)

Governor Distance
Identification Control Control system

Operating path: closed open
(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 faults have to be
be controlled, comparison of considered, low expense
nominal and actual value, if not faults occur.
power amplification
Performance in For unstable systems closed In unstable systems
unstable systems loop controls must be used. controls cannot be used.

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Current and voltage measurement
Ohm’s law:
U =R∗I
U = Voltage
R = Resistance U
I = Current
I=
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 a 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.

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FaultLocation Output brake valve Y04 1001

FCode FaultDescription Terminal Possible Cause Diag Reac
1001 No or too low current flow out of this X35:64 17442Line breakage in current path 5
output
1002 The output to the valve has ground X35:64 17454Short circuit to ground (31) in the current path 5
contact, or the output current is higher
than permitted.
1003 Short circuit towards Ub X35:64 17463Current path has connection to +Ub (15 or 30) 5
FaultLocation Input BTS brake 1005

1005 Plausibility conflict in evaluation of X35:14 5
travel lever X- axis to the brake
contact signal
FaultLocation Output warning horn, K13 1015
1015 Although the output is switched off, X35:25 17512Line breakage in current path 3
voltage is present
than permitted.
FaultLocation Output backup warning (rear), H14 1020

output
than permitted.
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FaultLocation Travel lever, S55 1025

1025 Summarizing error X-axisError in CAN 2 3
redundant evaluation of axis
1026 Cable breakage X-axisSignal CAN 2 3
outside the valid range (see signal
description)
1027 Parameterization X-axis CAN 2 3
1028 Direction evaluation X-axisThe CAN 2 3
direction of travel lever movement
could not be determined
1029 Differential error X-axisError in CAN 2 3
redundant evaluation of travel lever
signal
1030 Software error X-axisSoftware does CAN 2 3
not work correctly
1031 Summarizing error Y-axisError in CAN 2 3
redundant evaluation of axis
1032 Cable breakage Y-axisSignal CAN 2 3
description)
1033 Parameterization Y-axis CAN 2 3
1034 Direction evaluation Y-axisThe CAN 2 3
direction of travel lever movement
could not be determined
1035 Differential error Y-axisError in CAN 2 3
redundant evaluation of travel lever
signal
1036 Software error Y-axisSoftware does CAN 2 3
not work correctly
9130 Fault in CAN communication 1
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FaultLocation Input travel stage selector switch, S42 1040

1040 Ground Connection faultySignal 17692Line breakage in current path
X23:5, X23:11 3
outside the valid range
1041 Supply connectionSignal outside 17703Current path has connection to +Ub (15 or 30)
X23:5, X23:11 2
the valid range
1042 Signal lineSignal outside the valid X23:5, X23:11 3
range
FaultLocation Output valve travel pump (rear) forward, Y16 1050
1050 The required control power cannot be X35:46 17722Line breakage in current path 2
transmitted to the proportional
solenoid.
1051 Output to proportional valve shorted X35:46 17734Short circuit to ground (31) in the current path 2
to ground.
1052 Supply voltage Ub is applied to the X35:46 17743Current path has connection to +Ub (15 or 30) 5
proportional valve output, even
though the output is not switched.
solenoid.
to ground.
1056 Fault current regulator X35:46 5
1058 Hardware initializing error X35:46 2
1190 5
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FaultLocation Output valve travel pump (rear) reverse, Y17 1060

solenoid.
to ground.
solenoid.
to ground.
FaultLocation Output valve travel pump (front) forward, Y72 1070
solenoid.
to ground.
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solenoid.
to ground.
1180 5
FaultLocation Output valve travel pump (front) reverse, Y73 1080
solenoid.
to ground.
solenoid.
to ground.
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FaultLocation Teach function travel pump flow controller 1090
1090 Informative code - The teach function System 18121Informative code - Follow the adjustment instructions 1
for the travel pump surge currents has
NOT yet been successfully
performed. Please follow the
adjustment instructions
1091 Error in teaching the surge current System 3
forward The current limit was reached
and the function terminated.
reverse The current limit was reached
and the function terminated
forward The current limit was reached
and the function terminated.
reverse The current limit was reached
and the function terminated
1099 Fault in surge currentValue outside System 26961Informative code - Follow the adjustment instructions 1
the limiting values 26968Software parameter fault, software update may be required.
26965Excessive current in current path
FaultLocation Output valve travel speed range selection front, Y30 1100
output
than permitted.
BW 220 D-5 267

valve output, even though the valve is
not switched.
FaultLocation Input speed sensor travel motor B59 1105
1105 No pulses from the speed sensor are X35:35 18202Line breakage in current path 3
detected, ven though the travel pump 18203Current path has connection to +Ub (15 or 30)
is actuated.
18204Short circuit to ground (31) in the current path
1820
11Hardware defect sensors, replacement required
1106 Plausibility of the sense of rotation X35:17 18212Line breakage in current path 3
does not match 18213Current path has connection to +Ub (15 or 30)
1821
FaultLocation Output valve travel speed range selection rear, Y31 1110
output
than permitted.
valve output, even though the valve is
not switched.
FaultLocation Input speed sensor travel motor, B60 1115
1115 No pulses from the speed sensor are X35:12 18252Line breakage in current path 3
detected, ven though the travel pump 18253Current path has connection to +Ub (15 or 30)
is actuated.
1825
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1116 Plausibility of the sense of rotation X35:13 18262Line breakage in current path 3
does not match 18263Current path has connection to +Ub (15 or 30)
1826
FaultLocation Input inclination sensor, B57 1201

1201 Ground Connection of sensor/switch X35:32 3
faultyThe voltage applied to the
input is outside the specified range
(see signal description).
1202 Supply connection Connection of X35:32 3
sensor/switch faultyThe voltage
applied to the input is outside the
specified range (see signal
description).
1203 Signal faultSignal outside the valid X35:32 3
range
1265 Information message, no fault! The X35:30 37231Informative code - Follow the adjustment instructions 1
cross-slope sensor has not been
adjusted.
FaultLocation Input pressure sensor travel pump (rear) forward 1210
output
1211 Signal rangeThe current signal is X35:6 3
specification)
1212 Pressure sensor does not measure any X35:6 3
pressure
1213 X35:6 2
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1255 The sensor is not correctly connected, X35:6 2042

14Sensors not correctly installed or not adjusted 2
it may be mixed up with another 2042
1131Sensor mixed up by mistake
sensor.
20422Line breakage in current path
FaultLocation Input pressure sensor travel pump (rear) reverse 1220

output
specification)
pressure
1223 X35:7 2
sensor.
FaultLocation Input pressure sensor travel pump (front) forward 1230

output
specification)
pressure
1233 X35:29 2
sensor.
270 BW 220 D-5

FaultLocation Input pressure sensor travel pump (front) reverse 1240

output
specification)
pressure
1243 X35:30 2
sensor.
FaultLocation Input seat contact switch, S06 1300

1300 Informative message, no fault! X35:15 18422Line breakage in current path 0
Driver's seat not occupied (driver not

seated!) or cable breakage in signal
line
FaultLocation Input armrest right, B146 1330
1330 Information message, no fault! X35:16 0
Right armrest raised Machine does

not pick up throttle and is braked to
stop.
1331 Signal faultSignal outside the valid X35:16 18542Line breakage in current path 2
range 1854
1332 Short circuit X35:16 2
1333 System fault, replace control X35:16 2
BW 220 D-5 271

FaultLocation Output vibration pump, low amplitude, Y08 3000

output
to ground.
3003 No or too low current flow out of this 2
output
to ground.
3006 Fault current regulator System 2
3008 Hardware initializing error System 2
FaultLocation Vibration frequency controller, low amplitude 3011
3011 Frequency adaptation, saved control 18688Software parameter fault, software update may be required. 0
values are outside limiting values
3012 Frequency adaptation, controller has System 18698Software parameter fault, software update may be required. 0
reached upper limiting value
3013 Frequency adaptation, controller has System 18708Software parameter fault, software update may be required. 0
reached lower limiting value
3014 Frequency/speed to high System 2
3015 Hardware initializing error System 18729ESX hardware defect, hardware replacement may be 3
necessary
272 BW 220 D-5

3016 Hardware initializing error System 18739ESX hardware defect, hardware replacement may be 3
necessary
FaultLocation Output vibration pump, high amplitude, Y07 3020
output
to ground.
output
to ground.
3028 Hardware initializing error ystem 2
FaultLocation Vibration frequency controller, high amplitude 3031
3031 Frequency adaptation, saved control 18868Software parameter fault, software update may be required. 0
values are outside limiting values
3032 Frequency adaptation, controller has 18878Software parameter fault, software update may be required. 0
reached upper limiting value
3033 Frequency adaptation, controller has 18888Software parameter fault, software update may be required. 0
reached lower limiting value
3034 Frequency/speed to high 2
BW 220 D-5 273

3035 Hardware initializing error 18909ESX hardware defect, hardware replacement may be 3
necessary
3036 Hardware initializing error 18919ESX hardware defect, hardware replacement may be 3
necessary
FaultLocation Vibration system 3040
3040 Fault in vibration frequencyValue 26971Informative code - Follow the adjustment instructions 1
outside the limiting values 26978Software parameter fault, software update may be required.
FaultLocation Output vibration pump plates, Y98 3051

3051 Signal faultSignal outside the valid 1
range
3052 Hardware initializing error 1
range (see signal description)
3054 The required control power cannot be 33092Line breakage in current path 1
transmitted to the valve
3055 Hardware initializing error 33112Line breakage in current path 1
3056 Fault current regulator 1
FaultLocation Input plates position measuring system height adjustment, B3123060
3060 Cable breakage or sensor defective 33142Line breakage in current path 1
274 BW 220 D-5

FaultLocation Input plates position measuring system side adjustment, B313 3063
3063 Cable breakage or sensor defective 1
FaultLocation Attachment plates potentiometer, S139 3066
3067 Cable breakage UB 1
FaultLocation Backup alarm 3077
3077 Information message, no fault! The 1
machine travels backwards with
lowered attachment plates.
FaultLocation Output amplitude changeover relay, K43 3090
output
3091 Output to relay shorted to ground. X35:48 18944Short circuit to ground (31) in the current path 3
relay output, even though it is not
switched.
FaultLocation Input pressure sensor vibration pump, high amplitude 3230
output
BW 220 D-5 275


specification)
pressure
sensor.
FaultLocation Input pressure sensor vibration pump, low amplitude 3240
output
specification)
pressure
sensor.
FaultLocation Input exciter position, B97 4001
4001 Cable breakage UB X88:9 21592Line breakage in current path 2
4002 Cable breakage GND X88:9 21602Line breakage in current path 2
range
4201 ADC initialization 4
4208 Sensor 1 software error 2
4209 Input initialization error 4
276 BW 220 D-5

FaultLocation Input switch amplitude adjustment, S107 4010

4010 Cable breakage UB X88:32 21632Line breakage in current path 2
4011 Cable breakage GND X88:32 21642Line breakage in current path 2
4012 Signal lineSignal outside the valid X88:32 2
range
FaultLocation Measuring controller 4019
4019 Information message, no fault! The 37251Informative code - Follow the adjustment instructions 1
serial number has not been adjusted.
4071 38581Informative code - Follow the adjustment instructions 1
4150 Software incompatibility measuring 2
controller software to machine
software
4210 Incorrect parameter setting 2
4251 Machine type conflict After replacing 4
the control the machine type does not
match the old one.
match the old one.
BW 220 D-5 277


match the old one.
software
software
4271 Fault: Overvoltage 8.5 V supply 4
4272 Fault: Undervoltage 8.5 V supply 4
4990 Measuring technology not compatible System 1
1886 0
FaultLocation Output valve exciter up, Y140 4021

4023 Cable breakage or sensor defective X88:47 2
FaultLocation Output valve exciter down, Y141 4026
FaultLocation 4081
1886 0
278 BW 220 D-5

4777 Unknown fault in control of System

measuring technology
FaultLocation Input acceleration transducer, B62 4101
4101 Signal faultSignal outside the valid X88:29, 2
FaultLocation Input acceleration transducer, B171 4106
FaultLocation Input engine speed B92 5014
5014 Fault: Engine speed sensor 18972Line breakage in current path 3
1897
14Sensors not correctly installed or not adjusted
1897
17No voltage supply (+Ub Pot 15 or 30)
1897
5015 Fault: Engine speed sensor 18982Line breakage in current path 3
1898
1898
14Sensors not correctly installed or not adjusted
1898
17No voltage supply (+Ub Pot 15 or 30)
5016 Frequency/speed to high 18998Software parameter fault, software update may be required. 3
1899
26Parameter error, possibly machine type incorrectly chosen,
control see adjustment instructions
FaultLocation Input D+ detection 5017
BW 220 D-5 279

5017 Engine running but no D+ signal X35:9 19002Line breakage in current path 0
present 1900
27Generator or charge regulator defective
5017 Engine running but no D+ signal X35:9 48372Line breakage in current path 0
present 4837
27Generator or charge regulator defective
FaultLocation Input engine oil pressure monitoring, B06 5020

5020 Warning: No oil pressure X35:37 0
5021 Fault: No oil pressure X35:37 5
FaultLocation Input coolant level monitoring, B55 5024
5024 Warning: Coolant filling level too low X35:39 0
5025 Fault: Coolant filling level too low X35:39 19041Informative code - Follow the adjustment instructions 5
1904
725Check the coolant level, top up if necessary
FaultLocation Input air filter sensor, B03 5026

5026 Warning: Air filter dirty X35:38 1
5027 Fault: Air filter dirty X35:38 19061Informative code - Follow the adjustment instructions 5
1906
25Check filter, if necessary clean or replace as per service
instructions
FaultLocation Input water separator, B124 5028
5028 Warning: Water in fuel filter X35:36 0
5029 Fault: Water in fuel filter X35:36 5
FaultLocation Output relay solenoid gas control, K 114 5040
5040 Wire breakage at the output to the X35:44 19132Line breakage in current path 3
relay
280 BW 220 D-5

5041 Output to relay shorted to ground. X35:44 19144Short circuit to ground (31) in the current path 3
switched.
FaultLocation Input feedback from solenoid for throttle control 5043
5043 The voltage applied to the input is X35:52 19162Line breakage in current path 3
1916
1540Solenoid mechanically blocked
below the valid range
FaultLocation Output engine shut-down, K22 5045
5045 Wire breakage at the output to the 5
relay
5046 Supply voltage Ub is applied to the 2
switched.
5047 Insufficient current flow at output to 5
relay
FaultLocation Input level switch for fuel filling level, R03 5050
5050 Signal faultSignal outside the valid X33:2 19172Line breakage in current path 1
range (see signal description) 1917
FaultLocation Engine speed detection 5061

2698
2699
BW 220 D-5 281

FaultLocation Engine control unit 5100

5100 Info message - Engine control unit System 19181Informative code - Follow the adjustment instructions 1
reports a warning
5101 Error message - Engine control unit System 19191Informative code - Follow the adjustment instructions 1
reports an error
5102 Error message - Engine control unit System 19201Informative code - Follow the adjustment instructions 1
reports a severe fault and has
switched off
5110 Throttle pedal position Motor 1
5111 Engine oil level not correct Motor 19222Line breakage in current path 1
19223Current path has connection to +Ub (15 or 30)
1922
5112 Fault: No oil pressure Motor 19232Line breakage in current path 0
1923
5113 Turbo charger pressure not correct Motor 19242Line breakage in current path 1
1924
5114 Fault: Intake manifold temperature Motor 19252Line breakage in current path 1
1925
282 BW 220 D-5

5115 Fault: Ambient pressure sensor Motor 19262Line breakage in current path 1
1926
5116 Fault: Engine temperature sensor Motor 19272Line breakage in current path 0
1927
5117 Fault: Diesel temperature sensor Motor 19282Line breakage in current path 1
1928
5118 Fault: Engine speed sensor Motor 19292Line breakage in current path 1
1929
5119 Warning: Water in fuel filter Motor 19302Line breakage in current path 1
1930
5120 Communication fault with engine System 1931
715CAN communication fault 1
control unit 19312Line breakage in current path
5121 Communication fault with engine System 5
control unit
5123 Communication fault with engine Motor 1
control unit
control unit
BW 220 D-5 283


control unit
control unit 19372Line breakage in current path
5127 Fault: Coolant filling level too low Motor 19382Line breakage in current path 1
1938
5128 Fault: Injection pressure in rail system Motor 1
5130 Fault: Oil pressure sensor Motor 19402Line breakage in current path 1
1940
5131 Fault: Turbocharger pressure sensor Motor 19412Line breakage in current path 1
1941
1942
5133 Fault: Engine temperature sensor Motor 19432Line breakage in current path 1
1943
284 BW 220 D-5

5134 Fault: Engine speed sensor Motor 19442Line breakage in current path 1
1944
5135 Fault: Water in fuel filter Motor 19452Line breakage in current path 1
1945
1946
5137 Fault: Coolant level sensor Motor 19472Line breakage in current path 1
1947
5138 Fault: Sensor for injection pressure in Motor 19482Line breakage in current path 1
rail system 19483Current path has connection to +Ub (15 or 30)
1948
5139 Fuel pump Motor 19492Line breakage in current path 1
19495Excessive current in current path
1949
5140 Error message - Engine control unit Motor 1
reports a fault, which has not been
classified. Engine diagnose required.
BW 220 D-5 285

5142 Fault pressure limiting valve 3

5143 Fault: Injection pressure in rail system 3
5144 Fault: Sensor, ambient temperature 1
5145 Fault: Sensor, ambient temperature 1
5151 Information code - Regeneration level Motor 1
1
2
3
4
5
5156 Information code - external Motor 3
regeneration required
5160 Information code - automatic Motor 1
regeneration active
5161 Information code - parked Motor 1
regeneration active
5165 Warning: SCR tank filling level System 4833
1655Carbamide filling level too low, top up carbamide, otherwise 1
power reduction!
control unit
FaultLocation Exhaust gas after-treatment 5180
5180 Information message, no fault!The Motor 1
EndOfLine test (EOL test) has not
been performed.
286 BW 220 D-5

6064 Fault: No DEF system pressure Motor 3390

1887 0
building up! 3390
1888
3390
1889
6068 Fault: DEF system pressure outside of Motor 0
limit values!
6069 Fault: Regeneration requirement Motor 0
ignored too long!
6070 Engine oil change required Motor 3
6071 DPF filter change required Motor 3
6072 DPF filter change required, system Motor 3
response is active
6073 Power reduction Step 1 Motor 0
6074 Power reduction Step 2 Motor 0
6075 Motor 0
6076 Fault: Differential pressure below Motor 0
limit value!
6200 Motor 0
6201 Motor 0
6202 Motor 0
6203 Motor 0
6204 Motor 0
6205 Motor 0
FaultLocation Engine fault 5190
5190 Diesel engine recording does not 40038Software parameter fault, software update may be required. 3
work. Communication error.
5191 Diesel engine recording does not 3
work. Communication error.
BW 220 D-5 287

FaultLocation Input hydraulic oil filter 5500

5500 Warning: Hydraulic oil filter dirty X35:37 1978
25Check filter, if necessary clean or replace as per service 1
instructions
5501 Fault: Hydraulic oil filter dirty X35:37 1979
25Check filter, if necessary clean or replace as per service 5
instructions
FaultLocation Exhaust Gas Recirculation (EGR) 6000
limit value!
FaultLocation DEF quality sensor, B222 6001
6001 Plausibility error, DEF tank fill level Motor 0
6002 Fault: DEF tank temperature has Motor 0
exceeded upper limit value.
6003 Fault: DEF tank temperature has Motor 0
dropped below lower limit value.
6009 Supply connection Connection of Motor 0
description).
6010 Ground Connection of sensor/switch Motor 0
6011 Fault: Temperature too high! Motor 0
6012 Fault: Temperature invalid! Motor 0
6013 Warning: bad DEF quality! Motor 0
288 BW 220 D-5


description).
6016 Fault: DEF quality invalid! Motor 0
description).
6065 Fault: CAN message failed! Motor 0
FaultLocation Diesel particulate filter (DPF) 6004
6004 Plausibility error, DPF differential Motor 0
pressure
limit value!
6060 Fault: Excessive ash load! Motor 0
6061 Fault: Excessive soot load! Motor 0
FaultLocation DEF metering valve, Y293 6006
6006 Short circuit towards Ub Motor 0
BW 220 D-5 289

6007 Cable breakage or sensor defective Motor 0

6008 The output to the valve has ground Motor 0
than permitted.
6062 Fault: Valve blocked! Motor 0
FaultLocation DEF supply module 6017
6017 Fault: Pressure too high! Motor 0
6041 Signal outside the valid range Motor 0
6050 Fault: Temperature has dropped Motor 0
below lower limit value!
6051 Fault: Temperature implausible! Motor 0
FaultLocation Temperature sensor upstream of SCR catalyst, B223 6018
6018 Fault: Temperature has exceeded Motor 0
upper limit value!
6022 Fault: Temperature too low! Motor 0
FaultLocation DEF pump, M41 6025
6025 Supply voltage Ub is applied to the Motor 0
output to the pump, even though the
output is not switched.
6026 Output to pump shorted to ground Motor 0
290 BW 220 D-5


FaultLocation DEF suction valve, Y291 6028
6028 Supply voltage Ub is applied to the Motor 0
output to the pump, even though the
output is not switched.
6029 Output to pump shorted to ground Motor 0
FaultLocation Temperature sensor upstream of OXY catalyst, B214 6031
upper limit value!
FaultLocation Temperature sensor downstream of OXY catalyst, B215 6032
upper limit value!
FaultLocation Temperature sensor upstream of SCR catalyst, B224 6042
BW 220 D-5 291


6055 Short circuit Motor 0
6057 Fault: Lambda has exceeded upper Motor 0
limit value!
6059 Fault: Lambda has dropped below Motor 0
lower limit value!
FaultLocation Temperature sensor downstream of SCR catalyst, B225 6045
6053 Short circuit Motor 0
6056 Fault: Lambda has exceeded upper Motor 0
limit value!
6058 Fault: Lambda has dropped below Motor 0
lower limit value!
FaultLocation Pressure sensor upstream of SCR catalyst, B305 6048
6048 Fault: Pressure has exceeded upper Motor 0
limit value!
6048 Fault: Pressure has exceeded upper Motor 0
limit value!
6049 Fault: Pressure has dropped below Motor 0
lower limit value!
FaultLocation EndOfLine test (EOL test) 6186
292 BW 220 D-5

6186 Warning: Error before EOL test has Motor 0

started (read out error log)!
6187 Warning: Diesel engine not running! Motor 0
6188 Fault: Excessive soot load! Motor 0
6189 Warning: Check OXY cat sensors! Motor 0
6190 Warning: Error during EOL test (read Motor 0
out error log)!
6191 Warning: Check parking brake (travel Motor 0
lever in brake gate?)!
6192 Warning: Diesel engine no longer at Motor 0
operating point!
6193 Warning: Temperature downstream of Motor 0
Oxy catalyst too high!
6194 Warning: Differential pressure too Motor 0
high!
6195 Warning: EAT system not warmed up! Motor 0
6196 Warning: Diesel engine not warmed Motor 0
up!
6197 Warning: Stationary conditions not Motor 0
met!
6198 Warning: SCR system not ready! Motor 3408
1887 0
3408
1888
3408
1889
6199 Warning: Check NOx sensors! Motor 0
FaultLocation Machine type management 7012
7012 Machine type conflict After replacing System 2
match the old one.
BW 220 D-5 293

FaultLocation Setup operating hour meter 7013

7013 Operating hour meter not yet System 19871Informative code - Follow the adjustment instructions 1
reconstructed
FaultLocation Software Approval System 7020
7020 Software Approval Missing System 4
7021 Software release incomplete System 3
FaultLocation CAN communication 9005
9005 Fault: CAN communication Bus 1, 3958
check bus hardware 3958
760Faults on CAN line
9055 Fault: CAN communication Bus 2, 3960
check bus hardware 3960
760Faults on CAN line
FaultLocation Immobilizer A67 9107

FaultLocation Cabin module 9109
294 BW 220 D-5

Functional System500Output brake valve, Y04

Input Description Category ValueRange
500 Start function "Drive against closed brake" 1 [bar]
501 Quit function "Drive against closed brake" 1
Functional System554BMESX Module

554 Display of serial number 1
Functional System555System
555 Display of the firmware version of the travel 1
control (ESX)
556 Display of firmware version in display 1
720 Display of machine type 1
4010 Enable parameter change serial number 2
4011 Start parameter change serial number - xxx 2
xxx xx XXX
4012 Start parameter change serial number - type - 2
xxx xxx xx XXX
4013 Start parameter change serial number - high 2
number - xxx xxx xx XXX
4014 Start parameter change serial number - works 2
number - xxx xxx xx XXX
4019 Display of serial number 2
1001Output brake valve Y04

Functional System
BW 220 D-5 295

1001 Display voltage output brake 1 Display in V
1020Travel lever, S55

Functional System
1020 Display "Travel lever end positions" 1 100 = Forward0 = Neutral1 = Reverse
1021 Display of travel lever position direction X 1 -1000..0..1000
1022 Display of travel lever position direction Y 1 -1000..0..1000
1025 Display "Movement direction acc. to travel 1 100 = Forward0 = Neutral1 = Reverse
lever"
1026 Display travel direction switch 1 0 = Neutral1 = Forward2 = Reverse
1027 Display "Enabled travel range" 1 1= Driving permitted; 2= Driving disabled
1030Input inclination sensor, B57

Functional System
1030 Display inclination sensor status 1 0 = no movement1 = up2 = down3 = error
1260 Display inclination sensor position 1 -1000..1000
1261 Display inclination sensor value in percent 1 -1000..1000 > -100 % ..100%
gradient
1262 Display inclination sensor voltage measuring 1 [mV/ Digit]
value
1263 Display inclination sensor voltage measuring 1
value standardized to 1000
1264 Display inclination sensor status 1 0= Not Initialized, 1 = Initialized (Normal operation), 2 = Error
1265 Enable parameter change inclination sensor 1
1266 Set inclination sensor to zero 1
1040Input travel stage selector switch, S42

Functional System
296 BW 220 D-5

1040 Display "Selected travel range" 1

1041 Display input voltage for travel range switch 1 10 mv/ Digit
track 1
1050Output valve travel pump (front) forward, Y72
Functional System
1050 Display "Actual current value travel pump 1 1 mA/ Digit
forward"
1058 Display start current valve travel pump forward 1 Display in mA
1059 Display final current valve travel pump 1 Display in mA
forward
1060Output valve travel pump (front) reverse, Y73
Functional System
reverse"
1068 Display start current valve travel pump reverse 1 Display in mA
1069 Display final current valve travel pump reverse 1 Display in mA
1070Output valve travel pump (rear) forward, Y16

Functional System
forward"
1078 Display start current valve travel pump forward 1 Display in mA
1079 Display final current valve travel pump 1 Display in mA
forward
1080Output valve travel pump (rear) reverse, Y17
Functional System
BW 220 D-5 297


reverse"
1088 Display start current valve travel pump reverse 1 Display in mA
1089 Display final current valve travel pump reverse 1 Display in mA
1090Teach function travel pump flow controller

Functional System
1090 Release teaching surge currents travel pump 1
1091 Start teaching surge currents travel pump 1 [mA / Digit]
1095Travel system
Functional System
1095 1
1096 1
1097 1
1290 Display travel pressure 1 [bar]
1100Input speed sensor travel motor B59

Functional System
1100 Display of pulses per 10m 1
1104 Travel speed 1 Display in km/h
1105 Travel speed 1 Display in m/min
1106 Pulses of speed sensor 1
1107 Display "Movement direction of machine" 1 0 = Backwards
1 = Forwards
1109 Status display travel motor 1 0: Qmax1: Qmin
1114 Travel speed 1 Display in km/h
298 BW 220 D-5

1110Input speed sensor travel motor, B60

Functional System
1110 Display of pulses per 10m 1
1115 Travel speed 1 Display in m/min
1116 Pulses of speed sensor 1
1117 Display "Movement direction of machine" 1 0 = Backwards
1 = Forwards
1119 Status display travel motor 1 0: Qmax1: Qmin
1150Travel drive, speed adaptation

Functional System
1160 Release of teach function pulses from rotary 1
speed sensor
1161 Teach function pulses from rotary speed 1
sensor for 5m
sensor for 10m
sensor for 20m
sensor for 50m
sensor for 100m
1168 Restoration of default values for the rotary 1
speed sensor pulses
1169 Saving the rotary speed sensor pulses 1
BW 220 D-5 299

1270Input pressure sensor travel pump (rear) forward

Functional System
1271 Display pressure sensor current measuring 1 4..20 mA
value in mA
1272 Display pressure sensor measuring value 1 0..1000
standardized to 1000
1273 Display pressure sensor status 1 0= Not Initialized, 1 = Initialized (Normal operation), 2 = Error
1274Input pressure sensor travel pump (rear) reverse

Functional System
value in mA
1276 Display pressure sensor measuring value 1 0.. 1000
1280Input pressure sensor travel pump (front) forward

Functional System
value in mA
300 BW 220 D-5

1284Input pressure sensor travel pump (front) reverse

Functional System
value in mA
1286 Display pressure sensor measuring value 0.. 1000
1300Input seat contact switch, S06

Functional System
1300 Status seat contact switch 1 0 = off, 1 = on
1330Input armrest right, B146

Functional System
1330 Status of right armrest 1 1= arm rest up; 2= arm rest down
1331 Status of right armrest 1 Display in V
3010Measuring controller
Functional System
3010 Display enable measuring 2 0= Off1 = On
3011 Enable parameter change measuring 2
3012 Activate measuring 2
3013 Deactivate measuring 2
3014 2
3015 Display enable printer 2 0= Off1 = On
3016 Enable parameter change measuring 2
BW 220 D-5 301

3017 Activate printer 2

3018 Deactivate printer 2
4020 Release of change to printer language 2
4021 Printer language - German 2
4022 Printer language - English 2
4023 Printer language - French 2
4024 Printer language - Dutch 2
4025 Printer language - Danish 2
4026 Printer language - Spanish 2
4027 Printer language - Finnish 2
4028 Printer language - Swedish 2
4029 Printer language - Portuguese 2
4030 Printer language - Hungarian 2
4031 Printer language - Italian 2
4032 Printer language - Norwegian 2
4033 Printer language - Polish 2
4034 Printer language - Slovakian 2
4035 Printer language - Slovenian 2
4036 Printer language - Czech 2
4037 Printer language - Romanian 2
4040 Activating the simulation mode 2
4041 Activating the diagnostics mode 2
4050 Show exciter voltage 2 Display in V
4051 Show voltage of acceleration sensor 1 2 Display in V
4052 Show voltage of acceleration sensor 2 2 Display in V
302 BW 220 D-5

4060 Display vibration operation hour meter 2

4555 Display of the firmware version of the 2
measuring control (ESX)
3020Dozewr blade parameters
Functional System
3020 Display "Enabled dozer blade" 1 0= Off1 = On
3021 Enable dozer blade parameter change 1
3022 Activate the dozer blade 1
3023 Deactivate the dozer blade 1
3047Vibration system
Functional System
3047 Release of change to parameter vibration no 2
travel speed limit
3048 Change to parameter vibration activate travel 2
speed limit
3049 Change to parameter vibration no travel speed 2
limit
3050 Enable parameter change vibration 2
3052 Enable parameter change low amplitude 2
3053 Enable parameter change high amplitude 2
3058 Display of vibration parameter low amplitude 1
3059 Display of vibration parameter high amplitude 1
3060Attachment plate parameters

Functional System
3060 Display enable attachment plates 1
BW 220 D-5 303

3061 Enable parameter change attachment plates 1

3062 Activate parameter change attachment plates 1
3063 Deactivate parameter change attachment plates 1
3068 Display actual current vibratory pump 1 Display in mA
attachment plates
3069 Display nominal current vibratory pump 1 Display in mA
attachment plates
3075 Enable adjust attachment plates if position 1
measuring system defective
3076 Enable vibrate attachment plates if position 1
measuring system defective
3077 Enable parameter change reverse travel with 1
lowered attachment plates
3078 Activate reverse travel with lowered 1
attachment plates.
3079 Deactivate reverse travel with lowered 1
attachment plates.
3080 Display attachment plates connected 1 0= Off1 = On
3081 Display attachment plates value position 1 0..1000
measuring system vertical
3082 Display attachment plates position measuring 1 0..1000
system horizontal
3083 Display attachment plates switch vibration 1 0= Off1 = On
3084 Display attachment plates value potentiometer 1 0..1000
vibration
3085 Display valve lift attachment plates, Y122 1 0= Off1 = On
3086 Display valve lower attachment plates, Y123 1 0= Off1 = On
3087 Display valve attachment plates left, Y142 1 0= Off1 = On
3088 Display valve attachment plates right, Y143 1 0= Off1 = On
304 BW 220 D-5

3089 Display valve attachment plates priority, Y145 1 0= Off1 = On

3090 Display valve attachment plates floating 1 0= Off1 = On
position, Y60/Y144
3280Input pressure sensor vibration pump, high amplitude
Functional System
3280 Display of vibration pressure 1 [bar]
value in mA
3284Input pressure sensor vibration pump, low amplitude

Functional System
3284 Display of vibration pressure 1 [bar]
value in mA
3286 Display pressure sensor measuring value 0.. 1000
4070Acceleration transducer
Functional System
4070 1 0 = not Ok1 = ok
4071 1
4072 1
BW 220 D-5 305

4080
Functional System
4080 1 0 = not Ok1 = ok
4081 1
4082 1
4100
Functional System
4100 1 0 = not active,1 = active
4101 1
4102 1
4103 1
5000Engine speed detection

Functional System
5000 Display of diesel engine speed 1 Display in rpm
5001 Display of diesel engine speed command 1 Display in rpm
5002 Display engine speed mode diesel engine, 1
default value of switches
5003 Display engine speed mode diesel engine, 1 0 = Low idle speed1 = Eco mode2 = Full speed position
command for EGAS actuator
5010 Display parameters min speed diesel engine 1 Display in rpm
(idle speed)
5011 Display parameters max speed diesel engine 1 Display in rpm
(full speed)
306 BW 220 D-5

5004Engine speed default

Functional System
5004 Display input switch min (idle speed position) 1 0= Off1 = On
5005 Display input switch max (full speed position) 1 0= Off1 = On
5030 Enable parameter change engine speed 2
5032 Enable parameter change min. engine speed 2 Display in rpm
(idle speed)
5033 Enable parameter change max. engine speed 2 Display in rpm
(full speed)
5020Input engine oil pressure monitoring, B06
Functional System
5020 Display status oil pressure switch in diesel Oil pressure present: = 1 = ok No oil pressure = 0 = not ok
engine when engine is running
5021Input coolant level monitoring, B55

Functional System
5021 Display "Engine status - coolant level" 1 0= Coolant level OK1= Coolant level too low
5024Input D+ detection
Functional System
5024 Display D+ status of engine 1 0 = not Ok1 = ok
5025Input air filter sensor, B03

Functional System
5025 Display "Engine status - air filter" 1 0= Air filter OK1= Air filter soiled
BW 220 D-5 307

5026Input water separator, B124

Functional System
5026 Display "Status water separator in filter" 0 = ok 1 = Water in filter
5055 Release of parameter change for water 1
separator
5056 Parameter change water separator - engine 1
shut-down in case of water in fuel
5057 Parameter change water separator - no engine 1
shut-down in case of water in fuel
5040Input coolant level monitoring B55
Functional System
5040 Display of coolant filling level sensor mode 1 0: Normally open contact
1: Normally open contact
2: Normally closed contact
5050Input level switch for fuel filling level, R03

Functional System
5050 Display input level sensor in fuel tank 1 0..255 (raw values)
5060Exhaust gas after-treatment

Functional System
5060 Display DPF: Ash load 1 0..100%
5150 1
5151 1
5152 1
5153 1
308 BW 220 D-5

5160 Status display regeneration switch 1 100 = Suppress regeneration010 = automatic

regeneration001 = Request regeneration at standstill
5161 Display of DPF-load 1 0..100%
5170 Display type regeneration switch 1 0 = grid (default) 1=
grid 2=
button
5171 Input code enable change to regeneration 1
switch
5172 Input code regeneration switch type switch 1
5173 Input code regeneration switch type button 1
5110Setup operating hour meter

Functional System
5110 Display operating hour meter hours 1
5180EndOfLine test (EOL test)

Functional System
5180 Enable start EOL test 2
5181 Start EOL test 2
5600Auto-Stop system
Functional System
5600 Display of release of Auto-Stop-System 2 0= Off1 = On
5601 Release of parameter change to Auto-Stop- 2
System
5602 Activate Auto-Stop system 2
5604 Deactivate Auto-Stop system 2
5608 Release of changes to time Auto-Stop.System 2
BW 220 D-5 309

5609 Change to time Auto-Stop.System 2
7090Immobilizer A67
Functional System
7090 Release to enter the immobilizer code via 1
travel lever
7091 Start to enter the immobilizer code via travel 1
lever
8830 Release activation of immobilizer 2
8831 Activate immobilizer 2
8800Setup display
Functional System
8800 Enable parameter change display units 1
8801 Enable code - Display units in metric 1 Units in metric
8802 Input code - Display units in imperial Units in imperial
8820Cabin module
Functional System
8820 Display of cabin module release 1 0= Off1 = On
8821 Release of parameter change for cabin module 1
8822 Activate cabin module 1
8823 Deactivate cabin module 1
310 BW 220 D-5

Electric systems – Inspection and maintenance work
4.8 Inspection and maintenance work

4.8.1 Maintenance Table
No. Maintenance works Page

Every 500 operating hours
4.8.2.1 Servicing the battery, checking the main battery isolation 311
As required
4.8.3.1 Battery service during prolonged machine downtimes 312
4.8.2 Every 500 operating hours

4.8.2.1 Servicing the battery, checking the main battery isolation
4.8.2.1.1 Battery service

need to be checked.
ranty!
Protective equipment: n Working clothes

n Protective gloves
n Safety goggles
1. Park the machine in secured condition Ä Chapter 1.3.4
‘Parking the machine in secured condition’ on page 60.
2. Remove the battery and clean the battery compartment.
3. Clean the outside of the battery.
4. Clean battery poles and pole clamps and grease them with
pole grease (Vaseline).
5. Install the battery and check the battery fastening.
6. On serviceable batteries check the acid level, if necessary
top up to the filling mark with distilled water.
Fig. 161
BW 220 D-5 311

4.8.2.1.2 Checking the main battery shutoff

1. Turn the main battery switch counter-clockwise and pull it
out.
2. Check by turning the ignition key, whether the battery is dis-
connected from the electric system of the machine.
Fig. 162
4.8.3 As required
4.8.3.1 Battery service during prolonged machine downtimes
WARNING!
ture!
the battery.
the battery.

n Protective gloves
n Safety goggles
1. Switch off all consuming devices (e.g. ignition, light).
2. Measure the open-circuit voltage of the battery at regular
intervals (at least 1 x per month).
ð Reference values: 12.6 V = fully charged; 12.3 V = dis-
charged to 50%.
3. Recharge the battery immediately after an open-circuit
voltage of 12.25 V or less is reached. Do not perform boost
charging.
ð The open-circuit voltage of the battery occurs approx. 10
hours after the last charging process or one hour after
the last discharge.
4. Switch off the charging current before removing the charging
clamps.
5. After each charging process allow the battery to rest for one
hour before taking it into service.
312 BW 220 D-5

6. For standstill periods of more than one month you should

always disconnect the battery. Do not forget to perform reg-
ular open-circuit voltage measurements.
BW 220 D-5 313

314 BW 220 D-5

Hydraulic system
5 Hydraulic system
BW 220 D-5 315

Hydraulic system – Basic principles
5.1 Basic principles...................................................... 316

5.1.1 Open and closed hydraulic circuit.......................... 317
5.1.2 Swash plate principle, pump.................................. 319
5.1.3 Swash plate principle, motor.................................. 320
5.1.4 External gear pumps.............................................. 322
5.2 Overview of hydraulics.......................................... 325
5.3 Description of hydraulic components.................. 328
5.3.1 Travel / vibration pump, H1.................................... 328
5.3.2 Travel motor, H1.................................................... 332
5.3.3 Vibration motor A2FM............................................ 334
5.3.4 Steering valve........................................................ 336
5.4 Description of hydraulic circuits........................... 338
5.4.1 Charge circuit......................................................... 339
5.4.2 Travel circuit........................................................... 341
5.4.3 Vibration circuit...................................................... 346
5.4.4 Steering circuit....................................................... 353
5.5 Flushing and bleeding............................................ 356
5.5.1 Flushing in general................................................ 356
5.5.2 Flushing the travel circuit....................................... 359
5.5.3 Flushing the vibration circuit.................................. 368
5.5.4 Bleeding................................................................. 373
5.6 Inspection and maintenance work........................ 377
5.6.2 Checks prior to start up.......................................... 378
5.6.4 Every 1000 operating hours................................... 379
5.1 Basic principles

5.1.1 Open and closed hydraulic circuit.......................... 317
5.1.2 Swash plate principle, pump.................................. 319
5.1.3 Swash plate principle, motor.................................. 320
5.1.4 External gear pumps.............................................. 322
316 BW 220 D-5

5.1.1 Open and closed hydraulic circuit

Open circuit
Fig. 163: Open circuit

Open in this case means that the suction line of a pump (1) nor-
mally is situated below the fluid level, the surface of which is in
open contact with atmospheric pressure. Reliable equalization of
pressure between the air in the hydraulic oil tank and the ambient
air ensures problem free suction of the pump.
In an open circuit the hydraulic oil is fed to the consumer (2 or 3)
and also returned to the tank through way valves.
BW 220 D-5 317

Closed circuit
Fig. 164: Closed circuit

One talks about a closed hydraulic system, when the hydraulic oil
flows from the consumer (3) directly back to the pump (2).
The closed circuit consists of a high and a low pressure side,
depending on the load direction (take-off moment on the con-
sumer).
The high pressure side is protected by high pressure relief valves
(4), which release oil into the low pressure side. The medium
remains in the circuit.
Only the leakage on pump and motor needs to be replenished.
This is accomplished by a charge pump (1) which permanently
draws a sufficient amount of hydraulic fluid (charge capacity) from
the tank and feeds it through a check valves (5) into the low pres-
sure side of the closed circuit. The excess quantity delivered by the
charge pump flows through a charge pressure relief valve (6) back
into the tank. Charging the low pressure side enables the pump (2)
to work with higher operating data.
318 BW 220 D-5

5.1.2 Swash plate principle, pump
Fig. 165
The swash plate pump is a positive displacement machine with oil
displacing pistons arranged axially to the drive shaft. The pistons
are thereby supported by the swash plate.
Axial piston units based on the swash plate principle with fixed or
variable displacement can be used as hydraulic pumps or hydraulic
motors. In pump mode the mechanical energy is converted to
hydrostatic energy, when used in motor mode the hydrostatic
energy is converted to mechanical energy. When used as a pump,
the flow volume is proportional to the drive speed and the
swashing angle. The available (pump) torque increases with the
pressure drop between high and low pressure side.
Variable displacement pumps and motors can be change their dis-
placement, i.e. the pump delivery rate or motor throughput, by
simply changing the angle of the swash plate.
Description of function
Fig. 166
1 Drive shaft
2 Piston
3 Piston area
4 Piston stroke
5 Slipping disc
6 Adjusting angle
7 Cylinder
BW 220 D-5 319

8 Through drive
9 Valve plate
10 Top dead centre TDC
11 Bottom dead centre BTC
12 Control slots in suction side of swash plate (for sense of rota-
tion shown)
13 Control slot on pressure side
Driven by the engine, the drive shaft rotates and drives the cylinder
via a splined connection. The cylinder rotates with the drive shaft
and drives the 9 pistons. The pistons rest with their slipper pads on
the sliding face of the swashing cradle and perform an axial move-
ment. The slipper pads are held on the sliding face and are posi-
tively guided by a retaining device. During a complete rotation of
the cylinder block each piston moves through the bottom and top
dead centre back to its initial position. From dead centre to dead
centre is performs a full piston stroke. During this process the flow
volume determined by the stroke is drawn in through the control
slots in the valve plate or pumped out. During the suction stroke
the hydraulic fluid is drawn into the increasing piston chamber, i.e.
it is actually pressed in. On the opposite side the oil is pressed out
of the piston bores into the hydraulic system during the compres-
sion stroke.
5.1.3 Swash plate principle, motor
Fig. 167
The swash plate pump is a positive displacement machine with oil
displacing pistons arranged axially to the drive shaft. The pistons
are thereby supported by the swash plate.
Axial piston units based on the swash plate principle with fixed or
variable displacement can be used as hydraulic pumps or hydraulic
motors. In pump mode the mechanical energy is converted to
hydrostatic energy, when used in motor mode the hydrostatic
energy is converted to mechanical energy. Variable displacement
motors can change their displacement, i.e. the pump delivery rate
or motor throughput, by simply changing the angle of the swash
plate.
If the unit is used as motor, the output speed is proportional to the
supplied volume of fluid. The available (motor) torque increases
with the pressure drop between high and low pressure side.
320 BW 220 D-5

Fig. 168
1 Drive shaft
2 Piston
3 Piston area
4 Piston stroke
5 Slipping disc
6 Adjusting angle
7 Cylinder
8 Through drive
9 Valve plate
10 Top dead centre TDC
11 Bottom dead centre BTC
12 Control slots in suction side of swash plate (for sense of rota-
tion shown)
13 Control slot on pressure side
The motor function is a reversal of the pump function. In this case
the hydraulic fluid the hydraulic system directs the oil flow to the
hydraulic motor. The medium flows through control slots in the
valve plate to the cylinder bores. 4 or 5 cylinder bores are opposed
to the kidney shaped control slots in the pressure side. The other
control slot is in this case connected with the rest of the cylinder
bores, which in turn are connected with the return flow side or are
partly covered by the connecting web between the kidney shaped
control slots. By loading the piston it slides down the slanted swash
plate and drives the cylinder that guides it. The cylinder with the 9
pistons rotates with the drive shaft, whereby the piston perform a
stroke-like movement. The hydraulic pressure generates the torque
on the cylinder and thus the rotation of the drive shaft. The sup-
plied fluid quantity determines the output speed.
BW 220 D-5 321

5.1.4 External gear pumps

External gear pumps mainly consist of the gear pair, which is
mounted in friction bearings, and the housing with front and rear
covers. The drive shaft, which is sealed with a radial seal, pro-
trudes from the front cover. The bearing forces are absorbed by
friction bearings. These have been designed for high pressures
and have excellent emergency operation properties—particularly at
low speeds. The gears wheels have 12 teeth each. This keeps flow
pulses and noise emissions at a low level.
Fig. 169: Axial compensation of gear pump
1 Axial seal 5 Cover

2 Outer pressure field 6 Flange
3 Inner pressure field 7 Sealing zone
4 Radial seal 8 Compensation forces
Internal sealing of the pressure chambers is achieved by flow

volume dependent forces. This results in an excellent degree of
efficiency. On the rear side, the moveable bearing bushings are
pressurised and the operating pressure presses them tightly
against the gears. The applied pressure fields are limited by spe-
cial seals. Sealing around the circumference of the gears to the
housing is ensured by very small gaps, which appear between
gears and housing depending on the pressure.
322 BW 220 D-5

Function
Fig. 170
The increasing volume caused by a tooth exiting a tooth gap
results in a vacuum in the suction chamber. The pressure fluid is
transported into the pressure chamber. There the meshing of teeth
and tooth gaps displaces the pressure fluid into the upper supply
line.
Fig. 171
1 Cover 6 Gear (driven)

2 Seals 7 Shaft
3 Housing 8 Flange
4 Gear (driving) 9 Bearing plate
5 Displacement chamber 10 Bearing plate
BW 220 D-5 323

Multiple gear pumps Gear pumps are suited for multiple pump arrangements, in which
the drive shaft of pump 1 is extended to drive a second or third
pump. The shafts are connected by drivers in between. The indi-
vidual pump stages are sealed to each other, i.e. the suction ports
are separated from each other.
Fig. 172
324 BW 220 D-5

Hydraulic system – Overview of hydraulics
5.2 Overview of hydraulics
Fig. 173
1 Drum drive motor
2 Steering valve
7 Vibration pump
8 Charge oil filter
9 Brake valve, Y04 & travel speed range selection for drum, Y30
10 Rear travel motor, with travel speed range selector Y31
11 Manifold block with thermostat
12 Steering cylinder
13 Vibration motor
BW 220 D-5 325

Fig. 174
1 Pressure sensor B235, axle MB
2 Pressure sensor B237, drum MB
3 Vibration pump
5 Pressure sensor B236, drum MA
6 Pressure sensor B234, axle MA
8 Steering/ charge pump with installed vibratory plates, BVC or dozer blade as tandem gear pump
MS Pressure test port, charge pressure
ML Pressure test ports for steering
Vibration pump
high amplitude low amplitude
Current on coil C1 C2
Plugs Y07 Y08
Pressure on port A B
326 BW 220 D-5

Travel pump for drum drive

Forward travel Backward travel
Plugs Y73 Y72
Travel pump for axle drive

Forward travel Backward travel
Plugs Y16 Y17
BW 220 D-5 327

Hydraulic system – Description of hydraulic components
5.3 Description of hydraulic components

5.3.1 Travel / vibration pump, H1.................................... 328
5.3.2 Travel motor, H1.................................................... 332
5.3.3 Vibration motor A2FM............................................ 334
5.3.4 Steering valve........................................................ 336
5.3.1 Travel / vibration pump, H1

5.3.1.1 Variable displacement pumps, H1 P045/P053/P060/P078/P089/P100 RA
General The variable displacement axial piston pump generates, controls
and regulates a volumetric pressure fluid flow. It has been
designed for mobile applications, e.g. in construction equipment.
The pump is a variable displacement axial piston pump in swash
plate design for hydrostatic drives in closed circuits. The volumetric
flow is proportional to drive speed and displacement.
328 BW 220 D-5

Fig. 175: Axial piston pump H1

1 Control unit
2 Servo piston
3 Valve plate
4 Cover plate
5 Auxiliary pump (only with vibration pump)
6 Cylinder block
7 Swash disc
8 Drive shaft
9 Radial seal, drive shaft
10 Slipper pad
11 Piston
12 Feedback lever
NOTICE!
Components may get damaged!
– The aggregate must always be filled with
hydraulic oil and purged before start-up and
during operation.
– This must also be considered for longer
periods of rest, because the aggregate may
run empty through the hydraulic lines.
BW 220 D-5 329

Schematic
Fig. 176: Block diagram

1 Control unit
2 Radiator
3 Tank
4 Charge pump
5 Charge oil filter
6 High pressure limiting valves
7 Hydraulic motor
8 Charge valve
9 Control pressure relief valves
10 Servo control
11 Servo adjustment plate
330 BW 220 D-5

H High pressure
S Servo pressure
N Low pressure
R Return flow
High pressure relief valves with Pressure peaks occurring during very fast swashing processes, as
integrated boost check valves and well as the maximum pressures are safeguarded by superordinate
bypass for towing high pressure relief valves, which open when the adjusted value is
exceeded and relieve oil into the low pressure side.
The boost check valves are integrated in the high pressure relief
valves. These valves open to the low pressure side and let cool
and filtered oil flow from the charge oil circuit into the closed
hydraulic circuit, in order to compensate leaks and flushing quanti-
ties.
Bypass for towing operations:
NOTICE!
Do not back out more than 3 turns!
Observe the tightening torque of 70 Nm.
Charge pressure relief valve The charge pressure valve belongs to the group of safety elements
in a closed hydraulic circuit. This valve limits the pressure in the
charge circuit to a fixed value.
Control pressure relief valve, pres- If the adjusted pressure is reached, the pressure override will move
sure override the swash plate quickly back towards neutral position, thereby lim-
iting the system pressure. 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.
BW 220 D-5 331

RA - control
Fig. 177: RA - control

1 Feedback lever
2 Proportional solenoids
Depending on the pre-selected ampacity “I” on the proportional sol-
enoids, the control cylinder on the pump is supplied with control
pressure through the RA control unit. This way the swash plate and
thus the displacement of the pump is infinitely variable. Each of the
proportional solenoids is assigned to a certain flow direction.
NOTICE!
The spring reset in the control unit is no safety fea-
ture.
Internal contamination – like e.g. contaminated
hydraulic fluid, abrasion or dirt residues from
system components – can cause blockage of the
spool valve in the control unit. The flow volume
from the variable displacement pump will in this
case no longer follow the instructions of the oper-
ator.
5.3.2 Travel motor, H1

5.3.2.1 Swash plate motor (H1) with variable displacement
A plug-in fixed displacement motor converts the hydrostatic volu-
metric flow into mechanical rotary motion. It has mainly been
designed for installation into mechanical gear drives.
332 BW 220 D-5

Fig. 178
1 Valve plate
2 Bearing plate
3 Synchronizing joint
4 Ring gear for sensor
5 Tapered roller bearing
6 Fastening flange
7 Piston
8 Minimum swashing angle setting
9 Sensor
10 Control piston
11 Flushing pressure relief valve
12 4-way valve
13 Shuttle valve
NOTICE!
during operation.
BW 220 D-5 333

Flushing valve
The flushing valve is used to discharge heat from
the hydraulic circuit.
When the travel circuit is switched on, a pressure difference will be

generated between the two sides (A & B) 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 pres-
sure side.
The flushing valve is fitted with a downstream 16 bar pressure
relief valve. This valve makes sure that only a certain quantity of
hydraulic oil is flushed out. This oil flows back to the hydraulic oil
tank and is immediately replaced by oil from the charge circuit.
Control 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 dis-
placement, 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 piston rod side (M5) is
thereby permanently pressurized with the actual travel pressure. In
1st gear the piston side (M4) is connected with the tank (solenoid
de-energized). In speed range 2 the solenoids are energized, the
valve switches and the piston side is also pressurized with the cur-
rent travel pressure. Due to the area differential between piston rod
side and piston side and the force resulting from this, the pilot con-
trol moves to Qmin position.
5.3.3 Vibration motor A2FM

5.3.3.1 Axial piston motor A2FE/FM
The plug-in fixed displacement motors A2FE and
A2FM just differ by a different housing.
NOTICE!
during operation.
334 BW 220 D-5

XX is a slide-in fixed displacement motor with a tapered axial

piston drive of inclined axis design for hydrostatic drives in open
and closed circuits. Due to this inclined axle design the torque is
generated directly on the drive shaft. The pistons only apply very
little transverse forces to the cylinder, which has a favourable effect
on wear, efficiency and starting torque.
Fig. 179
1 Drive shaft
2 Piston
3 Cylinder
4 Valve plate
5 Connecting plate
6 Flushing valve, optional
In fixed displacement motors in inclined axis design, the pistons (2)
Ä Fig. 179 are arranged in an inclined position to the drive shaft
(1). The pistons perform an axial movement, which is then con-
verted to a rotary movement by the piston joint on the drive shaft
flange. The cylinder (3) is driven by the pistons.
Motor function A fixed displacement plug-in motor converts the hydrostatic energy
into mechanical energy. Pressure fluid is fed through the con-
necting plate (5) and the valve plate (4) into the cylinder bores. The
pistons (2) inside the cylinder bores perform an axial movement,
which is then converted to a rotary movement by the piston joint on
the drive shaft flange (1). The pistons thereby drive the cylinder (3)
and thereby generate the output torque on the drive shaft. The
output torque is generated by the force resulting from pressure and
piston area. The output speed is proportional to the supplied fluid
volume and the displacement. The available motor output torque
increases with the pressure drop between high and low pressure
side.
Flushing valve
The flushing valve is used to discharge heat from

the hydraulic circuit.
BW 220 D-5 335

S-HYD-0088
Fig. 180
1 Flushing spool
2 Flushing pressure limiting valve
The hydraulic motor is equipped with an integrated flushing valve.
When the hydraulic circuit is switched on, a pressure difference will
be generated between the two sides of the closed circuit. The
sure side.
The flushing valve is fitted with a downstream 16 bar pressure lim-
iting valve. This valve makes sure that only a certain quantity of
hydraulic oil is flushed out. The oil flows back to the hydraulic oil
5.3.4 Steering valve

The steering unit works hydrostatically, i.e. there is no mechanical
connection between the steering wheel and the wheels to be
steered (articulated joint, drum, etc.). The mechanical connection is
replaced by hydraulic piping and hoses between the steering unit
and the steering cylinder(s).
When the steering wheel is operated, the steering unit measures
the exact oil quantity proportional to the rotation of the steering
wheel. This oil quantity is directed to the steering cylinders.
336 BW 220 D-5

The steering unit mainly consists of a rotary spool valve and a

metering pump (gear set). The steering column connects the
steering unit to the steering wheel of the vehicle. When turning the
steering wheel, the rotary spool valve makes sure that oil from the
steering pump is guided through the gear set to the cylinder ports L
or R, depending on the turning direction of the steering wheel. The
gear set measures the oil flow to the steering cylinder proportion-
ally to the turning angle of the steering wheel.
Fig. 181
1 Check valve
2 Shock valve
3 Pressure limiting valve
4 Housing with replenishing valves
5 Inner spool
6 Neutral position spring
7 Pin
8 Outer spool
9 Cardan shaft
10 Distributor plate
11 Gear
12 Ring gear
13 Cover
The steering valve is additionally equipped with a pressure limiting
valve which limits the steering pressure.
Suddenly occurring pressure peaks, which may be caused by e.g.
external influences such as driving against a curb stone, are com-
pensated by two shock valves, which are integrated in the steering
valve. Each of these shock valves is fitted with an additional
replenishing valve. These replenishing valves protect the system
against cavitation which could be caused by the reaction of the
shock valves.
A check valve inside the steering unit makes sure that the
hydraulic oil cannot flow to the steering pump if outside forces are
introduced. In such a case, the steering cylinders would act as
pumps and press the oil back to the pump.
BW 220 D-5 337

Hydraulic system – Description of hydraulic circuits
5.4 Description of hydraulic circuits

5.4.1 Charge circuit......................................................... 339
5.4.2 Travel circuit........................................................... 341
5.4.3 Vibration circuit...................................................... 346
5.4.4 Steering circuit....................................................... 353
338 BW 220 D-5

5.4.1 Charge circuit
Fig. 182
2 Charge circuit filter
4 Vibration pump with integrated charge pump
5 Travel pump
6 Brake valve
7 Steering valve
BW 220 D-5 339

B21 Differential pressure switch on charge circuit filter

MS Pressure test port for charge circuit
ML Pressure test port for steering
The charge circuit provides the oil for the charge system and the
control functions in the closed circuits for travel and vibration drive,
as well as to release the parking brakes.
The steering/charge pump is a gear pump with constant displace-
ment. The gear pump unit is driven by the auxiliary drive of the
diesel engine and draws the hydraulic oil directly out of the oil tank.
Another charge pump is integrated in the vibration pump.
The flows from steering/charge pump and integrated charge pump
(in vibration pump) are joined together before the charge circuit
filter.
The charge circuit is equipped with a 12 µ fine filter with bypass
valve. This valve opens at a differential pressure (pressure differ-
ence between filter inlet and filter outlet) of Δp = 3.5 bar. This differ-
ential pressure depends on the filter contamination and the vis-
cosity of the hydraulic oil.
The differential pressure switch (B21) switches when a differen-
tial pressure of Δp 2.5 bar is reached. The fault information will
therefore already be available before the bypass valve opens.
340 BW 220 D-5

5.4.2 Travel circuit
2 MS
4
3 MA
L2
M3
MB
L4
B
1 A
Y04
P
T
A2
A1
5
55 - 70°C
B
10 D F
I
A
B
L2
6
T B
A
B
A
9
Y31
8
7
S-586-0188
Fig. 183
2 Radiator
3 Travel pump
4 Vibration pump
5 Brake valve
6 Axle with brake discs
7 Travel motor of axle drive
8 Travel gear with brake discs
BW 220 D-5 341

9 Travel motor of drum drive

10 Return flow manifold with thermostat
MS Pressure test port for charge pressure
Each travel circuit is a closed hydraulic circuit, it consists mainly of
travel pump and travel motors.
Travel pump
Forward travel Reverse travel
Plug Y16 Y17
Travel pump and vibration pump are mounted together to a tandem

unit which is driven by the flywheel side of the diesel engine via an
elastic coupling. The travel pump has the task of supplying the
travel circuit with hydraulic oil.
Flushing valves in the drive motors

The flushing valves are used to discharge heat
from the hydraulic circuit.
When the travel circuit is switched on, a pressure difference will be

generated between the two sides (A & B) of the closed circuit. The
sure side.
The flushing valve is fitted with a downstream flushing pressure
relief valve. This valve makes sure that only a certain quantity of
hydraulic oil is flushed out. The oil flows back to the hydraulic oil
Return flows All return flows pass through the return flow manifold block with
thermostat. This thermostat guides the oil flow directly back to the
hydraulic oil tank, until the operating temperature is reached. At an
oil temperature of 55 °C the valve starts to switch over and at 70
°C the total amount of oil will flow through the hydraulic oil cooler.
Service brake During operation the closed hydrostatic travel circuit has the func-
tion of a service brake. When the travel lever is returned towards
neutral position, the displacement of the travel motor is adjusted
towards zero accordingly and the machine is hydraulically braked.
Parking brake To avoid creeping movements of the machine, the machine is addi-
tionally equipped with spring accumulator multi-disc parking brakes
in drum drive gear and in the axle. These close in neutral position
of the travel lever and when the engine is stopped.
342 BW 220 D-5


1 Vibration motor
2 Exciter unit
3 Clutch
4 Travel gear
5 Travel motor
6 Drum shell
7 Rubber buffer
9 Travel bearings
Rear axle The rear axle is equipped with no-spin differential with automatic
locking up to 100 percent.
The no-spin differential denotes a special form of axle gear used

primarily in slow-moving construction machinery. It enables both
wheels of an axle to be driven at the same constant speed and
with maximum power transmission.
The wheel with the lower speed is assigned the higher torque.
Structure
BW 220 D-5 343

S-586-0482
Fig. 185: No-spin differential

The design of such axle drives largely corresponds to that of a
"normal" bevel gear differential, but the centre of the component is
a double claw coupling. This in turn consists of three main compo-
nents: a central ring with claw toothing and two claw rings, each of
which is connected to the corresponding axle shaft in a torsion-
resistant manner and is spring-loaded against the central ring.
Straight ahead and cornering

When driving straight ahead, both the axle shafts are rigidly con-
nected to each other and to the drive shaft. This position corre-
sponds to a 100 percent locked axle with "normal” differential.
However, a "normal" axle with maximum locking causes problems
when cornering: Since the wheels are constantly driven with the
same speed and force, the lock must be released again when cor-
nering on solid ground, such as asphalt. Otherwise, mechanical
damage will occur to the axle gear due to the different rotational
speeds of the wheels. This is where the advantages of the no-spin
differential come into play. When cornering, the claw coupling of
the outer wheel is released.
Advantages
On the one hand, the wheels can rotate at different speeds
because there is no longer any rigid connection.
On the other hand, the entire power of the drive is directed into the
inner wheel of the curve and there is no loss of force.
344 BW 220 D-5

Compared to a standard differential, the wheel is not driven with

less resistance. If a wheel loses grip or is on or in loose ground,
the claw coupling closes and both wheels are equally driven again.
The gearbox locks and releases itself “independently”, which
makes operation easier, eliminates the risk of mechanical damage
due to improper use and, at the same time, provides maximum
traction and off-road performance.
Locking value
The locking value defines the maximum difference of the torques
distributed on both wheels.
Example: 0% locking value: 0% is the locking value when there
is no slip between the wheels and the road.
Example: 50% locking value: 50% is the locking value when the
faster wheel is driven with 1/4 of the input torque and the slower
one with 3/4 (3/4 - 1/4 = 1/2 or 50%).
Example: 100% locking value: 100% lock means that the slow-
turning wheel receives the same power (100%) as the other wheel.
BW 220 D-5 345

5.4.3 Vibration circuit
Fig. 186
2 Radiator
3 Travel pump
346 BW 220 D-5

4 Vibration pump
5 Vibration motor
6 Return flow manifold with thermostat
MS Pressure test port for charge pressure
Vibration pump
High amplitude Low amplitude
Plugs Y07 Y08
Vibration circuit The vibration circuit is a closed hydraulic circuit, it consists mainly
of the vibration pump with the integrated safety elements and the
vibration motors.
Travel pump and vibration pump are mounted together to a tandem
unit which is driven by the flywheel side of the engine via an elastic
coupling. The vibration pump has the function of supplying the
vibration circuit with hydraulic oil.
When changing the swashing angle in the vibration pump through

the neutral position to the opposite side, the flow direction of the oil
and the sense of rotation of the vibration motor will change.
Since the displacement of the vibration pump is different to the two
flow directions, the speeds of the vibration motor are also different.
S-586-0444
Fig. 187
1 Low amplitude
BW 220 D-5 347

S-586-0446
Fig. 188
2 High amplitude
The vibration system is designed in such a way, that the high
exciter shaft speed (frequency) is coupled with the low amplitude
(1) Ä Fig. 187 and the low exciter shaft speed (frequency) with the
high amplitude (2) Ä Fig. 188.
The eccentric weights on the exciter shaft are fitted with additional
change-over weights. Depending on the sense of rotation of the
exciter shaft, these change-over weights are added to or sub-
tracted from the basic weights.
n Basic weight minus change-over weight = low amplitude (1)
Ä Fig. 187
n Basic weight plus change-over weight = high amplitude (2)
Ä Fig. 188
348 BW 220 D-5

Fig. 189
1 Basic weight
2 Change-over weight
3 Exciter shafts
When vibration is switched on, the vibration motor must first move
the resting exciter shaft. This resistance causes a hydraulic starting
pressure, which is limited by the pressure override valve. Once the
exciter shaft has reached its final speed, the pressure will drop to
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
Soft ground = low operating pressure
Fig. 190: low amplitude
BW 220 D-5 349

Use of low amplitude

n thin layers
n gravels, sands, mixed soils
n gravel and road metal bearing courses
n surface compaction
Fig. 191: high amplitude

Use of high amplitude
n thick layers
n non-cohesive soils and cohesive soils
n gravel and road metal bearing courses
n hydraulically bonded base courses
n frost protection layers
n subsoils
n dam constructions
350 BW 220 D-5


1 Vibration motor
2 Exciter unit
3 Clutch
4 Travel gear
5 Travel motor
6 Drum shell
7 Rubber buffer
9 Travel bearings
The vibration motor output shaft is connected to the exciter shaft in

the drum via a Bowex coupling. The rotation of the exciter shafts
with eccentric weights causes the vibration of the elastically sus-
pended drum.
Vibration motor with flushing valve The vibration motor is equipped with an integrated flushing valve.
In the closed hydraulic circuit the flushing and charge pressure
relief valve is used to avoid excessive temperatures and to secure
the minimum charge pressure. The valve is integrated in the con-
necting plate.
BW 220 D-5 351

A certain amount of pressure fluid, which is determined by the size

of an orifice, is taken out of the corresponding low pressure side
and discharged into the motor housing. This fluid is returned to the
tank, together with the leak oil. The pressure fluid taken out of the
circuit is then replaced by cooled oil from the charge pump.
Return flows All return flows pass through the return flow manifold with tempera-
ture controlled valve (thermostat). This thermostat guides the oil
flow directly back to the hydraulic oil tank, until the operating tem-
perature is reached. At an oil temperature of 55 °C the valve starts
to switch over and at 70 °C the total amount of oil will flow through
the hydraulic oil cooler.
352 BW 220 D-5

5.4.4 Steering circuit
Fig. 193
2 Steering/ charge pump with installed vibratory plates, BVC or dozer blade as tandem gear pump
3 Charge circuit filter
4 (Optional equipment for cabin) Silencer, it is always subjected to hydraulic oil flow and has the function
of eliminating any vibrations and noises
5 Steering cylinder
6 Steering valve
ML Pressure test ports for steering
BW 220 D-5 353

The steering/charge pump is a gear pump with constant displace-

ment. The gear pump unit is driven by the auxiliary drive of the
diesel engine and draws the hydraulic oil directly out of the oil tank.
Oscillating articulated joint
Fig. 194: Illustrated example: single drum rollers

1 Drum
2 Front frame
3 Oscillating articulated joint with two steering cylinders
4 Oscillating articulated joint with one steering cylinder
5 Steering cylinder
6 Rear frame
7 Drive axle
8 Single drum roller with one steering cylinder
9 Single drum roller with two steering cylinders
354 BW 220 D-5

Oscillating articulated joints are used to flexibly connect the rear

and front frames of agricultural and construction machinery. The
machine can be steered around the vertical axis by means of an
articulated movement; the rear frame can oscillate on the hori-
zontal axis. The advantage of the oscillating articulated joint is the
fact that the front and rear frame move in the same track.
The oscillating joint compensates for uneven ground and creates
an even wheel pressure. The combination with a rigid axle pro-
vides good off-road performance. Good stability is achieved by the
low pivot point of the oscillating joint in connection with the low
centre of gravity of the machine.
BW 220 D-5 355

Hydraulic system – Flushing and bleeding
5.5 Flushing and bleeding

5.5.1 Flushing in general................................................ 356
5.5.2 Flushing the travel circuit....................................... 359
5.5.3 Flushing the vibration circuit.................................. 368
5.5.4 Bleeding................................................................. 373
5.5.1 Flushing in general
NOTICE!
Changing a component
– Always flush the complete oil circuit after you
have replaced a component.
– Particulate contamination circulating in fluid
systems causes surface damage due to gener-
ally known wear mechanisms (abrasion, ero-
sion, surface fatigue).
Fig. 195
Effect of contamination
n Coarse particles (>15 µm)
– Sudden failure of components.
n Fine particle contamination (5–15 µm)
– Wear of components, internal leaks, inaccurate controlling
behaviour, blockage of valves.
n Extra fine particle contamination (<2–5 µm)
– Silting of oil, accelerated ageing of oil, corrosion.
356 BW 220 D-5

n Water in oil
– Increased wear, accelerated ageing of oil.
n Chips (abrasion) in the oil
– Open and clean all components in the oil circuit; replace if
necessary.
– Clean all high pressure hoses in the oil circuit; replace if
necessary.
– If abrasion is found in the travel circuit you should also
flush the vibration circuit.
– If abrasion is found in the vibration circuit you should also
flush the travel circuit.
Before flushing
1. Change the filter element (1).
Fig. 196
2.
NOTICE!
Clean the hydraulic tank
Change the oil in case of excessive contami-
nation, oil discolouration or if the oil change
interval is almost due.
Filter the tank content with the filling and filtering unit and
pump it into an oil container.
3. Mark all hoses and disconnect them from the hydraulic oil
tank.
Fig. 197
4. Clean the oil tank thoroughly from inside; remove the tank
cover, if necessary.
5. Reconnect all hoses.
6. Fill the hydraulic oil tank again with the filling and filtering
unit.
BW 220 D-5 357

Bleeding
1. Always bleed closed hydraulic circuits if lines had been
removed or connected.
Fig. 198
Servicing the flushing filter kit

1. Replace the filter element of the flushing filter when the red
control pin of the contamination indicator is pressed out
during the flushing process.
2. Clean hoses and connections and store the flushing kit in a
clean and protected environment.
Fig. 199
358 BW 220 D-5

5.5.2 Flushing the travel circuit

Travel circuit flushing diagram, BW
211/212/213/214 D/PD-5
5
6
2 A B
7
A
8
4
9
OUT
IN
R 10
L
1
2 3 B
A
B
A
L
R 11
BW 211/212 D/PD
BW 213/214 D/PD
S-586-0129
Fig. 200
1 Elbow union (tool)
2 Connecting union (tool)
3 Travel motor of axle
4 High pressure hose A <> B
5 Travel pump
6 High pressure hose B <> A
BW 220 D-5 359

7 Flushing hose 25S - 20S (tool)

8 Screw socket R1 - 25S (tool)
9 Flushing filter with filter element 1μ (tool)
11 Travel motor of drum
360 BW 220 D-5

Travel circuit flushing diagram, BW

216/219 D/PD-5
5
6
2 A B
7
A
8
4
9
OUT
IN
A
10
B
1
A
2 3 B
A
A
B B
BW 216 D/PD
BW 219 D/PD
11 S-586-0491
Fig. 201
3 Travel motor of axle
4 High pressure hose A <> B
5 Travel pump
6 High pressure hose B <> A
BW 220 D-5 361

9 Flushing filter with filter element 1μ (tool)

11 Travel motor of drum
5.5.2.1 Flushing the travel system
Observe the chapter "Flushing - General"
Installing the flushing filter

NOTICE!
Before the installation of the filters check hoses
and connections for cleanliness.
The flushing filter must be installed in the low pres-
sure side in the return flow to the pump, so that
only cleaned oil will enter the travel pump in for-
ward travel.
With the connection shown in the illustration the
travel pump must therefore be actuated to forward
direction.
1. Disconnect the high pressure hose (6) from the axle drive
motor (port A) and connect it with the flushing hose (7,
flushing filter outlet “OUT”).
2. Connect flushing hose (10) to the axle drive motor (port A).
Disconnect the drum drive motor

1. Take the drum drive motor (11) out of the hydraulic circuit by
joining the hoses together.
Fig. 202
362 BW 220 D-5

Bleeding the travel circuit

1.
Bleeding the travel circuit, see chapter
"Bleeding the travel circuit".
Fig. 203
Flushing the hoses

1. Keep circulating the complete tank content with the filling and
filtering unit throughout the entire flushing process.
Fig. 204
2. Block drums and wheels with suitable chocks.
Fig. 205
BW 220 D-5 363

3.
NOTICE!
Move the travel lever only to travel direction
forward, as otherwise the flushing filter will be
subjected to oil flow from the wrong direction.
Start the engine and shift the travel lever to travel direction
forward.
4. Perform the flushing process at various engine speeds for
approx. 10 minutes.
5. Shut down the engine.
6. Reconnect the high pressure hoses (L & R) to the drum drive
Fig. 206
motor (11).
Flushing the drum drive motor

WARNING!
Danger of accident!
The drum must rotate freely.
1. Jack up the front of the machine, so that the drum can rotate
freely.
2. Secure the rear wheels with chocks.
3. Pre-select the slow speed range.
Fig. 207
Fig. 208
364 BW 220 D-5

5.
NOTICE!
Start the engine, run it with maximum speed and shift the
travel lever to travel direction forward.
6. Run the flushing procedure for approx. 10 minutes. During
this process keep changing the pump flow by shifting the
travel lever several times between full and halve forward
travel.
Fig. 209 7. Shut down the engine.
Flushing the axle motor

WARNING!
Danger of accident!
Both wheels must be off the ground. The wheels
must be able to rotate freely.
1. Jack up the rear of the machine, so that the wheels can

rotate freely.
2. Secure the drum with wheel chocks.
3. Pre-select the slow speed range.
Fig. 210
Fig. 211
BW 220 D-5 365

5.
NOTICE!
Start the engine, run it with maximum speed and shift the
travel lever to travel direction forward.
6. Run the flushing procedure for approx. 10 minutes. During
this process keep changing the pump flow by shifting the
travel lever several times between full and halve forward
travel.
8. Remove the flushing filter and reconnect the high pressure
lines.
Bleeding the travel circuit

1.
Bleeding the travel circuit, see chapter
"Bleeding the travel circuit".
Fig. 213
Circulating the tank content

1. After completing the bleeding process circulate the tank con-
tent with the filtering unit for another 15 minutes.
Fig. 214
366 BW 220 D-5

Function test
1. Check the hydraulic oil level in the tank, fill up if necessary.
2. Check all connections for leaks with the engine running
(visual inspection).
3. Perform a test drive, load the travel system in forward and
reverse, e.g. by driving uphill or starting on a gradient.
4. Check all ports and connections once again for leak tightness
Fig. 215
BW 220 D-5 367

5.5.3 Flushing the vibration circuit

Flushing diagram for vibration
drive
Fig. 216
1 Vibration pump
368 BW 220 D-5

2 High pressure hose, A <> A

3 High pressure hose, B <> B
6 Vibration motor
7 Flushing filter with filter element 1µ (tool)
5.5.3.1 Flushing the vibration circuit
Observe the chapter "Flushing - General"
Installing the flushing filter

NOTICE!
Before the installation of the filters check hoses
and connections for cleanliness.
The flushing filter must be installed in the low pres-
sure side in the return flow to the pump, so that
only cleaned oil will enter the vibration pump in
high frequency.
D, DH and PDH machines: For the connection
schematic shown here the vibration must always
be filtered with “high frequency / low amplitude”.
Disconnect the vibration motor

1. Take the vibration motor (6) out of the hydraulic circuit by
joining the hoses (3 & 9) together.
Fig. 217
BW 220 D-5 369

Bleeding the vibration circuit

1.
Bleeding the vibration circuit, see chapter
"Bleeding the vibration circuit".
Fig. 218
Flushing the hoses

1. Block drum and wheels with suitable chocks.
Fig. 219
Fig. 220
3.
NOTICE!
D, DH and PDH machines: Use only high
frequency, as otherwise the flushing filter will
be subjected to oil flow from the wrong direc-
tion.
Switch on vibration with high frequency.

4. Start the engine and run it with maximum speed.
5. Flush the circuit for approx. 10 minutes, thereby switch the
Fig. 221 vibration on and off at intervals of approx. 30 seconds.
370 BW 220 D-5

Flushing the vibration motor 1. Reconnect the hoses (3 and 9) to the vibration motor.
2. Unscrew the fastening screws for the vibration motor and pull
the motor out of the coupling.
Fig. 222
Fig. 223
4.
NOTICE!
D, DH and PDH machines: Use only high
tion.
Start the engine and run it with maximum speed.

5. Run the flushing procedure for approx. 10 minutes. Switch
the vibration on and off at intervals of approx. 30 seconds.
Removing the flushing filter and 1. Remove the flushing filter, install the vibration motor and
reinstalling the vibration motor reconnect the high pressure hoses (2 & 3).
BW 220 D-5 371

Bleeding the vibration circuit

1.
Bleeding the vibration circuit, see chapter
"Bleeding the vibration circuit".
Fig. 225
Circulating the tank content

1. After completing the bleeding process, circulate the tank con-
tent with the filling and filtering unit for approx. 15 minutes.
Fig. 226
Function test
1. Check the hydraulic oil level in the tank, fill up if necessary.
2. Perform a test drive.
3. Check all ports and connections once again for leak tightness
Fig. 227
372 BW 220 D-5

5.5.4 Bleeding
5.5.4.1 Bleeding the travel circuit
1. Install a pressure test hose to the charge pressure test port.
2. Install a pressure test hose each to the high pressure test
ports.
3. Actuate the emergency stop switch.
Actuating the emergency stop switch pre-

vents the engine from starting.
Fig. 228
4. Hold the open ends of the pressure test hoses into a con-
tainer.
5. Operate the starter motor for approx. 30 seconds. Wait one
minute and repeat this procedure until oil starts to run out of
the pressure test hoses.
6. Remove the pressure test hoses.
Fig. 229
7. Unlock the emergency stop switch.
Fig. 230
BW 220 D-5 373

8. Connect a 60 bar pressure gauge to the charge pressure test

port and run the diesel engine max. 15 seconds at idle
speed.
9. Wait for approx. 30 seconds and keep repeating this proce-
dure until the gauge shows a constant charge pressure
reading.
Fig. 231
10.
NOTICE!
With the flushing filter installed shift the travel
lever only to travel direction forward, as oth-
erwise the flushing filter will be subjected to
oil flow from the wrong direction.
NOTICE!
Run the engine with idle speed.
Fig. 232 Start the diesel engine.

11. Shift the travel lever approx. 1/3 to forward direction.
12. After approx. 1 to 2 minutes shut down the diesel engine for
a minute.
ð
This waiting time is necessary to allow air
bubbles to escape through the leak oil
return line.
13. After a waiting time of approx. 1 minute keep repeating this

procedure until the indicated charge pressure drops directly
to zero when shutting down the diesel engine.
374 BW 220 D-5

5.5.4.2 Bleeding the vibration circuit

1. Install a pressure test hose to the charge pressure test port.
2. Install a pressure test hose each to the high pressure test
ports.
WARNING!
The engine must not start.
3. Actuate the emergency stop switch.
Fig. 233
4. Hold the open ends of the pressure test hoses into a con-
tainer.
5. Crank the engine approx. 10 seconds with the starter motor.
Wait one minute and keep repeating this procedure, until oil
starts to run out from the pressure test hoses.
6. Remove the pressure test hoses.
Fig. 234
7. Unlock the emergency stop switch.
Fig. 235
BW 220 D-5 375

8. Connect a 60 bar pressure gauge to the charge pressure test

port and run the engine max. 15 seconds at idle speed.
9. Wait for approx. 30 seconds and repeat the procedure, until
the pressure gauge shows a constant charge pressure.
Fig. 236
10.
NOTICE!
With the flushing filter installed use only high
tion.
For bleeding switch on vibration with high frequency.

12. After running the engine 1 to 2 minutes pause for approx.
Fig. 237 one minute.
ð
This waiting time is necessary to allow air
bubbles to escape through the leak oil
return line.
13. After a waiting time of approx. 1 minute keep repeating this

procedure, until the indicated charge pressure drops directly
to zero when shutting down the engine.
376 BW 220 D-5

Hydraulic system – Inspection and maintenance work
5.6 Inspection and maintenance work


Checks prior to start up
5.6.2.1 Checking the hydraulic oil level 378
5.6.3.1 Checking the hydraulic lines 378
5.6.4.1 Replacing the hydraulic oil filter 379
5.6.5.1 Changing the hydraulic oil 381
BW 220 D-5 377

5.6.2 Checks prior to start up

5.6.2.1 Checking the hydraulic oil level
NOTICE!
– Check the hydraulic oil level at room tempera-
ture (approx. 20 °C (68 °F)).
– If, during the daily inspection of the oil level the
hydraulic oil level is found to have dropped,
check all lines, hoses and components for
leaks.
– Use only oil of the permitted specification
Ä Chapter 2.4.4 ‘Hydraulic oil’ on page 77.

n Safety shoes
n Protective gloves
1. Check the oil level in the inspection glass.
Normal level approx. 3 cm (1.2 in) below the top

edge of the sight glass
Minimum level Middle of inspection glass
2. For topping up, clean the area around the filling port.
3. Unscrew the cover and fill in hydraulic oil.
B-587-0045
4. Close the cap.
Fig. 238

5.6.3.1 Checking the hydraulic lines
This work must only be performed by an expert / qualified
person!
378 BW 220 D-5


2. Check all hydraulic lines.
Hydraulic hoses must be immediately replaced if:
n the outer layer is damaged down to the inlay (e.g.
chafing, cuts, cracks),
n embrittlement of the outer layer or formation of cracks in
the hose material,
n the hose shows deformation in pressurized and depres-
surized condition, which do not comply with the genuine
shape of the hydraulic hose (e.g. layer separation, forma-
tion of blisters, crushed spots, buckling),
n leaks on hose, socket or fitting,
n the hydraulic hose has separated from the fitting,
n fittings are damaged or deformed, whereby the function
and strength of the hose - fitting connection is impaired,
n the fitting shows corrosion that impairs both function and
strength,
n incorrect installation (squeezing, shearing or chafing
points),
n paint covered hydraulic hoses (no detection of identifica-
tions or cracks),
n shelf life and service life exceeded.
3. Replace damaged hydraulic hoses immediately, fasten these
properly and avoid chafing.
4. Only operate the machine after it has been repaired.

5.6.4.1 Replacing the hydraulic oil filter
Perform this maintenance work at the latest after

one year.
NOTICE!
– If the filter has to be changed together with the
hydraulic oil, the filter must only be changed
after the oil change and after the test run.
– Do not use the oil in the filter housing again.
– Apart from the normal oil change intervals, the
filter element must also be changed after major
repairs in the hydraulic system.
BW 220 D-5 379

If the hydraulic oil filter warning light comes on during start or oper-
ation, replace the hydraulic oil filter immediately.
B-SYM-1154
Fig. 239

n Safety shoes
n Protective gloves
1. Park the machine safely Ä Chapter 1.3.4 ‘Parking the
machine in secured condition’ on page 60.
2. Allow the engine to cool down.
3. Unscrew the filter housing (3).
1 NOTICE!
Negligence may cause destruction to the entire
hydraulic system!
– Visible dirt may be an early sign for the failure
2 of system components and indicate the pos-
sible failure of components.
3 B-HYD-0013
– In this case determine the cause and replace
or repair the defective components, if neces-
Fig. 240 sary.
– Do not clean or reuse the filter element.
4. Take out the filter element (1) and clean the filter housing.
5. Clean the thread on the filter housing.
6. Reassemble the filter housing with a new filter element and a
new O-ring (2).
7. Tighten the filter housing; tightening torque max. 30 Nm
(max. 22 ft·lbf).
8. After a short test run check the filter for leaks.
max. 30 Nm 9. Dispose of the oil and filters in line with environmental regula-
tions.
max. 22 ft·lbf
B-HYD-0014
Fig. 241
380 BW 220 D-5


5.6.5.1 Changing the hydraulic oil

two years.
The hydraulic oil must also be changed after major repairs in the
hydraulic system.
Always replace the hydraulic oil filter after each hydraulic oil
change. Change the hydraulic oil filter only after the hydraulic oil
change and after the test run.
Do not start the engine after draining off the hydraulic oil.
Do not use any detergents to clean the system.
Use only lint-free cleaning cloths for cleaning.
When changing from mineral oil based hydraulic oil to an ester
based biologically degradable hydraulic oil, you should consult the
lubrication oil service of the oil manufacturer, or our customer
service for details.
NOTICE!
Risk of damage!
– Perform the oil change when the hydraulic oil is
warm.
– Use only hydraulic oil of the permitted specifi-
cation Ä Chapter 2.4.4 ‘Hydraulic oil’
on page 77.
– Filling quantity: Ä Chapter 2.5 ‘List of fuels and
lubricants’ on page 79.

n Safety shoes
n Protective gloves
2. Clean the area around the filling port and remove the cap.
B-586-0105
Fig. 242
BW 220 D-5 381

WARNING!
Danger of burning on hot components!
– Avoid touching hot components.
3. Unscrew the plug.

4. Drain off and collect all hydraulic oil.
5. Turn the plug tightly back in.
We recommend to use our filling and filtering unit

with fine filter to fill the system. This ensures finest
filtration of the hydraulic oil, prolongs the lifetime of
the hydraulic oil filter and protects the hydraulic
B-586-0392
system.
Fig. 243 6. Fill in new hydraulic oil.
7. Check the oil level in the inspection glass.
Normal level Approx. 3 cm (1.2 in) below the top

edge of the sight glass
Minimum level Middle of inspection glass
8.
The breather filter for the hydraulic oil tank is
integrated in the cap, you must therefore
B-587-0045
replace the complete cap.
Fig. 244 Close the tank with a new cap.

9. Dispose of oil in line with environmental regulations.
382 BW 220 D-5

Machine assemblies
6 Machine assemblies
BW 220 D-5 383

Machine assemblies
6.1 Diesel engine........................................................... 385

6.1.1 Overviews.............................................................. 386
6.1.2 Lubrication oil circuit.............................................. 391
6.1.3 Cooling circuit........................................................ 393
6.1.4 Fuel system........................................................... 395
6.1.5 Deutz Common Rail............................................... 398
6.1.6 Wastegate charge pressure controller................... 403
6.1.7 Exhaust gas recirculation ...................................... 404
6.1.8 Engine electrics..................................................... 406
6.1.9 Inspection and maintenance work......................... 441
6.2 Drum........................................................................ 464
6.2.1 Repair overview for drum....................................... 465
6.2.2 Dismantling the drum............................................. 469
6.2.3 Dismantling and assembling the change-over
weight.................................................................... 484
6.2.4 Assembling the drum............................................. 487
6.2.5 Changing the rubber buffers, adjusting the preten-
sion........................................................................ 509
6.2.6 Smooth drum scraper; installation and removal.... 514
6.2.7 Pad foot scraper; installation and removal............. 518
6.3 Padfoot shell........................................................... 529
6.3.1 Attaching the padfoot shells................................... 529
6.3.2 Removing the padfoot shells................................. 541
6.4 Oscillating articulated joint.................................... 549
6.4.1 Overview................................................................ 549
6.4.2 Dismantling the oscillating articulated joint............ 550
6.4.3 Assembly of oscillating articulated joint................. 551
6.5 Drive axle................................................................. 555
6.5.2 Checks prior to start up.......................................... 556
6.5.5 As required............................................................ 562
6.6 Air conditioning...................................................... 564
6.6.1 Overview of air conditioning system...................... 564
6.6.2 Physical principles................................................. 567
6.6.3 Refrigerant R134a................................................. 569
6.6.4 Compressor oil / refrigeration oil............................ 571
6.6.5 Working principle of the air conditioning system.... 573
6.6.6 Monitoring devices................................................. 574
6.6.7 Description of components.................................... 575
6.6.8 Compressor........................................................... 580
6.6.9 Emptying in case of repair..................................... 582
6.6.10 Drying and evacuation......................................... 583
6.6.11 Filling instructions................................................. 583
6.6.12 Steam table for R134a......................................... 586
384 BW 220 D-5

Machine assemblies – Diesel engine
6.6.13 Inspection and maintenance work....................... 590

6.7 Auxiliary heating, AIRTRONIC............................... 598
6.7.1 Description of function........................................... 599
6.7.2 Fuse assignment................................................... 602
6.7.3 Control panel......................................................... 603
6.8 Cabin assembly...................................................... 607
6.8.1 Safety..................................................................... 607
6.8.2 Preparations.......................................................... 608
6.8.3 Cabin assembly..................................................... 609
6.8.4 Final function tests and checks.............................. 614
6.9 ROPS FOPS............................................................. 616
6.9.1 ROPS/FOPS assembly.......................................... 616
6.10 VM31 BCM/GPS installation................................. 624
6.10.1 Safety................................................................... 624
6.10.2 Assembly work for holding fixture and cable of
BCM/GPS............................................................ 626
6.10.3 Concluding work.................................................. 632
6.1 Diesel engine

6.1.1 Overviews.............................................................. 386
6.1.2 Lubrication oil circuit.............................................. 391
6.1.3 Cooling circuit........................................................ 393
6.1.4 Fuel system........................................................... 395
6.1.5 Deutz Common Rail............................................... 398
6.1.6 Wastegate charge pressure controller................... 403
6.1.7 Exhaust gas recirculation ...................................... 404
6.1.8 Engine electrics..................................................... 406
BW 220 D-5 385

6.1.1 Overviews
1
2
5
S-586-0458
4

1 Diesel engine
2 Fuel filter
4 Main fuses
386 BW 220 D-5

6
5
4
3 7
2
1 X32
X100 - X109 A124
A161
X34
A162
B57
8
A34
A48
9
X45
A83
10
11
S-586-0467

General This BOMAG machine is powered by a Deutz diesel engine series

TCD 2012 with 4 or 6 cylinders respectively.
The engines are water cooled in-line engines with EMR3 elec-
tronics.
The engines are mainly designed in two-valve technology with
turbo charging and intercooler. They are highly compact and come
with a Deutz-Common-Rail injection system, called DCR in short.
All engines are designed with exhaust gas recirculation and thus
reach emission values complying with EPA/ COM/ Tier/ stage lll.
BW 220 D-5 387

These engines are characterized by the following positive proper-

ties:
n compact design
n low noise level
n almost vibration free operation
n low fuel consumption
n low exhaust emission EPA/COM IIl
n high power density
n good access to all service points
n high reliability
n low running costs
n long lifetime.
Fig. 247: Deutz diesel engine TCD2012/2013

1 Exhaust turbocharger
2 Coolant return flow from heating
3 Coolant outlet to radiator
4 Connection from intercooler
5 Generator
6 Coolant pump
7 Spring loaded idler pulley
8 Deflection pulley
9 Front power take-off
10 Oil sump
11 Coolant inlet nozzle from radiator
12 Lubrication oil filter
13 Fuel filter
14 Compressor (optional)
15 Connection housing
388 BW 220 D-5

16 Lubrication oil cooler

17 Crankcase ventilation box
18 Rail
19 Engine suspension
20 Cylinder head cover
Fig. 248: Deutz diesel engine TCD 2013 4V

21 EGR exhaust gas recirculation system
22 Throttle lever for exhaust gas recirculation system
23 Cooling line to exhaust gas recirculation system
24 Fuel inlet to engine
25 Fuel outlet to fuel tank
26 Starter
27 Lubrication oil filling neck
28 Air conditioning compressor
29 Ribbed V-belt
30 Fan mounting / coolant pump
31 Thermostat housing, coolant outlet to radiator
32 Ventilation line to radiator
33 Charge air flow to intercooler
34 Exhaust gas recirculation from EGR cooler
Common Rail diesel injection The engine has a diesel fuel injection system with the Amplified
system Pressure Common Rail System (APCRS), which reduces the fuel
quantity required for combustion to a minimum. The advantage of
this system is the fact that the pressure in rail and high pressure
lines is relatively low. If needed, the fuel pressure is increased by a
pressure booster in a second stage inside the injector. This has
highly positive effect on the loading of materials and the longevity
of components.
BW 220 D-5 389

Lifting points The engine comes from the factory with lifting points, which
ensure secure and proper handling of the engine during assembly
and disassembly. The lifting points have been sufficiently dimen-
sioned to match engine geometry (centre of gravity) and engine
weight, they should not be altered or modified.
1 adjustable transport beam

2 Transport device, remove before starting operation of engine
Fig. 249
390 BW 220 D-5

6.1.2 Lubrication oil circuit

Overview - lubrication oil circuit
Fig. 250: Lubrication oil schematic

1 Compressor (optional)
2 Exhaust turbo charger
3 Rocker arm
4 Piston cooling nozzle
5 Main lubrication oil gallery
6 By-pass valve
7 By-pass valve
9 Check valve
10 Lubrication oil pump
11 Lubrication oil sump
12 Pressure control valve
13 Lubrication oil filter
BW 220 D-5 391

Description - oil circuit Modern diesel engines put high demands on the lubrication oil
system. DEUTZ engines are designed with a pressure lubrication
system. Oil pressure and oil flow quantity secure engine lubrication
and also the cooling of the engine.
The lubrication oil pump draws oil from the oil sump and directs it
through the lubrication cooler and the oil filter to the various lubri-
cation points.
The check valve ensures permanently uniform pressure in the
lubrication oil system.
392 BW 220 D-5

6.1.3 Cooling circuit

Coolant circuit TCD 2012/2013
Fig. 251: Coolant circuit TCD 2012/2013

1 Coolant outlet on radiator
2 Thermostat
3 Coolant - supply to water pump
4 Coolant pump
6 Cylinder cooling
7 Cylinder liner / head cooling
8 Coolant flow to heating
9 Cabin heater (optional)
10 Coolant to thermostat
11 Connection for cabin heater
12 Compensation line
13 Ventilation line to compensation tank
14 Coolant outlet to radiator
15 Compensation tank
16 Compensation line to heat exchanger
General Depending on the coolant temperature, the coolant will flow in two
circuits.
The coolant pump (coolant pump, water pump) draws coolant
through the hose lines directly out of the radiator and forces it first
of all through the lubrication oil cooler, which is integrated in the
engine. The coolant then enters into the engine, flows up along the
cylinders into the cylinder head and to the thermostat at the coolant
outlet. Form there the coolant is returned through the corre-
sponding lines to the radiator inlet.
BW 220 D-5 393

When the engine is cold the coolant is pumped in a short circuit

through the engine, until the response temperature of the thermo-
stat (start of opening) is reached. The coolant pump draws cold
coolant out of the radiator, as required to replenish the hot out
flowing coolant.
Coolant level monitoring The level watchdog based coolant level monitoring in the compen-
sation tank protects the engine against damage caused by a lack
of coolant. Monitoring of the coolant level takes place via the
engine control unit.
Heating system Water-cooled DEUTZ diesel engines utilize the heat contained in
the coolant to heat driver's cab or passenger compartments. For
this purpose the engine coolant is guided directly to the heat
exchanger and the heat is directly dissipated into the environment.
394 BW 220 D-5

6.1.4 Fuel system
Fig. 252: Fuel system TCD 2012/2013

1 Fuel tank (A corresponds to the minimum distance of 500 mm)
2 Fuel pre-filter with hand pump (pump serves the purpose of filling the low pressure area, if required)
3 Line to fuel lift pump
4 Fuel lift pump (TCD 2012)
5 Fuel filter
6 Fuel supply line to fuel control block
7 Rail
8 High pressure pump
9 Fuel supply line to injector
10 Injector
11 Control block FCU (Fuel Control Unit)
12 Fuel return line on cylinder head
BW 220 D-5 395

13 Fuel return line to fuel tank

14 Fuel lines from control block to high pressure pumps and rail
15 Fuel lift pump (TCD 2013)
Fig. 253: Fuel pre-filter

1 Fuel supply to pump
2 Fuel return line from control block FCU (Fuel Control Unit)
3 Fuel hand pump (bayonet lock)
4 Thermostat valve with shut-down lever (optional)
5 Filter cartridge
6 Possibility to connect an electric water level sensor
7 Drain tap
8 Water collecting vessel
9 Fuel supply from fuel tank
10 Fuel return line to fuel tank
A Plug for electric water level sensor
396 BW 220 D-5

Fig. 254
1 Fuel pre-filter
2 Hand pump
3 Fuel pressure filter, min. 3µm
4 Input of fuel metering unit
5 Fuel low pressure sensor
BW 220 D-5 397

6.1.5 Deutz Common Rail

Deutz Common Rail (DCR) injection The diesel engines type TCD 2012 and 2013 are equipped with a
system for TCD 2012/2013 “Deutz Common Rail” injection system, DCR in short.
The term Common Rail describes the use of a common high pres-
sure fuel line with corresponding branches to supply all cylinders
with fuel.
The “Common Rail” injection is an injection system for combustion
engines, in which a high pressure pump pressurizes the fuel to a
high pressure level. The pressurized fuel fills a piping system,
which is permanently under pressure while the engine is running.
The general idea is the total isolation of the pressure generation
from the actual injection process. An injection solely controlled by
mapping is only possible under this condition. Injection timing and
injection quantity are controlled by the engine electronics. The
electric signals control an electrically operated valve per cylinder,
which is integrated in the injection nozzle. The short distances
between valve and injection nozzle result in short pressure rise
times, which has a positive effect on the combustion process and
its control. Various types of injection (pre-injection, main injection
and post-injection) can be realized. These are freely controllable, in
dependence on the control unit.
The electric control is accomplished by the electronic control unit
(EDC16) with EMR3, in dependence on the operating parameters.
The system is capable of providing a wide range of limp-home
functions, should any of the sensors fail. This ensures a reliable
and safe completion of travel and work.
Fig. 255: Overview of electronic diesel fuel control

1 Sensors
2 Control unit (EMR3)
3 Actuators
398 BW 220 D-5

Fig. 256: Schematic of the Deutz Common Rail System

1 Engine control unit
2 Injectors (6 pieces)
3 Rail pressure sensor
4 Pressure relief valve (PRV)
5 Rail
6 High pressure pumps (2 pieces)
7 FCU (Fuel Control Unit) with metering unit
8 Fuel low pressure sensor
9 Main fuel filter (high pressure filter)
10 Fuel lift pump
11 Fuel pre-cleaner with water separator
12 Hand pump
Pressures: n The rail pressure is 300 to 1350 bar.
n The PRV is factory set to 1600 bar. If this pressure in the rail is
exceeded, the PRV will open and relieve the excess pressure
back into the tank. In case of a defective PRV the pressure in
the rail can only reach 700 bar.
n The minimum rail pressure that is required to start the engine is
1.5 bar.
BW 220 D-5 399

FCU
Fig. 257
1 Housing
2 Metering unit with electrical connection
3 Outlet to suction side of fuel pump (not visible)
4 Outlet to high pressure pumps
5 Return flow to tank
6 Inlet from the fuel pump
The FCU consists of housing (1) and metering unit (2). The FCU
has various connections (3), (4), (5) and (6). The metering unit is a
proportional solenoid valve and is controlled by the control unit by
means of PWM (Pulse Width Modulation). This takes place in
dependence on engine load and engine speed. The metering unit
meters the fuel quantity, which then flows through the high pres-
sure pumps to the Rail, and from there to the injectors.
400 BW 220 D-5

Rail
Fig. 258
1 Pressure relief valve
2 Fuel line connections
3 Tube
4 Bores to fasten the Rail
5 Rail pressure sensor
The Rail generally consists of a pipe (3) with different connections
(2), which has the function of a pressure accumulator. The Rail is
bolted to the engine through the bores (4).
One side contains the pressure relief valve (PRV) (1), which makes
sure that the system pressure will not exceed the defined pressure
of 1600 bar. Should the pressure rise beyond the value of
1750-1950 defin3ed for the PRV. the PRV will open and release
fuel through the return line to the tank.
On the other side you find the rail pressure sensor (5), which sub-
mits a signal directly to the engine control.
The different connections (2) on the none hand serve as an inlet
for the fuel delivered by the high pressure pumps. On the other
hand they are used to connect the lines to the injectors.
BW 220 D-5 401

High pressure pump
Fig. 259
1 High pressure port
2 Low pressure connection
3 Fastening flange
4 Roller plunger
The high pressure pumps (2 pieces) are directly driven by the cam-
shaft of the engine. They produce the high pressure to be for-
warded to the Rail. The pump is not self-priming, but is pre-pres-
surized by the fuel pump via the FCU. Due to its design, the high
pressure pump is highly susceptible to dirt particles. Contamination
can cause problems in building up pressure and maintaining the
pressure stability in the Rail.
402 BW 220 D-5

Injector
Fig. 260
1 Electrical connections
2 Flange to fasten the claw clamp
3 Injection nozzle
4 Injector CRIN 2
The injector is equipped with a solenoid, which is controlled by he
engine control unit. This solenoid opens the discharge nozzle in
the control chamber, which causes the valve piston and the nozzle
needle to move up and open the flow path for fuel.
6.1.6 Wastegate charge pressure controller

The Wastegate is a exhaust gas bypass valve and is located on or
in the exhaust gas turbocharger. The Wastegate (exhaust gas
bypass valve) controls the charge air pressure.
The charge air pressure is controlled by a pressure valve triggered
by charge air pressure, in connection with the exhaust gas bypass
valve. Depending on the bypass valve hot exhaust gases flow
along the exhaust gas turbine into the exhaust pipe, whereby their
work energy is not being utilized.
BW 220 D-5 403

Fig. 261: Exhaust gas turbocharger with Wastegate

1 Control line
2 Pressure control valve
3 Bypass valve closed
The bypass valve is normally closed.
6.1.7 Exhaust gas recirculation

Exhaust gas recirculation TCD In order to be able to meet the exhaust gas standards EC and
2012/2013 stage/Tier3, all engines are designed with exhaust gas recircula-
tion.
On 4 cylinder engines TCD 2012/2013 the exhaust gas recircula-
tion has been realized internally through the intake valves. For this
purpose the cam shaft has an additional cam which opens the
intake valve for a short time and thereby directs flue gases back
into the intake air flow.
404 BW 220 D-5

Fig. 262: Exhaust gas recirculation internally via intake valve
BW 220 D-5 405

6.1.8 Engine electrics

6.1.8.1 CAN BUS overview............................................. 408
6.1.8.2 EMR3 system overview...................................... 410
6.1.8.3 Pin assignment of engine control........................ 419
6.1.8.4 Rotary speed sensor for camshaft, B114............ 424
6.1.8.5 Crankshaft speed sensor, B130.......................... 425
6.1.8.6 Rail pressure sensor, B93................................... 427
6.1.8.7 Fuel pressure sensor, B145................................ 429
6.1.8.8 Fuel Control Unit Y137....................................... 431
6.1.8.9 Injectors, Y147, Y149, Y169 and Y170............... 431
6.1.8.10 Oil pressure sensor, B88.................................. 432
6.1.8.11 Charge air temperature/charge pressure sensor,
B133.................................................................. 433
6.1.8.12 EMR coolant - temperature sensor, B113......... 435
6.1.8.13 Glow plugs, R81 to R84.................................... 438
6.1.8.14 Fuel pre-heating................................................ 439
6.1.8.15 Removing and installing the electric starter...... 440
1
2
5
S-586-0458
4
406 BW 220 D-5

1 Diesel engine
2 Fuel filter
4 Main fuses
6
5
4
3 7
2
1 X32
X100 - X109 A124
A161
X34
A162
B57
8
A34
A48
9
X45
A83
10
11
S-586-0467

BW 220 D-5 407

6.1.8.1 CAN BUS overview
A87
P15
CAN 4
X400
A67
A161 A162
A162
A178
A161
CAN 3
A103
CAN 1
A15
A83
X34
A124
S55
A175
CAN 2
A177
A48
A34
A48
X32
S-586-0449
Fig. 265: CAN bus

A34 Travel control
A48 ECU engine control unit, not available in BW177D-5 (Kubota engine, exhaust classification Tier3a)
408 BW 220 D-5

A67 Keyboard anti-theft protection

A178 Module for cabin operating console
P15 BCM05
S55 Travel lever
X32 Diagnostics interface for engine control unit, not available in BW177D-5 (Kubota engine, exhaust clas-
sification Tier3a)
X34 Diagnostics interface for ESX machine control
X400 Interface for measuring technology
At the end of the eighties, CAN-Bus, Controller Area Network

was created by Bosch for applications in the automotive industry.
The objectives of this development was to ensure real-time, reli-
able and cheap communication between control units, such as
gearbox and engine control unit, but also less time-critical functions
in the area of convenience electronics, such as air-conditioning.
Why CAN? n Connection of control units to realise complex functions.
n Reduction of effort when installing cables and plug-in connec-
tions.
n Better possibilities for diagnostics (central diagnostics socket).
Features of CAN
It is a serial communication interface. The individual bits are trans-
ferred one at a time; only 2 lines are required.
CAN lines are twisted together 30 to 40 times per metre. Electro-
magnetic interferences always occur simultaneously in both lines,
which makes it easier for the software to filter out any interference
signals.
A unified colour assignment does not exist. Both wires may have
different colours, depending on the manufacturer.
At Bomag, a standard has been defined for the wires. Ä Fig. 266
Fig. 266 n Wire (+)
= cable colour blue
n Wire (-)
= cable colour yellow
Measuring at the CAN Signals transmitted through the bus line can generally not be
measured with simple measuring instruments. Testing is therefore
quite complicated for the user. Only the correct line connections
can be tested by means of a continuity test. For the fitter or user to
recognize faults or retrieve information from the BUS, BOMAG
connects display modules to the BUS.
BW 220 D-5 409

Termination At the end of each line there should be a terminating resistance of

120 Ohm. For an individual CAN bus device on a stub line, this
functions just like a single 60 Ohm resistor, which is installed at the
branch location.
6.1.8.2 EMR3 system overview

Danger of destruction when 1. Never pull off the plug of the control unit as long as the con-
replacing control units trol unit is supplied with voltage.
ð There is a risk that the control unit may be damaged by
overvoltage.
Correct procedure: 1. Switch off the voltage supply (normally with the ignition key).
2. Wait until the main relay has switched off (delayed by up to
15 seconds, listen for clicking sound).
3. Pull the plugs off the control unit.
Loss of warranty! 1. It is not permitted to interchange control units from one man-
ufacturing series or against another engine number. In this
case the warranty will become null and void.
Replacing the control unit

Each control unit is clearly designated to the engine, in accordance
data set. When ordering a new control unit one not only must
specify the part number, but also the serial number of the engine
(this number is in most cases stuck on the control unit).
Engine control unit The engine control unit is the central component of the EMR3-
system. It has the function of ensuring optimal performance of the
engine under all possible operating conditions.
Consequences of optimal engine performance:
n excellent exhaust gas characteristics
n low fuel consumption
n smooth running of engine
n long lifetime of engine
n efficient servicing
For this purpose the engine control unit uses the recorded meas-
uring values and the parameters stored in its data memory to run a
number of calculations, which form the basis or all the available
functions.
The most important functions of the control unit are:
n exact control of the injection process (among others the
number, start and duration of injections)
n idle speed regulation
410 BW 220 D-5

n control of the exhaust gas recirculation quantity

n optimization of smooth running (by means of injection quantity
correction)
n engine monitoring
n system diagnostics.
Replacing the control unit
Each control unit is clearly designated to the engine, in accordance
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).
The Deutz part-number specified on the EMR-con-

trol unit is the part number without software spe-
cific for the engine. The correct part number can
be found in the spare parts catalogue.
Replacement of EMR or DCR components

n On TCD-engines with Common Rail technology the system
pressure is so high, that in case of leaks or repair all parts
need to be replaced. When replacing sensors or other electric
components, the new parts must be calibrated with the EMR
control unit. This calibration must be performed with SERDIA
(Level IIIa).
n Any other EMR components (e.g. sensors etc.) must under no
circumstances be repaired, but must be replaced if they are
defective.
BW 220 D-5 411

Fig. 267: EMR3-S

D2.1 Socket to connect the engine wiring loom
D2.2 socket to connect the vehicle wiring loom
The engine control unit EMR3-S is fitted with two sockets on the
front side of the housing.
412 BW 220 D-5

EMR3 system in connection with

injection system and electrics
Fig. 268
1 Fuel tank
2 Fuel pre-filter
3 Fuel lift pump
4 Fuel filter
5 High pressure fuel pump
6 Fuel metering unit MU (Y137)
7 Control unit (A48)
8 High pressure accumulator (rail)
9 Injectors (Y147, Y148, Y149 and Y166)
10 Rail pressure sensor (B93)
11 Exhaust gas turbocharger
12 Engine transfer plug
13 Exhaust gas recirculation (optional)
14 Engine sensors
15 Diagnostics lamp (H04)
16 Starter switch (S00)
17 Pedal, not used
18 Diagnostics button (S118)
BW 220 D-5 413

19 Pressure limiting valve

20 Battery (G01), terminal 31 and 30
21 Connecting line for engine control unit
22 Connecting line for engine wiring loom
23 Engine wiring loom
24 Sensor for water in fuel (B124)
414 BW 220 D-5

Sensors TCD 2012/2013
Fig. 269: Sensors TCD 2012/2013

1 Fuel control unit FCU (Y137)
2 Coolant temperature sensor (B113)
3 Charge air temperature - charge air pressure sensor (B133)
4 Engine wiring loom connecting cable
5 Engine control unit (A48)
6 Crankshaft speed sensor (B130)
7 Rail pressure sensor (B93)
8 Oil level sensor (optional)
9 Oil pressure sensor (B88)
10 Fuel pressure sensor (B145)
11 Rotary speed sensor for camshaft (B114)
12 Central plug (X38)
BW 220 D-5 415

Shut down the engine. When shutting down the engine, the starter switch isolates the
electronic system from terminal 15. The injectors are closed imme-
diately, the Rail pressure is discharged in an orderly manner and
the counter readings are saved in the non-volatile memory. During
this time the system must not be disconnected from terminal 30
(+Ubatt). Once the time has expired the main relay switches off
and the control unit is no de-energized..
The main relay serves the purpose of releasing the vehicle energy
supply for the EMR3 system. The engine control unit EMR3-S
requires an external main relay.
When terminal 15 is no longer connected to battery (+) (i.e. after
the ignition has been switched off), the main relay is switched off
after approx. 10 seconds. The main relay thereby disconnects the
control unit from terminal 30 battery (+), whereby it becomes de-
energized. On the EMR3-S the switching state of the main relay
can be examined directly on Pin72.
Fig. 270: System overview

1 Engine side
2 Vehicle side
3 Service
4 Sensors and actuators
5 EMR
6 Diagnostics socket, X32 in central electrics
7 CAN-display
8 SerDia2010
416 BW 220 D-5

Changes to the control units with respect to set-

tings, parameterization, deleting the fault log and
calibration are level dependent and only possible
with SerDia2010.
Diagnostic interface
A Ubat electric power supply

B Battery minus (-)
F CAN2 low
G CAN1 low
H CAN1 high
K K-Line
M CAN2 high
Fig. 271: Diagnostic interface
CAN-display
A CAN display is available for showing measuring
values and fault messages of the EMR control unit.
BOMAG part-no.: 057 189 94
The following data can be displayed, as far as these are trans-

mitted by the control unit.
n Engine speed
n Engine torque (current)
n Coolant temperature
n Intake air temperature
n Exhaust gas temperature
Fig. 272: CAN-display n Lubrication oil pressure
n Coolant pressure
n Charge air pressure
n Fuel pressure
n Regeneration status of diesel particulate filter
n Operation monitoring of diesel particulate filter
n Fault in exhaust gas aftertreatment system
n Battery voltage
n Position of throttle pedal
n Fuel consumption
n Operating hours
Fault messages appear as plain text and audibly, the fault log of
the control unit can be read out.
BW 220 D-5 417

Cable for diagnostics interface

The display is connected to the diagnostic inter-
face by means of a special cable.
Fig. 273: Cable for diagnostics inter-

face
418 BW 220 D-5

23 EMR3 System Description
1.4.2.3 Control Unit EMR3-EDC16

The engine control unit EMR3-EDC16 has two connecting sockets arranged on the top of the
housing: Machine assemblies – Diesel engine
socket D2.1 for connecting the engine cable harness,
socket D2.2 for connecting the vehicle/device side cable harness.
6.1.8.3 Pin assignment of engine control
Pin assignment
Max. cable cross section: 2,5 mm², 1,5mm², 0,75 mm²
Pinout for EMR3-EDC16

Pin Signal type Function / components Remark / Technical data
D2.2.1 power supply (+)
D2.2.3 power supply (+) power supply ECUs UBat (terminal 30)

D2.2.2 power supply ( )
D2.2.4 power supply ( ) power supply ECUs UGnd (terminal 31)

UBat switched (terminal 15)
D2.2.28 signal input, digital operating signal for ECU U > 4,79 V: ECU switched on
U < 3,63 V: ECU switched off
12V: 140 mA, 120 mH at 1 kHz
D2.2.72 power supply ( ), switched main relay
24V: 80 mA, 350 mH at 1 kHz
signal input, analog, with Pulldown- Uin= 0...5 V, Rdown = 100 kW
D2.2.9 footpedal (setpoint)1
resistance
D2.2.22 power supply (+) footpedal (setpoint)1 Uout = 5 V
D2.2.30 power supply ( ) footpedal (setpoint)1 Intern with UGnd connected
external switch to UGnd,

D2.2.58 signal input, digital, with Pullup-resistance idle switch footpedal1 Rup = 100 kW, Ulow = 2,1 V,
Uhigh = 3,9 V
signal input, analog, with Pulldown- Uin = 0...5 V, Rdown = 100 kW

D2.2.31 handthrottle (setpoint) 2
resistance
D2.2.46 power supply (+) handthrottle (setpoint) 2: Uout = 5 V
D2.2.8 power supply ( ) handthrottle (setpoint) 2: Intern with UGnd connected

D2.2.81 signal input, digital, with Pullup-resistance idle switch footpedal2 Rup = 100 kW, Ulow = 2,1 V,
Uhigh = 3,9 V
Temperature sensor 2 internal with U

(optional) Gnd connected
V.1.4.0 Copyright © 2008 DEUTZ AG
BW 220 D-5 419

EMR3 24

Temperature sensor 2 U = 0...5 V, R = 1,3 kW
D2.2.11 signal input, analog,with Pullup-resistance in up
(optional)
D2.2.12 power supply ( ) Oil level sensor internal with UGnd connected
D2.2.13 signal input, analog,with Pullup-resistance Oil level sensor Uin = 0...5 V, Rup = 1,28 kW
D2.2.45 power supply (+) Oil level sensor Uout = 5 V
D2.2.14 power supply ( ) multiple state switch for speed internal with UGnd connected
D2.2.15 signal input, analog,with Pullup-resistance multiple state switch for speed Uin = 0...5 V, Rup = 2,3 kW
D2.2.86 power supply ( ) multiple state switch for droop internal with UGnd connected
D2.2.89 signal input, analog,with Pullup-resistance multiple state switch for droop Uin = 0...5 V, Rup = 2,3 kW
external switch to UBat,

signal input, digital, with Pulldown- Rdown = 6,8 kW, Ulow = 2,2 V,
D2.2.17 break switch
resistance
Uhigh = 3,7 V
external switch zu UBat,

D2.2.80 break switch
resistance
Uhigh = 3,7 V

D2.2.40 clutch switch
resistance
Uhigh = 3,7 V

D2.2.54 exhaust gas break switch
resistance
Uhigh = 3,7 V

D2.2.43 Engine start switch
resistance
Uhigh = 3,7 V

signal input, digital, with Pulldown- intake air differential pressure R
D2.2.77
resistance switch down = 6,8 kW, Ulow = 2,2 V,
Uhigh = 3,7 V

D2.2.52 signal input, digital,with Pullup-resistance switch (customer-specific) Rup = 5 kW, Ulow = 2,2 V,
Uhigh = 3,7 V

D2.2.19 signal input, digital,with Pullup-resistance Override switch Rup = 5 kW, Ulow = 2,3 V,
Uhigh = 3,7 V

D2.2.79 signal input, digital,with Pullup-resistance coolant level switch Rup = 6,8 kW, Ulow = 2,2 V,
Uhigh = 3,7 V

D2.2.87 signal input, digital,with Pullup-resistance governor mode switch Rup = 6,8 kW, Ulow = 2,2 V,
Uhigh = 3,7 V

D2.2.57 signal input, digital,with Pullup-resistance droop switch Rup = 5 kW, Ulow = 2,2 V,
Uhigh = 3,7 V
0,3 A at 12 V, 4 W at 24 V
D2.2.55 power supply (+), switched diagnosis lamp
switch-on current 0,9 A
Copyright © 2008 DEUTZ AG V.1.4.0
420 BW 220 D-5


D2.2.71 power supply ( ), switched Oil alarm lamp 0,3 A at 12 V, 4 W at 24 V
D2.2.51 power supply (+), switched Oil alarm lamp switch-on current 0,9 A
engine running or boost temp

D2.2.7 power supply (+), switched
lamp 0,3 A at 12 V, 4 W at 24 V
engine running or boost temp switch-on current 0,9 A
D2.2.94 power supply ( ), switched
lamp
D2.2.29 power supply (+), switched Alarm lamp (customer-specific) Uout = UBat, Imax = 6 A
0,3 A at 12 V, 4 W at 24 V
D2.2.70 power supply ( ), switched Temperature alarm lamp
0,3 A at 12 V, 4 W at 24 V
D2.2.92 power supply ( ), switched heater lamp
D2.2.63 power supply ( ) fuel filter water level sensor internal with UGnd connected
D2.2.64 signal input, analog,with Pullup-resistance fuel filter water level sensor Uin = 0...5 V, Rup = 120 kW
D2.2.76 power supply ( ) Oil Temperature sensor internal with UGnd connected
D2.2.66 signal input, analog,with Pullup-resistance Oil Temperature sensor Uin = 0...5 V, Rup = 1,28 kW

D2.2.75 signal input, digital,with Pullup-resistance velocity sensor Rup = 6,8 kW, Ulow = 2,2 V,
Uhigh = 3,7 V
D2.2.53 power supply ( ) velocity sensor internal with UGnd connected
signal output, digital (PWM),with Pullup- Imax = 50 mA, fmax 5kHz,

D2.2.48 engine speed sensor
resistance, minus-switched Standard: 60 Impulse/Rotation
D2.2.23 power supply (+) Fan speed sensor UOut = 5 V
D2.2.84 signal input, digital,with Pullup-resistance Fan speed sensor Imax = 20 mA, fmax = 1 kHz
D2.2.59 power supply ( ) Fan speed sensor internal with UGnd connected
D2.2.73 power supply (+) Fan control R > 30 W at 24 V

R > 10,6 W at 12 V
L = 15...80 mH
switch-on current 1,9 A at 16 V
D2.2.90 power supply ( ), switched Fan control (15 Minutes)
fmax = 300Hz
fmin = 15Hz

D2.2.83 signal input, digital,with Pullup-resistance PDM-setpoint Rup = 100 kW, Ulow = 2,1 V,
Uhigh = 3,9 V
D2.2.85 power supply ( ) PDM-setpoint internal with UGnd connected
Temperature sensor U = 0...5 V, R = 1,3 kW

(customer-specific)
Temperature sensor internal with U
(customer-specific) Gnd connected
exhaust gas Temperature U = 0...5 V, R = 11,05 kW

sensor
exhaust gas Temperature internal with U
sensor Gnd connected
PDM-output (customer- I
D2.2.26 signal output, digital
specific) max = 50 mA, fmax = 1 KHz
PDM-output (customer- internal with U

specific) Gnd connected
PDM-output torque (customer- I

D2.2.27 signal output, digital
specific) max = 50 mA, fmax = 300 Hz
D2.2.74 signal input, digital, with Pulldown- switch (customer-specific) external switch to UBat,
BW 220 D-5 421

EMR3 26

Rdown = 6,8 kW, Ulow = 2,2 V,
resistance
Uhigh = 3,7 V
D2.2.24 power supply (+) Sensor (customer-specific) UOut = 5 V
D2.2.36 signal input, analog,with Pullup-resistance Sensor (customer-specific) Uin = 0...5 V, Rup = 680 kW
D2.2.37 power supply ( ) Sensor (customer-specific) internal with UGnd connected.
D2.2.61 Communication, CAN low CAN-Bus 2, for customer

D2.2.62 Communication, CAN high application
D2.2.60 Communication, CAN low CAN-Bus 1, for diagnosis

D2.2.82 Communication, CAN high tasks
D2.2.25 Communication, K-Line ISO-9141-Bus
D2.1.23 power supply ( ) boost pressure sensor internal with UGnd connected
D2.1.40 signal input, analog,with Pullup-resistance boost pressure sensor Uin = 0...5 V, Rup = 680 kW
D2.1.14 power supply (+) boost pressure sensor UOut = 5 V
D2.1.53 signal input, analog,with Pullup-resistance boost temperature sensor Uin = 0...5 V, Rup = 1,28 kW
D2.1.20 Shield Cam shaft speed sensor internal with UGnd connected
signal input (+), digital, with Schmitt-Trigger

D2.1.10 Cam shaft speed sensor
with Threshold-Application Inductive sensor, Uin = 0,2...80 V
signal input ( ), digital, with Schmitt-Trigger ~
D2.1.50 Cam shaft speed sensor
with Threshold-Application
D2.1.41 power supply ( ) coolant Temperature sensor internal with UGnd connected
D2.1.58 signal input, analog,with Pullup-resistance coolant Temperature sensor Uin = 0...5 V, Rup = 1,28 kW
D2.1.7 Shield crank shaft speed sensor internal with UGnd connected
signal input ( ), digital, with Schmitt-Trigger

D2.1.12 crank shaft speed sensor
with Threshold-Application Inductive sensor, Uin = 0,2...80 V
signal input (+), digital, with Schmitt-Trigger ~
D2.1.27 crank shaft speed sensor
with Threshold-Application
power supply ( ), switched, with recovery exhaust R > 42 W at 24 V

gas break valve
D2.1.45 diode to UBat R > 14 W at 12 V
control
L < 480 mH at 12 V
exhaust gas break valve
D2.1.29 power supply (+), switched
control
for 12-V-applications:
IOut = 1,7 A at Vbat = 14,4 V,
L = 160 mH, f = 300 Hz,
internalal exhaust gas break or L = 10 mH, f = 1 Hz,
EGR for 24-V-applications:
L = 600 mH, f = 300 Hz,
L = 44 mH, f = 1 Hz
fuel control unit (FCU, U
MPROP) Out = UBat, Imax = 5 A
fuel control unit (FCU,

MPROP)
fuel Temperature sensor or
D2.1.39 power supply ( ) crankshaft housing pressure internal with UGnd connected
sensor
fuel Temperature sensor or U = 0...5 V, R = 1,28 kW

D2.1.52 signal input, analog,with Pullup-resistance
crankshaft housing pressure In up
Copyright © 2008 DEUTZ AG V.1.4.0
422 BW 220 D-5


sensor
fuel valve flame starting or INenn = 1,3 A at 24 V

D2.1.59 power supply ( ), switched or PWM-Signal
external EGR L = 0...15 mH at 24 V
fuel valve flame starting or
external EGR
D2.1.54 power supply ( ) fuel low pressure sensor internal with UGnd connected
D2.1.57 signal input, analog,with Pullup-resistance fuel low pressure sensor UIn = 0...5 V, Rup = 680 kW
D2.1.11 power supply (+) fuel low pressure sensor UOut = 5 V
max. 130 mH
D2.1.24 power supply (+) heater relay
2A at 12 V, 1,5A at 24V
D2.1.34 power supply ( ), switched heater relay
external switch depending on
Mass,
D2.1.21 signal input, digital,with Pullup-resistance sense for heater relay Rup = 6,8 kW, Ulow = 2,2 V,
Uhigh = 3,7 V
D2.1.51 power supply ( ) Oil pressure sensor internal with UGnd connected
D2.1.13 power supply (+) Oil pressure sensor UOut = 5 V
D2.1.56 signal input, analog,with Pullup-resistance Oil pressure sensor UIn = 0...5 V, Rup = 6,81 kW
D2.1.8 power supply ( ) Rail pressure sensor internal with UGnd connected
D2.1.43 signal input, analog,with Pullup-resistance Rail pressure sensor UIn = 0...5 V, Rup = 4,6 kW
D2.1.26 power supply (+) Rail pressure sensor UOut = 5 V
D2.1.30 power supply (+), switched Starter relay Lmax = 130 mH, Imax = 6 A
D2.1.15 power supply ( ), switched Starter relay

Rup = 6,8 kW, Ulow = 2,2 V,
D2.1.35 signal input, digital,with Pullup-resistance engine stop switch (optional)
Uhigh = 3,7 V
D2.1.22 power supply ( ) External EGR (optional) internal with UGnd connected
crankshaft housing pressure U

sensor (optional) Out = 5 V
Injector 1 (Y15.1), 3 (Y15.3)

D2.1.16 power supply (+) and 5 (Y15.5) = Y15.1/3/5 DCR, 4 and 6 cylinder
Bank 1
Injector 2 (Y15.2), 4 (Y15.4)
D2.1.1 power supply (+) and 6 (Y15.6) = Y15.2/4/6 DCR, 4 and 6 cylinder
Bank 2
D2.1.47 power supply ( ) Injector 1 Y15.1 DCR, 4 and 6 cylinder
D2.1.33 power supply ( ) Injector 5 Y15.5 DCR, 6 cylinder
D2.1.46 power supply ( ) Injector 6 Y15.6 DCR, 6 cylinder
The table above illustrates the maximum assignment of the control unit pins. However, in practice,
not all the named pins are actually assigned. Pins which are not listed are generally not used by
the EMR3 system. (See circuit diagram)
BW 220 D-5 423

6.1.8.4 Rotary speed sensor for camshaft, B114

n Inductive sensor
n Determination of TDC
n Limp-home function in case of crankshaft sensor failure
Fig. 274: Camshaft speed sensor
Disassembling the speed sensor

1. Remove the cable strap
2. Disconnect the plug (1).
Fig. 275
3. Unscrew the screw (1).

4. Take off the speed sensor.
Fig. 276
424 BW 220 D-5

Installing the speed sensor

1. Clean the sealing surfaces.
2. Install the new O-ring (1).
3. Cover the O-ring (1) slightly with oil.
Fig. 277
4. Install the speed sensor.
NOTICE!
Secure the screw!
Install the screws with screw retention agent.
5. Install the screw and tighten it.
Fig. 278
6. Push the plug (1) back on.

7. Fasten the cables with new cable straps.
Fig. 279
6.1.8.5 Crankshaft speed sensor, B130

n Inductive sensor
n Exact determination of engine speed
n Limp-home function in case of camshaft sensor failure
BW 220 D-5 425

Disassembling the speed sensor

1. Disconnect the plug (1).
Fig. 280

3. Take off the speed sensor.
Fig. 281
Installing the speed sensor

1.
NOTICE!
Secure the screw!
Install the screw (1) with screw retention
agent.
Install the speed sensor and tighten the screw (1).
Fig. 282
426 BW 220 D-5

Fig. 283
6.1.8.6 Rail pressure sensor, B93

n Pressure sensor
n Monitoring the injection pressure
DANGER!
Danger of injury caused by the explosive
escape of diesel fuel
– Wear your personal protective outfit (protective
gloves, protective clothing, goggles).
– Only work on the Common Rail System when it
is completely depressurized.
CAUTION!
fuel!
– Avoid contact.
Fig. 284
BW 220 D-5 427

Disassembling the rail pressure

sensor
1. Unlock and pull off the cable plug (1).
2. Unscrew the rail pressure sensor.
Fig. 285
3. Check thread (1) and sealing edge (2) of the rail pressure
sensor for signs of damage.
4. Attach a suitable locking cap.
Fig. 286
428 BW 220 D-5

Installing the rail pressure sensor 1. Remove the locking cap from the rail pressure sensor.
2. Check thread (1) and sealing edge (2) of the rail pressure
sensor for signs of damage.
3. Slightly grease the thread (1) and sealing edge (2) of the rail
pressure sensor with assembly grease.
NOTICE!
Observe the tightening torques!
Tightening torque: 40+5Nm.
4. Insert and fasten the rail pressure sensor.
Fig. 287
5. Plug on the cable plug (1) and ensure correct locking.
Fig. 288
6.1.8.7 Fuel pressure sensor, B145

n Pressure sensor
n Monitoring the inlet pressure
The fuel pressure sensor is located after the fuel filter module.
Under normal conditions the pressure measured here is between 5
and 7 bar.
BW 220 D-5 429

Disassembling the fuel pressure

sensor CAUTION!
fuel!
– Avoid contact.
WARNING!
Danger of burning by ignited diesel fuel!
– Do not allow diesel fuel to come into contact
CAUTION!
Danger of slipping on spilled diesel fuel!
binding agent.
1. Unlock and pull off the cable plug (1) from the fuel pressure
sensor.
2. Unscrew the fuel pressure sensor.
Fig. 289
430 BW 220 D-5

Installing the fuel pressure sensor

1. Remove the locking cap from the fuel pressure sensor.
2. Check the thread of the sensor for signs of damage.
3. Insert the fuel pressure sensor with a new seal ring and
tighten it.
NOTICE!
Observe the tightening torque!
Tightening torque: 30+5/-5Nm.
4. Insert and tighten the sensor.
Fig. 290
6.1.8.8 Fuel Control Unit Y137

Function
n The fuel control unit meters the fuel flowing into the pump ele-
ments by means of an infinitely controllable solenoid valve.
n This valve is mounted to the FCU (Fuel Control Unit) control
block and adapts the fuel quantity supplied to the Rail to the
system requirements.
n The solenoid valve is controlled by a pulse width modulated
(PWM) signal.
When controlling the valve, the piston is operated by magnetic
force. It opens a flow cross-section that corresponds to its position.
This quantity regulation reduces the power requirement of the high
pressure pump, it will only deliver as much fuel as is needed by the
mapped Rail pressure.
Fig. 291
6.1.8.9 Injectors, Y147, Y149, Y169 and Y170

Function
n The injectors are installed in the cylinder head and connected
to the rail by means of high pressure lines.
n In the injector, the beginning and end of injection of the nozzle
are determined by a valve.
n The operating forces for opening and closing the valve are
generated by a solenoid.
n The injectors work with approx. 50 to 70 Volt, instead of the 24
Volt vehicle voltage, which causes undelayed opening of the
injectors. This high voltage is generated by capacitors in the
control unit. The solenoid valves are then held in position by 24
Volt.
n The forces required to open and close the nozzle needle
cannot be generated only by a solenoid valve. The nozzle
Fig. 292 needle is therefore indirectly controlled via a hydraulic booster
system in the injector.
BW 220 D-5 431

6.1.8.10 Oil pressure sensor, B88

The oil pressure switch serves the purpose of monitoring the
engine oil pressure. The operator is warned as soon as:
n the oil pressure drops below the warning limit
n the power is reduced by the EMR after a pre-warning time
n the oil pressure falls short of the shut-down limit and the engine
is shut down after a pre-warning time.
Fig. 293
Engine oil pressure warning light The oil pressure is detected by the engine control unit and for-
warded to the instrument cluster (A15) via the CAN bus connec-
tion.
Designation Note
Engine oil pres- Lights up if the engine oil pressure is
sure warning too low. The engine is shut down after
light a short while.
Check the engine oil level; if neces-
sary, repair the engine.
Disassembling the oil pressure

sensor
1. Unlock and pull off the cable plug (1).
2. Unscrew oil pressure sensor (2).
ENVIRONMENT!
Collect leaking oil and dispose of in an envi-
ronmentally friendly way.
Fig. 294
432 BW 220 D-5

Installing the oil pressure sensor

1.
NOTICE!
Tightening torque: 20 Nm.
Insert the oil pressure sensor (2) with a new seal ring and
tighten it.
Fig. 295
6.1.8.11 Charge air temperature/charge pressure sensor, B133

The charge air temperature/charge air pressure sensor unites two
functions in one housing. It detects the pressure and the tempera-
ture of the charge air. Both variables influence the injection quantity
and the EMR then has the function of limiting the development of
smoke from the engine.
With a faulty pressure sensor the engine continues

to run with charge pressure simulation.
With a defective temperature sensor the engine
also carries on running.
The operator is warned if:

n the temperature exceeds the warning limit
Fig. 296 n the power is reduced by the EMR 3 after a pre-warning time
n the temperature exceeds the shut-down limit and the engine is
shut down after a pre-warning time.
BW 220 D-5 433

Disassembling and installing the

sensor, B133
Disassembling the sensor
2. Remove the cover plate.
Fig. 297
3. Unlock and disconnect the plug.

4. Remove the pressure/temperature sensor.
Fig. 298
Installing the sensor

1. Install a new loop ring.
Fig. 299
434 BW 220 D-5

2. Attach the charge air temperature/charge air pressure

sensor.
3. Push on the plug until it clicks into place.
Fig. 300
4. Position the cover plate.

5. Insert and tighten the screw (1).
Fig. 301
6.1.8.12 EMR coolant - temperature sensor, B113

The coolant temperature has an effect on the calculated injection
quantity and the preheating behaviour of the glow plugs.
The operator is warned as soon as:
n the temperature exceeds the warning limit
n the power is reduced by the EMR after a pre-warning time
n the temperature exceeds the shut-down limit and the engine is
shut down after a pre-warning time.
Fig. 302
Coolant temperature warning light The coolant temperature is detected by the EMR control (A48) and
forwarded to the instrument cluster (A15) via the CAN bus connec-
tion.
BW 220 D-5 435

Designation Note
Coolant tem- Lights up when the engine overheats.
perature The engine power is reduced after a
warning light short while.
Run the engine at idle speed or, if
necessary, shut it down and clean the
radiator; if necessary, repair the
engine.
Removing the temperature sensor

CAUTION!
Health hazard caused by contact with coolant
and coolant additives!
– Do not inhale any fumes.
– Avoid contact.
CAUTION!
Danger of slipping on spilled coolant!
binding agent.
WARNING!
– Open the coolant compensation tank only after
the engine has cooled down.
gloves, protective clothing, goggles).
ENVIRONMENT!
Coolant is an environmentally hazardous sub-
stance!
– Always keep coolant and coolant additives in
proper containers.
binding agent and dispose of it according to
regulations.
– Dispose of coolant according to regulations.
436 BW 220 D-5

1. Unlock and disconnect plug (1) .
Fig. 303
2. Unscrew the coolant temperature sensor (1).
Counter the hexagon on the engine case with

an open end spanner.
Fig. 304
Installing the temperature sensor 1. Make sure that the seal ring of the temperature sensor is
present and does not show any damage.
2.
NOTICE!
Tightening torque: 22+2/-2 Nm.
Turn the temperature sensor (1) in and tighten it.
Counter the hexagon on the engine case with

an open end spanner.
Fig. 305
BW 220 D-5 437

3. Push on the plug (1) and ensure correct locking.
Fig. 306
6.1.8.13 Glow plugs, R81 to R84

The engines are equipped with glow plugs as cold starting aid. Pre-
heating the glow plugs in the combustion chamber of the diesel
engine ensures perfect cold starting and post-heating of the glow
plugs has a positive effect on the emissions from the still “cold run-
ning” diesel engine (e.g. avoidance of white smoke, noise reduc-
tion).
Fig. 307
Triggering of glow plugs

1 Battery
2 Main battery switch
3 Fuse box
4 Relay (K14)
During cold starting the EMR control switches the relay (K14). The
coil is excited and the switching contacts supply the glow plugs
with Ubat via fuse (F48).
4 3 2 1
S-538-0089
Fig. 308
Pre-heating control light Pre- and after-heating is passed on to the instrument cluster (A15)
via the CAN bus connection.
Designation Note
Pre-heating Lights up during pre-heating.
control light
438 BW 220 D-5

6.1.8.13.1 Main fuses

Fig. 309

6.1.8.14 Fuel pre-heating

Fuel pre-heating optional equipment
1 Water separator sensor connection (B124)
2 Fuel pre-heating connection (R79) 200 Watt (option)
The preheating system is not monitored by the

engine control unit.
In diesel engines the pre-heating of the fuel prevents malfunctions

caused by the formation of jelly (paraffin separation) in the fuel
under low temperatures.
Operating the ignition switch activates the heater, this should take
place at least 5 minutes before starting the engine.
The generated heat works directly under the filter element and
melts the wax crystals that have formed, so that the fuel can flow
through the filter element without restriction. The 200W heating is
supplied with 12V DC current.
Fig. 310
BW 220 D-5 439

6.1.8.15 Removing and installing the electric starter

Disassembling the starter
1. Switch the main battery switch to position “0” (battery discon-
nected).
Fig. 311
2. Unscrew the cable connections (terminal 30 and 50).

3. Unscrew the screws (1).
4. Remove the starter.
Fig. 312
Installing the starter

1. Position the starter.
2. Install the screws (1).
Fig. 313
440 BW 220 D-5

3. Fasten cable connections (terminal 30 and 50) with the

specified torque.
NOTICE!
To prevent the starter terminals or compo-
nents from being damaged you should make
sure that the cable connections are tightened
with the following torque values.
– Terminal 30:Tightening torque: 20+4/-4
Nm.
– Terminal 50:Tightening torque: 1 - 1.3
Nm.
Excessively tightened nuts can cause
damage to starter components (e.g. cracks in
the cover of the solenoid switch). Penetrating
dampness can cause short circuit - or even
burning of cables.
Insufficiently tightened nuts can cause loos-
ening of cable connections and thus short cir-
cuit - or even fire.
6.1.9 Inspection and maintenance work

6.1.9.1 Maintenance Table

6.1.9.2.1 Checking the engine oil level 442
6.1.9.2.2 Checking the coolant level 443
6.1.9.3.1 Cleaning the radiator module 444
6.1.9.3.2 Checking, tensioning the V-belt of the air conditioning compressor 445
6.1.9.4.1 Change engine oil and oil filter cartridge 447
6.1.9.4.2 Replacing the fuel filter; bleeding the fuel system 448
6.1.9.4.3 Checking the anti-freeze concentration and the condition of the coolant 450
6.1.9.5.1 Checking the ribbed V-belt 451
6.1.9.5.2 Replacing the air conditioning compressor V-belts 452
6.1.9.5.3 Checking the engine mounts 453
BW 220 D-5 441


6.1.9.6.1 Checking, adjusting the valve clearance 453
6.1.9.6.2 Changing the coolant 454
6.1.9.7.1 Replace ribbed V-belt and idler pulley 457
As required
6.1.9.8.1 Air filter maintenance 458
6.1.9.8.2 Checking and cleaning the water separator 461
6.1.9.8.3 Measures prior to extended shut-down period 461
6.1.9.2 Checks prior to start up

6.1.9.2.1 Checking the engine oil level
NOTICE!
– If the engine is warm, shut it down and check
the oil level after five minutes. With a cold
engine the oil level can be checked immedi-
ately.
Ä Chapter 2.4.1 ‘Engine oil’ on page 72.

n Safety shoes
n Protective gloves
1. Pull the dipstick out, wipe it off with a lint-free, clean cloth and
reinsert it to the end stop.
2. Pull the dipstick out again.
3. The oil level must always be between the “MIN” and “MAX”
marks. If the oil level is too low, top up oil to the “MAX” mark
immediately.
B-586-0150
Fig. 314
442 BW 220 D-5

6.1.9.2.2 Checking the coolant level
NOTICE!
– If, during the daily inspection the coolant level
is found to have dropped, check all lines,
hoses and engine for leaks.
– Do not use radiator sealant to seal leaks.
– Use only coolant of the permitted specification
Ä Chapter 2.4.3 ‘Coolant’ on page 74.
A coolant level which is too low is indicated by the coolant level

warning light.
B-SYM-1007
Fig. 315

n Safety shoes
n Protective gloves
n Safety goggles
1. Check the coolant level in the compensation tank.
WARNING!
– Open the compensation tank only when the
engine is cold.
B-586-0372
2. For topping up, clean the area around the filling port.
Fig. 316 3. Unscrew the cover and fill in coolant up to the “MAX” mark.
4. Close the cap.
BW 220 D-5 443

6.1.9.3 Every 250 operating hours

6.1.9.3.1 Cleaning the radiator module
NOTICE!
– Dirt on fan blades and oil coolers reduce the
cooling effect. Dirt deposits in these areas are
substantially supported by oil and fuel on these
surfaces. For this reason you should always
seal any oil or fuel leaks in the vicinity of the
cooling fan or the radiator and clean the
cooling fins after.
– Do not damage any cooling fins on the cooler
core when cleaning.
Cleaning with compressed air Protective equipment: n Working clothes

n Protective gloves
n Safety goggles
LUFT 3.
CAUTION!
AIR Danger of eye injuries caused by particles
flying around!
– Wear your personal protective equipment
(safety gloves, protective working
clothes, goggles).
Blow the radiator out with compressed air from the air dis-
B-586-0134 charge side.
Fig. 317 4. Blow the radiator out with compressed air from the air supply
side.
Cleaning with cold cleansing agent

NOTICE!
Electric components can be damaged by water
entering into the system!
– Protect electrical equipment such as generator,
regulator and starter against the direct water
jet.
1. Spray engine and radiator with a suitable cleansing agent,

e.g. cold cleansing agent, let it soak in for a while and spray it
off with a strong water jet.
2. Warm up the engine for a while to avoid corrosion.
444 BW 220 D-5

6.1.9.3.2 Checking, tensioning the V-belt of the air conditioning compressor

Checking the condition of the V-belt

n Safety shoes
n Protective gloves
1. Check the entire circumference of the belt for damage and
cracks.
2. Replace a damaged or torn V-belt Ä Chapter 6.1.9.5.2
‘Replacing the air conditioning compressor V-belts’
on page 452.
B-870-0278
Fig. 318
Checking the V-belt tension

n Protective gloves
Tool: n Belt tension tester
1. Press the indicator arm (a) of the tester into the gap of the
measuring scale.
2. Place the meter in the middle between the V-belt pulleys on
the back of the belt.
Fig. 319
BW 220 D-5 445

3. Actuate the push button (b) evenly with a finger under a right
angle to the belt, until the pressure spring disengages audibly
and noticeably.
ð The indicator arm remains in the measured position.
4. Take the measuring unit carefully off, without moving the indi-
cating arm.
Fig. 320
5. Read the belt tension where the upper edge of the indicating
arm intersects with the measuring scale.
Belt tension nominal value
during initial assembly (new 400 N (90 lbf) (cold)
belt)
after a running-in time, in 300 N (67 lbf)
case of reassembly
6. Tighten the belt, if necessary.
Fig. 321
Tightening the V-belt

n Safety shoes
n Protective gloves
2. Turn the tensioning screw (2) to tighten the V-belt to the
2 specified value.
1 3. Retighten the screw (1).
B-870-0279
Fig. 322
446 BW 220 D-5


6.1.9.4.1 Change engine oil and oil filter cartridge

one year.
NOTICE!
– Change the oil only with the engine at oper-
ating temperature.
Ä Chapter 2.4.1 ‘Engine oil’ on page 72.
lubricants’ on page 79

n Safety shoes
n Protective gloves
WARNING!
2. Unscrew the drain plug and collect any oil running out.
3. Screw the drain plug back in tightly.
B-586-0374
Fig. 323
BW 220 D-5 447

4. Thoroughly clean the outside of the oil filter cartridge.

5. Unscrew the oil filter cartridge using an appropriate strap
wrench.
6. Clean the sealing face on the filter carrier from any dirt.
7. Thinly apply oil to the rubber seal of the new oil filter car-
tridge.
8. Screw on the new oil filter cartridge tightly by hand.
B-586-0373
Fig. 324
9. Fill with new engine oil.

10. After a short test run check the oil level on the dipstick; if nec-
essary, top up to the top dipstick mark.
11. Check oil filter cartridge and drain plug for leaks.
12. Dispose of the oil and oil filter cartridge in line with environ-
mental regulations.
B-586-0150
Fig. 325
6.1.9.4.2 Replacing the fuel filter; bleeding the fuel system

Preliminary remarks
NOTICE!
– Ensure strict cleanliness! Thoroughly clean the
area around the fuel filters.
– Air in the fuel system causes irregular running
of the engine, a drop in engine power, stalls the
engine and makes starting impossible.
– After work on the fuel system bleed the
system, perform a test run and check for leaks.
– Additional bleeding of the fuel system by a 5
minute test run in idle speed or low load is
mandatory.

Replacing the fuel filter

one year.
448 BW 220 D-5


n Safety shoes
n Protective gloves
1. Loosen and unscrew the fuel filter cartridge using an appro-
priate strap wrench.
2. Clean the sealing face on the filter carrier from any dirt.
3. Slightly oil the rubber seal on the new filter cartridge.
4. Screw the new filter cartridge on by hand until the seal fits
closely.
5. Tighten the filter cartridge by another half turn.
B-586-0375
Fig. 326
Replacing the fuel pre-filter

one year.

n Safety shoes
n Protective gloves
1. Pull the plug-in connection off the sensor on the water sepa-
rator.
2. Place a collecting vessel under the drain bore.
1 2 3. Loosen the bleeding screw and drain off fuel at the drain
plug.
B-GEN-0108
Fig. 327
4. Unscrew and remove the fuel pre-filter using a suitable strap

wrench.
5. Unscrew the water separator from the filter cartridge.
6. Apply a thin coat of oil to the rubber seal of the water sepa-
rator.
7. Screw the water separator to the new fuel pre-filter by hand,
until the seal fits closely, then tighten hand-tight.
8. Slightly oil the rubber seal on the new fuel pre-filter.
B-GEN-0109
9. Screw the fuel pre-filter on by hand until the seal contacts;
Fig. 328 then tighten hand-tight.
10. Push the plug-in connection onto the sensor on the water
separator.
BW 220 D-5 449

11. Dispose of fuel and filter in line with environmental regula-

tions.
Bleeding the fuel system

n Safety shoes
n Protective gloves
1. Slacken the bleeding screw (1) on the fuel pre-filter for 2 to 3
1 turns.
2. Unlock the bayonet lock of the fuel hand pump (2) by
pressing it down and turning it anticlockwise.
3. Operate the fuel hand pump manually, until fuel flows out of
the slackened bleeding screw without air bubbles.
4. Then tighten the bleeding screw while pumping.
2 5. Lock the bayonet lock of the fuel hand pump by pressing it

B-GEN-0066 down and turning it clockwise.
Fig. 329 6. Start the engine and run it for 5 minutes at idle speed.
7. Check the fuel pre-filter for leaks.
6.1.9.4.3 Checking the anti-freeze concentration and the condition of the coolant
n Safety shoes
n Protective gloves
n Safety goggles
3. Unscrew the cap and check the anti-freeze concentration
with a conventional tester.
4. Check the condition of the coolant.
5. Thoroughly flush the cooling system if the coolant is contami-
nated by corrosion residues or other suspended matter
Ä Chapter 6.1.9.6.2 ‘Changing the coolant’ on page 454.
6. Close the cap.
B-586-0376
Fig. 330
450 BW 220 D-5


6.1.9.5.1 Checking the ribbed V-belt
n Protective gloves
3. Remove the air conditioning compressor V-belt Ä Chapter
6.1.9.5.2 ‘Replacing the air conditioning compressor V-belts’
on page 452.
4. Swing the idler pulley back and fixate it by inserting a locking
pin into the fixing bore.
5. Take the ribbed V-belt first off the smallest pulley.
6. Check the condition of tensioning device and pulley (e.g.
excessively worn bearings of tensioning device, idler pulley
and reversing rollers as well as the profile wear on the pul-
leys).
7. Replace any damaged parts.
Fig. 331
Fig. 332: Images showing damaged ribbed V-belts

1 New condition (for comparison): Trapezoidal shape ribs
2 Flank wear: Ribs wedge shaped
3 Tensile strand in base of belt visible
4 Broken out ribs
5 Transverse cracks in several ribs
6 Rubber bulbs in base of belt
7 Embedding of dirt or stones
8 Ribs loosened from base of belt
BW 220 D-5 451

9 Tensile strand laterally ripped out

10 Fraying of outer tensile strands
11 Transverse cracks on back
12 Transverse cracks in several ribs
8. Check the ribbed V-belts for damage by using the images
with damaged belts.
9. Replace damaged ribbed V-belts.
10. Install the ribbed V-belt.
11. Pull the locking pin out of the fixing bore and slowly release
the idler pulley.
12. Check the correct seat of the ribbed V-belt on the V-belt pul-
leys.
13. Install the air conditioning compressor V-belt Ä Chapter
on page 452.
Fig. 333
6.1.9.5.2 Replacing the air conditioning compressor V-belts

two years.

n Protective gloves
3. Loosen the screws (2, 3, 4) on the air conditioning com-
pressor.
4. Relieve the V-belt with the tensioning screw (1) and take it
off.
5. Install the new V-belt for the air conditioning compressor.
specified value Ä Chapter 6.1.9.3.2.2 ‘Checking the V-belt
tension’ on page 445.
7. Tighten screws (2, 3, 4) again.
Fig. 334
452 BW 220 D-5

6.1.9.5.3 Checking the engine mounts

n Protective gloves
3. Check air intake and exhaust manifold fastenings for tight fit.
4. Check sockets and clamps between air filter, exhaust turbo-
charger and charge air line as well as the engine oil lines for
tight fit and leaks.
5. Check fastening screws on the engine oil sump and engine
mounts for tight fit.
6. Check condition and tight fit of engine pillow blocks.

6.1.9.6.1 Checking, adjusting the valve clearance
NOTICE!
We recommend to have this work carried out by
trained personnel or our after sales service.
– Before checking the valve clearance let the
engine cool down for at least 30 minutes. The
engine oil temperature must be below 80 °C
(176 °F).
Valve clearance adjustment

angle:
Intake valve 75° ±15°
Exhaust valve 120° ±15°
Valve Cylinder
overlapping 1 5 3 6 2 4
adjustment 6 2 4 1 5 3
BW 220 D-5 453


n Protective gloves
Tool: n Rotation angle disc
3. Remove the valve cover.
4. Turn the crankshaft with the cranking device until the valves
are overlapping.
5. Loosen counter nut (2).
7. Attach the rotation angle disc (3) and the spanner socket (4)
to the valve clearance adjustment screw (1).
8. Fix the magnet (5) of the rotation angle disc.
9. Turn the rotation angle disc (3) clockwise against the stop
(rocker arm no clearance) and set the scale to zero.
10. Turn the rotation angle disc (3) counter-clockwise, until the
specified angle is reached.
11. Hold the rotation angle disc tight, so that it does not turn, and
tighten counter nut (2), tightening torque: 20 Nm (15 ft·lbf).
12. Repeat this adjustment procedure on all other cylinders, after
cranking the crankshaft accordingly.
13. Install the cylinder head cover again with a new gasket.
ð Tightening torque: 9 Nm (7 ft·lbf)
14. After a short test run check the engine for leaks.
Fig. 335
1 Valve adjustment screw
2 Counter nut
3 Rotation angle disc
4 Socket
5 Magnet
6.1.9.6.2 Changing the coolant

two years.
Do not start the engine after draining off the coolant.

In case of lubrication oil entering into the cooling system or a suspi-
cious turbidity caused by corrosion residues or other suspended
matter, the coolant must be drained off and the complete cooling
system needs to be cleaned.
Oil can damage the sealing materials used in the cooling system.
454 BW 220 D-5

If oil has entered, you must add a cleansing agent in order to

remove any residues from the system. Follow the instructions of
the manufacturer! If in doubt, consult your Customer Service or the
engine manufacturer.
When changing the coolant without any signs of contamination,
cleaning of the cooling system is not necessary.
NOTICE!
– Use only coolant of the permitted specification
Ä Chapter 2.4.3 ‘Coolant’ on page 74.
– Do not mix different coolants and additives of
any other kind.
lubricants’ on page 79

n Safety shoes
n Protective gloves
n Safety goggles

3. Unscrew the cap from the compensation tank.
B-586-0376
Fig. 336
4. Unscrew the plug.

5. Drain off and collect all coolant.
6. Turn the plug tightly back in.
7. Check the condition of the coolant.
8. Thoroughly flush the cooling system if the coolant is contami-
nated by corrosion residues or other suspended matter.
9. Remove the thermostat.
B-586-0378 10. Fill with clean water.
Fig. 337 11. Start the engine and run to operating temperature.
12. Allow the engine to cool down to approx. 50 °C (122 °F).
BW 220 D-5 455

13. Drain off all water.

14. If using a cleaning agent repeat the flushing process twice
with clear water.
15. Reinstall the thermostat.
NOTICE!
The anti-freeze concentration (additive) must be at
least 35 Vol% and maximum 45 Vol%.
16. Fill up coolant.

17. Close the cap.
B-586-0372
Fig. 338
18. Set maximum cabin temperature.
B-SWI-0031
Fig. 339
19. Set maximum fan speed.

21. Run the machine with idle speed until operating temperature
has been reached and the thermostat opens.
22. As soon as the thermostat has opened, run the engine for
approx. 1 minute at high speed.
B-SWI-0035
25. Check the coolant level again when the engine has cooled
Fig. 340 down; top up if necessary.
26. Dispose of coolant in line with environmental regulations.
456 BW 220 D-5


6.1.9.7.1 Replace ribbed V-belt and idler pulley
n Protective gloves
3. Remove the air conditioning compressor V-belt Ä Chapter
on page 452.
4. Swing the idler pulley back and fixate it by inserting a locking
pin into the fixing hole.
5. Take the ribbed V-belt off the smallest pulley first.
6. Unscrew fastening screw and take off the idler pulley.
7. Attach the new idler pulley and tighten the fastening screw;
tightening torque of 80 Nm (59 ft·lbf).
B-DEU-0020
Fig. 341
8. Install the new ribbed V-belt.

9. Pull the locking pin out of the fixing hole and slowly release
the idler pulley.
10. Check the correct seat of the ribbed V-belt on the V-belt pul-
leys.
11. Install the air conditioning compressor V-belt Ä Chapter
on page 452.
Fig. 342
BW 220 D-5 457

6.1.9.8 As required
6.1.9.8.1 Air filter maintenance
NOTICE!
– Do not start the engine after having removed
the air filter.
– If necessary, the air filter may be cleaned up to
six times. After one year at the latest it must be
replaced together with the safety element.
– Cleaning does not make sense if the air filter
element is covered with a sooty deposit.
– Do not use gasoline or hot fluids to clean the
filter element.
– After cleaning, the air filter must be inspected
for damage using a torch.
– Do not continue to use a damaged air filter ele-
ment. If in doubt use a new air filter.
– If the air filter is damaged, the safety element
must be replaced as well.
– The safety element must not be cleaned.
We generally recommend to renew the air filter. A

new filter element is far less expensive than a pos-
sible engine damage.

n Protective gloves
n Safety goggles
1. Maintenance of the air filter is due when the air filter warning
light lights up, but at the latest after one year.
Fig. 343
4. Loosen both locking hooks on the housing cover and take the
cover off.
5. Clean housing cover and dust discharge valve.
Fig. 344
458 BW 220 D-5

6. Pull out the air filter with light turning movements.
CAUTION!
Danger of eye injuries caused by particles
flying around!
(safety gloves, protective working clothes, gog-
gles).
Fig. 345
7. Blow the air filter out with dry compressed air (max. 2.1 bar
(30 psi)) from inside to outside by moving the gun up and
down inside the element, until it is free of dust.
Fig. 346
8. Examine the air filter with a torch for cracks and holes in the
paper bellows.
9. In case of damage replace the air filter and the safety ele-
ment.
Fig. 347
10. Slide the air filter carefully into the housing.
NOTICE!
– The dust discharge valve must point vertically
downwards.
– Make sure that the cover locks engage cor-
rectly.
11. Reassemble the housing cover.

Fig. 348
BW 220 D-5 459

Replacing the safety element
NOTICE!
The safety element must not be cleaned and
should not be used again after it has been
removed.
The safety element must be replaced:
– if the air filter is damaged.
– at the latest after one year.
– if the air filter warning light comes on again
after the air filter has been cleaned.
1. Remove the housing cover and pull the air filter element off.
2. Pull the safety element out by turning it lightly.
3. Push in a new safety element.
4. Insert the air filter and reassemble the housing cover.
Fig. 349
460 BW 220 D-5

6.1.9.8.2 Checking and cleaning the water separator
The service intervals for the water separator

depend on the water content in the fuel and can
therefore not be determined precisely.
After taking the engine into operation you should
check for signs of water and dirt initially every day.

n Protective gloves
1. If the “water in fuel” warning light lights up when starting or
during operation, drain the water from the fuel pre-filter
immediately.
Fig. 350
3. Loosen the drain plug and drain the fluid until pure diesel fuel
starts to run out.
4. Collect running out fluid.
5. Screw the drain plug tightly back in. Check for leaks, if nec-
essary use a new seal ring.
ð Once the water separator is empty, the warning light for
water in fuel must go out.
Fig. 351
6.1.9.8.3 Measures prior to extended shut-down period

Measures before shutting down
If the machine is shut down for a longer period of time, e.g. winter
season, the following work must be carried out:
1. Clean the machine thoroughly.
2. After shutting down store the machine under cover in a dry
and well ventilated room.
3. Grease the bare piston rods of all hydraulic cylinders well
and pull them in as far as possible.
4. Spray a thin oil film onto to all lever joints and bearing points
without lubrication.
5. Repair damaged paint; preserve bare areas thoroughly with
anti-corrosive agent.
6. Clean the water separator.
7. Fill the fuel tank with diesel fuel to prevent the formation of
condensation water in the tank.
BW 220 D-5 461

8. Change engine oil and oil filter if the oil has been changed
more than 300 hours ago, or if the oil is older than 12
months.
9. Check the anti-freeze concentration and the coolant level.
10. Disconnect the ground strap from the battery (this avoids
self-discharge caused by closed-circuit consuming devices).
Battery service during prolonged machine downtimes
WARNING!
ture!
the battery.
the battery.

n Protective gloves
n Safety goggles
1. Switch off all consuming devices (e.g. ignition, light).
2. Measure the open-circuit voltage of the battery at regular
intervals (at least 1 x per month).
ð Reference values: 12.6 V = fully charged; 12.3 V = dis-
charged to 50%.
3. Recharge the battery immediately after an open-circuit
voltage of 12.25 V or less is reached. Do not perform boost
charging.
ð The open-circuit voltage of the battery occurs approx. 10
hours after the last charging process or one hour after
the last discharge.
4. Switch off the charging current before removing the charging
clamps.
5. After each charging process allow the battery to rest for one
hour before taking it into service.
6. For standstill periods of more than one month you should
always disconnect the battery. Do not forget to perform reg-
ular open-circuit voltage measurements.
462 BW 220 D-5

Measures before restarting

1. Replace the fuel filter.
2. Replace the air filter.
3. Change engine oil and oil filter.
4. Check the coolant level.
5. Check the charge condition of the batteries, recharge if nec-
essary. Check the battery fluid level before and after
charging.
6. Connect the ground straps to the batteries.
7. Check the function of the electric system.
8. Check cables, hoses and lines for cracks and leaks.
9. Check the service life of hydraulic hoses and replace if nec-
essary.
10. Start the engine and run it for 15 to 30 minutes with idle
speed.
11. While the engine is running keep an eye on the gauges for
engine oil pressure and coolant temperature.
12. Check the oil levels.
13. Check the function of electric system, steering and brakes.
14. Clean the machine thoroughly.
BW 220 D-5 463

Machine assemblies – Drum
6.2 Drum
6.2.1 Repair overview for drum....................................... 465
6.2.2 Dismantling the drum............................................. 469
6.2.3 Dismantling and assembling the change-over
weight.................................................................... 484
6.2.4 Assembling the drum............................................. 487
6.2.5 Changing the rubber buffers, adjusting the preten-
sion........................................................................ 509
6.2.6 Smooth drum scraper; installation and removal.... 514
6.2.7 Pad foot scraper; installation and removal............. 518
464 BW 220 D-5

6.2.1 Repair overview for drum

1 Vibration motor
2 Exciter unit
3 Clutch
4 Travel gear
5 Travel motor
6 Drum shell
7 Rubber buffer
9 Travel bearings
BW 220 D-5 465


1 Vibration motor
2 Exciter unit
3 Clutch
4 Travel gear
5 Travel motor
6 Drum shell
7 Rubber buffer
9 Travel bearings
466 BW 220 D-5

2 SILICON
1 59 1 2
OIL 47V
Nm 1000 CST
4
0,6 ... 1,8 mm
9
SAE
75W90
3 4 120
8
Nm
7
6 5
S-586-0478
Fig. 354: Repair overview for drum
NOTICE!
Ensure strict cleanliness!
– Thoroughly clean work place and components.
BW 220 D-5 467

NOTICE!
Notes on repair
– 1
Install the O-ring with some grease.
– 2
Fitting and contact surfaces of the connection
must be absolutely dry and free of grease, oil,
paint and conserving agent.
– 3
Grease radial seals + running surface on shaft
before assembling.
– 4
Install the dowel pins with the grooves offset by
180° to each other, but in line with the shaft
axis.
– 5
The thread must be free of grease, oil, paint
and conserving agents.
– 6
To ease assembly of the mechanical seal, wet
the elastomer part + bore in flanged hub with
spirit (not with oil).
– Clean the sliding surfaces on the seal and
apply a thin film of oil.
– During assembly fill the cavity up to 1/3 with
grease.
– 7
Fill the bearing completely with grease.
– Bearing chamber to 1/3 filled with grease.
– 8
Ventilation bore in cover pointing down.
– 9
Check the axial clearance of the shaft: Nom-
inal value 0.6 to 1.8 mm.
468 BW 220 D-5

6.2.2 Dismantling the drum

Removing the travel motor
DANGER!
Danger to life caused by suspended loads!
– Do not step or stand under suspended loads.
WARNING!
Danger of crushing caused by heavy compo-
nents!
– Be extremely cautious when working in the
danger zone
gloves, protective clothing).
1. Attach the lifting tackle to travel drive (3).

2. Unscrew all nuts (1) from the rubber buffers.
3. Take drive disc (2) with travel drive off the rubber buffers and
lay it down.
Fig. 355
4. Unscrew fastening screws (3) and take off gearbox bracket

(4).
5. Unscrew fastening screws (1) and take off drive disc (2).
Fig. 356
Removing the exciter unit (travel

motor side)
DANGER!
BW 220 D-5 469

WARNING!
nents!
danger zone
1. Unscrew both socket head cap screws from the flange.
Fig. 357
2. Mount bracket (1) for the lifting device to the flange.

3.
NOTICE!
The four short fastening screws (drawn with
thin lines) must remain installed.
Unscrew screws (2) from the flange.
Fig. 358
4. Slide the lifting device over the bracket.

5. Force the exciter unit off with two forcing screws.
Fig. 359
470 BW 220 D-5

6. Pull the exciter unit out of the drum .

7. Take the coupling element off the coupling half.
Fig. 360
Disassembling the exciter unit

(travel motor side)
1. Unscrew fastening screws (1) for the fan.
2. Loosen the clamping screw (2).
3. Pull the coupling hub off the shaft.
Fig. 361
4. Unscrew all other fastening screws (1) from the flange.

5. Press the flange off the flanged housing with forcing screws
(2).
Fig. 362
6. Lift the flange off the flanged housing.

7. Take the O-ring out of the groove in the flanged housing.
Fig. 363
BW 220 D-5 471

8. Unclip the circlip from the groove in the flange.
Fig. 364
9. Press the cylinder roller bearing with forcing screws out of

the flange.
Fig. 365
10. Lift the exciter unit out of the flanged housing.
Fig. 366
11. Knock the radial seal out of the flanged housing.
Fig. 367
472 BW 220 D-5

12. Unclip the circlip from the groove in the flanged housing.
Fig. 368
the flanged housing.
Fig. 369
14. Extract inner ring (1) for the radial seal and inner bearing
races (2).
Fig. 370
15.
If the rings are very tight, heat them up with a
torch.
WARNING!
Danger of burning!
Wear safety gloves.
Unclip the circlip from the basic weight.

Fig. 371
BW 220 D-5 473

16. To change shaft (1) knock out dowel pins (2 and 3) and press
the shaft out of the basic weight.
Fig. 372
474 BW 220 D-5

Removing the exciter unit (vibra-

tion motor side)
DANGER!
WARNING!
nents!
danger zone
1.
Perform work steps Ä Fig. 373 or
Ä Fig. 374 on both sides of the side plate.
– BW 213
4 rectangular rubber buffers
– BW 216
– BW 219
– BW 226
Fig. 373: shows BW 213-5 8 rectangular rubber buffers
2. Take up spacer block with rectangular rubber buffers

Ä Fig. 373 or Ä Fig. 374 with lifting tackle and unscrew fas-
tening screws (1).
3. Take rectangular rubber buffer (2) with spacer block (3) off
the side plate.
Fig. 374: shows BW 216-5
BW 220 D-5 475

4. Unscrew fastening screws (1).

5. Force cover (2) together with the attached vibration motor off
the side plate (4) with forcing screws (3).
Fig. 375: On -4 machines the vibra-

tion motor is installed with a 180° rota-
tion
6. To change the vibration motor loosen clamping screw (1) and

pull off coupling half (2).
Fig. 376

8. Take the vibration motor off the cover.
Fig. 377: On -4 machines the vibra-

tion motor is installed with a 180° rota-
tion
476 BW 220 D-5

9. Take off coupling element (1).
Fig. 378
10. Fasten the lifting device.
NOTICE!
The four short fastening screws (2) must remain
screwed in (the two others are not visible).
Fig. 379
12. Press the exciter unit out of the drum with forcing screws.
The second forcing screw is covered by the

side plate.
Fig. 380
BW 220 D-5 477

13. Pull the exciter unit out of the drum .
Fig. 381
Removing, dismantling the side

plate DANGER!
WARNING!
nents!
danger zone
1. Remove the V-ring (1).

2. Unclip circlip (2).
Fig. 382
478 BW 220 D-5

3. Attach the disassembly device to the side plate and force off
the side plate.
Fig. 383
4. Lift the side plate off the flanged hub.
Fig. 384
5.
New version with reinforced travel bear-
ings
On the single drum rollers BW 216 to BW
219, the new version is equipped with self-
aligning roller bearings.
Knock the self-aligning roller bearing/grooved ball bearing out

of the side plate and take out the spacer ring.
Fig. 385: Image shows old version

with grooved ball bearing
BW 220 D-5 479

6. Unclip the circlip from the side plate and knock out the
grooved ball bearing (1).
Fig. 386
7. Take the mechanical seal off the flanged hub.
Fig. 387
Dismantling the exciter unit (vibra-

tion motor side) WARNING!
nents!
danger zone
1. Unscrew the fastening from the coupling hub.

2. Pull the coupling hub off the shaft with a puller.
Fig. 388
480 BW 220 D-5

3. Loosen the clamping screw (1).

4. Pull coupling hub (2) off the shaft.
Fig. 389
5. Unscrew all other fastening screws (1) and press the flanged
hub off the flanged housing with forcing screws (2).
6. Take off the flanged hub.
7. Take the O-ring out of the groove in the flanged housing.
Fig. 390
8. Unclip the circlip from the groove in the flanged hub.
Fig. 391
9. Knock the cylinder roller bearing out of the flanged hub.
Fig. 392
BW 220 D-5 481

10. Lift the exciter unit out of the flanged housing.
Fig. 393
11. Knock the radial seal out of the flanged housing.
Fig. 394
12. Unclip the circlip from the groove in the flanged housing.
Fig. 395
the flanged housing.
Fig. 396
482 BW 220 D-5

14. Extract inner rings (1) for the radial seals and inner bearing
races (2) from the shafts.
Fig. 397
15.
If the rings are very tight, heat them up with a
torch.
WARNING!
Danger of burning!
Wear protective gloves.
Unclip the circlip from the basic weight and remove the cover.
Fig. 398
The shafts cannot be pressed out. If dam-

aged they must be replaced with basic
weight and cover.
If necessary disassemble, assemble the
change-over weight (see corresponding
chapter).
BW 220 D-5 483

6.2.3 Dismantling and assembling the change-over weight

Dismantling the change-over
weight ENVIRONMENT!
Environmental damage!
Catch running out oil and dispose of environmen-
tally.
1. Unscrew all screws.
Fig. 399
2. Force the cover off the basic weight with forcing screws.
Fig. 400
3. Take the change-over weight out of the basic weight.
Fig. 401
484 BW 220 D-5

4. Pull O-rings (1 and 2) out of the grooves.
Fig. 402
Assembling the change-over

weights NOTICE!
Ensure strict cleanliness.
1. Install new O-rings (1 and 2) with grease.
Fig. 403
2. Insert the change-over weight into the basic weight.
Fig. 404
BW 220 D-5 485

3. Fill silicon oil 47 V 1000 cst up to the upper edge of the

change-over weight (approx. 2.3 litres) into the basic weight.
Fig. 405
4. Attach the cover, so that the raised areas are in line.

5. Turn in screws with screw retention agent (e.g. Loctite blue
243) and tighten with 120 Nm.
6. Check the end float of the shaft.
ð
There must be play.
Fig. 406
486 BW 220 D-5

6.2.4 Assembling the drum

Assembling the exciter unit (vibra-
tion motor side)
WARNING!
nents!
danger zone
WARNING!
WARNING!
Danger of body parts freezing due to liquid
nitrogen!
Wear your personal protective outfit (face protec-
tion, protective gloves, protective clothing).
Avoid skin contact.
WARNING!
Danger of body parts freezing on cold sur-
faces!
Wear your personal protective outfit (protective
NOTICE!
1. Close the bore in the shaft with a screw.

2. Cool the shaft down with liquid oxygen.
3. Remove the screw from the shaft again.
4. Align and insert the cooled shaft with the bores into the basic
weight until it bottoms.
Fig. 407
BW 220 D-5 487

5.
NOTICE!
Assemble the dowel pins with the grooves
offset by 180° to each other, but in line with
the axis of the shaft.
Secure the shaft (1) with the dowel pins (2 and 3).
Fig. 408

9. Align and insert the cooled shaft with the bores into the cover
until it bottoms.
Fig. 409
10.
NOTICE!
Secure the shaft (2) with the dowel pins (1 u. 3).
Fig. 410
11. Insert the feather key into the groove of the respective shaft.
Fig. 411
488 BW 220 D-5

12. Insert the circlip into the groove on the basic weight and the
cover.
Fig. 412
13. Heat the inner bearing race up to approx. 100° C and slide it
on the basic weight with the bigger outer diameter facing for-
ward until it bottoms.
Fig. 413
14. Heat the shaft collar up to approx. 50° C and slide it on the
shorter shaft with the longer chamfer facing outward until it
bottoms.
Fig. 414
on the cover with the bigger outer diameter facing forward
until it bottoms.
Fig. 415
BW 220 D-5 489

longer shaft with the longer chamfer facing outward.
Fig. 416
17. Press the cylinder roller bearing (1) into the flanged housing
until it bottoms using pressing plate (2).
Fig. 417
18. Insert the circlip into the groove of the flanged housing.
Fig. 418
19. Insert the new O-ring with grease into the groove of the
flanged housing.
20. Fill approx. 1.2 l of SAE 15W-40 oil into the flanged housing.
Fig. 419
490 BW 220 D-5

21. Insert the exciter unit into the flanged housing with the longer
shaft facing forward.
Fig. 420
22. Press the cylinder roller bearing (1) into the flanged hub until
it bottoms using pressing plate (2).
Fig. 421
23. Insert the circlip into the groove of the flanged hub.
Fig. 422
24.
NOTICE!
Fitting and contact surfaces must be abso-
lutely dry and free of grease, paint and con-
serving agents.
Place the flanged hub on the flanged housing.

25. Unscrew the eye bolts (1) and screw in the short screws
instead.
26. Screw in and tighten four short screws (2) into the tapped
Fig. 423 bores of the flanged housing.
BW 220 D-5 491

27. Slightly lubricate the sealing lip of the radial seal (1).
28. Insert the radial seal into the flanged hub with the sealing lip
pointing down and press it until it bottoms using pressing
plate (2).
Fig. 424
29. Heat the coupling hub up to approx. 80° C and slide it on the
shaft until it bottoms.
Fig. 425
31. Slide the radial seal onto the shaft with the sealing lip
pointing forward and drive it into the flanged housing with a
suitable pipe (2) until it bottoms.
Fig. 426
32. Apply screw retention agent (Loctite CVX strong, blue, 582)
to the thread of the screw (1).
33. Slide on the new U-seal ring (2), insert and tighten the screw.
Fig. 427
492 BW 220 D-5

34. Heat the coupling hub (1) with the code letter “L“ up to
approx. 80° C and slide it on the shaft until it bottoms.
35. Turn in and tighten the clamping screw (2).
Fig. 428
Assembling and installing the side

plate WARNING!
nents!
danger zone
1. Fill grooved ball bearing (1) on both sides with grease.

2. Press the grooved ball bearing completely in using the
pressing plate (2).
Fig. 429
3. Insert the circlip into the groove of the side plate.
Fig. 430
BW 220 D-5 493

4. Apply a thick coat of grease to the spacer ring on both sides

and insert it into the side plate.
Fig. 431
5.
New version with reinforced travel bear-
ings
On the single drum rollers BW 216 to BW
219, the new version is equipped with self-
aligning roller bearings.
Fill grooved ball bearing/self-aligning roller bearing (1) on one

side completely with grease.
6. Press in the grooved ball bearing/self-aligning roller bearing,
greased side first, along with the pressing plate (2) until the
Fig. 432 end stop.
Grease the other side after installing the

exciter unit.
7. Clean the sliding surfaces of the mechanical seal and cover

them lightly with oil.
8. Insert the O-ring into the mechanical seal.
Fig. 433
494 BW 220 D-5

9.
Wet the elastomer part + bore with spirit (no
oil) to make the assembly easier.
Lay one half of the mechanical seal on the flanged hub with
the sliding surface pointing up.
Fig. 434
10. Lay the second half of the mechanical seal on top with the
sliding surface pointing down.
11. Fill the cavity of the mechanical seal up to 1/3 with grease.
Fig. 435
12. Bolt the threaded section of the assembly device to the

flanged hub.
Fig. 436
13. Lay the side plate on the flanged hub.
Fig. 437
BW 220 D-5 495

14. Attach bushing (2) of the assembly device and turn on nut
(1).
Fig. 438
15.
NOTICE!
During assembly make sure that the
mechanical seal slides correctly into the side
plate and the loop rings are not damaged .
Pull the side plate with the assembly device onto the flanged
hub.
Fig. 439
16. Remove the assembly device.

17. Insert the circlip into the groove of the flanged hub.
Fig. 440
496 BW 220 D-5

Assembling the exciter unit (travel

motor side)
WARNING!
nents!
danger zone
WARNING!
WARNING!
Danger of body parts freezing due to liquid
nitrogen!
Wear your personal protective outfit (face protec-
tion, protective gloves, protective clothing).
Avoid skin contact.
WARNING!
Danger of body parts freezing on cold sur-
faces!
Wear your personal protective outfit (protective
NOTICE!

4. Align and insert the cooled shaft with the bores into the basic
weight until it bottoms.
Fig. 441
BW 220 D-5 497

5.
NOTICE!
Secure the shaft (1) with the dowel pins (2 and 3).
Fig. 442
6. Insert the circlip into the groove on the basic weight and the
cover.
Fig. 443

on the basic weight with the bigger outer diameter facing for-
ward until it bottoms.
Fig. 444

shaft with the longer chamfer facing outward until it bottoms.
Fig. 445
498 BW 220 D-5


on the cover with the bigger outer diameter facing forward
until it bottoms.
Fig. 446
10. Press the cylinder roller bearing (1) into the flanged housing
until it bottoms using pressing plate (2).
Fig. 447
11. Insert the circlip into the groove of the flanged housing.
Fig. 448
12. Insert the new O-ring with grease into the groove of the
flanged housing.
13. Fill approx. 1.2 l of SAE-15W/40 oil into the flanged housing.
Fig. 449
BW 220 D-5 499

14. Insert the exciter unit into the flanged housing.
Fig. 450
15. Press the cylinder roller bearing (1) into the flange until it bot-
toms using pressing plate (2).
Fig. 451
16. Insert the circlip into the groove of the flange.
Fig. 452
17.
NOTICE!
Fitting and contact surfaces must be abso-
lutely dry and free of grease, paint and con-
serving agents.
Lift the flange to the flanged housing and align it with the
boreholes.
Fig. 453
500 BW 220 D-5

18. Turn in and tighten the screws into the tapped bores of the
flanged housing.
Fig. 454
20. Slide the radial seal onto the shaft with the sealing lip
pointing forward and drive it into the flanged housing with a
suitable pipe (2) until it bottoms.
Fig. 455
21. Apply screw retention agent (Loctite CVX strong, blue, 582)
to the thread of the screws (1).
22. Slide on the new U-seal ring (2), insert and tighten the screw.
Fig. 456
23. Insert the feather key into the groove of the shaft.
Fig. 457
BW 220 D-5 501

24. Slide the fan blade with the mounting disc on the shaft.
25. Heat the coupling hub (1) with the code letter “R“ up to
approx. 80° C and slide it on the shaft until it bottoms.
26. Turn in and tighten the clamping screw (2).
27. Mount the fan blade to the coupling hub .
Fig. 458
Installing the exciter unit (travel

motor side) DANGER!
WARNING!
nents!
danger zone
NOTICE!
between exciter unit and drum must be absolutely
dry and free of grease, oil, paint and conserving
agent.
1. Check coupling elements , replace if necessary.

2. Insert the coupling element into the coupling hub.
Fig. 459
502 BW 220 D-5

3. Fasten the lifting device to the exciter unit.

4. Insert the vibrator unit into the drum.
Fig. 460
5.
Insert the exciter unit so that oil filler plug 1 is
in line with bore (2) in the drum.
Fig. 461
6.
NOTICE!
The thread must be free of oil, grease and
conserving agents.
Turn in and tighten screws (2).

7. Remove bracket (1) for the lifting device.
Fig. 462
8. Cover the thread of screws with a screw retention agent (e.g.

Loctite green 270).
9. Slide on the new U-seal ring, turn in and tighten the screws.
Fig. 463
BW 220 D-5 503

Installing the travel motor

DANGER!
WARNING!
nents!
danger zone
1. Assemble drive disc (2) and gearbox bracket (4) with screws
(3).
Fig. 464
2. Attach drive disc (2) with assembled travel drive (3) to the
rubber buffers. Turn on and tighten the nuts (1).
Fig. 465
504 BW 220 D-5

Installing the exciter unit (vibration

motor side) DANGER!
WARNING!
nents!
danger zone
NOTICE!
between exciter unit and drum must be absolutely
dry and free of grease, oil, paint and conserving
agent.
1. Fasten the lifting gear to the exciter unit and insert it into the
drum.
Fig. 466
2.
NOTICE!
Ensure correct engagement of coupling and
alignment of shaft .
If the shafts are not correctly in line deter-
mine the cause, if necessary measure the
drum.
Fig. 467
BW 220 D-5 505

3.
NOTICE!
The thread must be free of oil, grease and
conserving agents.
Turn in and tighten screws (1).

4. Remove the lifting gear.
5. Fit cover (2) to the drum.
Fig. 468
6. Check the end float of the exciter shafts.

ð
Nominal value: 0.6...1.8 mm
Fig. 469
7. Attach disc (1), turn in and tighten the fastening screws (2).
Fig. 470
8. Lay a new V-ring over the journal of the flanged hub.

9. Fill the grooved ball bearing with grease.
Fig. 471
506 BW 220 D-5

10.
Check coupling element (1), replace if neces-
sary.
Insert the coupling element into the coupling hub.
Fig. 472
11. Install a new O-ring (1) and apply a thin coat of oil.
Fig. 473: Vibration motor
12.
Ventilation bore (3) in cover pointing down.
Mount vibration motor (1) to cover (2).

13. Turn in fastening screws with ball disc and ball socket and
tighten.
Fig. 474
BW 220 D-5 507

14. Slide on coupling half (2) and secure with clamping screw
(1).
Fig. 475
15. Install a new O-ring (1) and apply a thin coat of oil.
Fig. 476
16. Attach cover (2) with the assembled vibration motor,

assemble screws (1) with washers and tighten.
Fig. 477
508 BW 220 D-5

17.
Perform work steps Ä Fig. 478 or
Ä Fig. 479 on both sides of the side plate.
– BW 213
– BW 216
– BW 219
– BW 226
Fig. 478: The picture shows BW 213 8 rectangular rubber buffers
18. Take rectangular rubber buffers (2) with attached spacer

block (3) with lifting gear mount to the side plate with screws
and washers (1).
Fig. 479: The picture shows BW 216
6.2.5 Changing the rubber buffers, adjusting the pretension
BW 211/212/213/214 = 4 rectangular rubber buf-

fers
BW 216 = 6 rectangular rubber buffers
BW 219/226 = 8 rectangular rubber buffers
BW 220 D-5 509

Fig. 480: BW 211/212/213/214 D/PD

1 Weld-on nuts
Fig. 481: BW 211/212 DH/PDH

1 Weld-on nuts
510 BW 220 D-5

Fig. 482: BW 213 DH/PDH

1 Weld-on nuts
Fig. 483: BW 215/216 D/PD, BW216/219/226 DH/PDH

1 Weld-on nuts
BW 220 D-5 511

Relieve the rubber buffers

1. Lift the front frame up on both sides, until rubber buffers and
rectangular buffers are relieved of any load.
2. Loosen all fastening screws.
Fig. 484
3. Turn the screws into the weld-on nuts.
Fig. 485: Picture shows BW216
4. Remove the compensation plates.
Fig. 486
5. Unscrew the screws from the welded nuts.
512 BW 220 D-5

6.
NOTICE!
Check the rectangular rubber buffers,
replace if necessary
Observe the assembly direction, arrow up.
Fig. 488
Changing the rubber buffers

1. Unscrew nut (1) and remove the washer.
2. Unscrew screws (2).
3. Take off rubber buffer (3).
4. Attach the new rubber buffer to the drive disc and align the
bores to the tapped bores in the drum.
5. Turn in and tighten the screws.
6. Install the washer, turn on and tighten the nut.
Fig. 489
Adjusting the pretension

1. Measure distance “X” between spacer block and side plate.
2. Calculate the thickness of the compensation plates.
ð Nominal value: Distance “X” + 2 mm
3. Turn in screws into each welded nut and create sufficient

space to insert the compensation plates.
BW 220 D-5 513

4. Install the compensation plates.
Fig. 492
5. Unscrew the screws from the welded nuts.
6. Tighten the fastening screws.

7. Lower the front frame again.
Fig. 494
6.2.6 Smooth drum scraper; installation and removal

6.2.6.1 Removing the scrapers....................................... 515
6.2.6.2 Attaching the scrapers........................................ 517
514 BW 220 D-5

6.2.6.1 Removing the scrapers

n Safety shoes
n Protective gloves
Front scraper
1. Remove all nuts (1) from the fastening bolts between the
1 front scraper and drum.
WARNING!
Danger of injury caused by heavy component!
– When removing the bolts make sure nobody is
within the swivel range of the scraper!
– Persons may only stand to the side of the
crossbar.
B-586-0272
Fig. 495
2. Remove the rear bolts (1) on both sides.

1
B-586-0368
Fig. 496
3. Attach the lifting tackle to the front scraper as perpendicularly

as possible and secure with suitable lifting tackle.
4. Remove the remaining bolts on both sides.
5. Lower the front scraper to the ground or onto a pallet and pull
to the side.
B-586-0273
Fig. 497
BW 220 D-5 515

Rear scraper
6.
NOTICE!
– Make sure no components of the driver’s
stand get damaged.
– Particularly in the case of machines with
cabs, make sure that the windows do not
get damaged.
If necessary, protect the window (e.g.
B-586-0338 with a board).
Fig. 498 Attach the lifting tackle to the rear scraper as perpendicularly
7. Remove all nuts (1) from the fastening bolts between the rear
1 scraper and drum.
WARNING!
crossbar.
B-586-0274
Fig. 499
8. Remove the front bolts on both sides.

1
10. Lower the rear scraper to the ground or onto a pallet and pull
to the side.
B-586-0369
Fig. 500
516 BW 220 D-5

6.2.6.2 Attaching the scrapers

n Safety shoes
n Protective gloves
Front scraper
1. Position the scraper in front of the drum.
B-586-0273
Fig. 501
3. Carefully lift the scraper until it is in installation position.

1
4. Insert the fastening bolts, screw the nuts (1) on and tighten.
B-586-0272
Fig. 502
Rear scraper
6.
NOTICE!
stand get damaged.
get damaged.
B-586-0338
Fig. 503 with a board).
Attach the lifting tackle to the rear scraper as perpendicularly

BW 220 D-5 517


1
B-586-0274
Fig. 504
6.2.7 Pad foot scraper; installation and removal

6.2.7.1 Removing the scrapers....................................... 518
6.2.7.2 Attaching the scrapers........................................ 520

n Safety shoes
n Protective gloves
Front scraper
B-586-0363
Fig. 505
2. Remove the two lower bolts (1) from the half shells on both
sides.
3. Carefully set the scraper down on the floor.
1
B-586-0370
Fig. 506
518 BW 220 D-5

4. Remove all three nuts (1) on both sides.

1
5. Remove the bolts (2) and the upper half shells.
2
B-586-0364
Fig. 507
Rear scraper
6.
NOTICE!
stand get damaged.
get damaged.
sides.
out from under the machine.
1
B-586-0371
Fig. 509

1
2
B-586-0362
Fig. 510
BW 220 D-5 519


n Safety shoes
n Protective gloves
Front scraper
1. Attach both of the upper half shells of the padfoot scraper to
the front right and left of the machine.
B-586-0345
Fig. 511

4. Carefully lift the scraper until it is in the upper retainer half.
B-586-0346
Fig. 512
5. Attach the lower half shells, insert the screws with copper
paste (OKS 240, BOMAG 009 700 03) and secure them.
B-586-0347
Fig. 513
520 BW 220 D-5

6. Slide the scraper onto the drum leaving approx. 25 mm (1 in).

7. Tighten the bolts on the half shells using tightening torque:
463 Nm (341 ft·lbf).
B-586-0348
Fig. 514
Rear scraper
8. Attach both of the upper half shells of the scraper rear right
and left.
B-586-0349
Fig. 515

10.
NOTICE!
stand get damaged.
get damaged.
B-586-0360

11. Carefully lift the scraper until it is in the upper half shells.
BW 220 D-5 521

B-586-0361
Fig. 517
463 Nm (341 ft·lbf).
B-586-0348
Fig. 518


6.2.8.2.1 Checking the rubber-bonded metal rails and rubber buffers 523
6.2.8.2.2 Checking the oil level in the exciter housing 524
6.2.8.2.3 Checking the oil level in the drum drive reduction gear 524
6.2.8.3.1 Change the oil in the exciter housing 525
6.2.8.3.2 Change the oil in the drum drive reduction gear 527
As required
6.2.8.4.1 Retightening the padfoot shell 528
6.2.8.4.2 Adjusting the scrapers 528
522 BW 220 D-5


6.2.8.2.1 Checking the rubber-bonded metal rails and rubber buffers
n Safety shoes
n Protective gloves
1. Drive the machine onto horizontal, level, firm ground.
Make sure there is sufficient space to drive

the machine for at least one full turn of the
drum.

Checking the rubber-bonded metal
rails
3. Check the rubber-bonded metal rails on the left-hand side for
a tight fit, cracks and tear-offs.
4. Have damaged any rubber-bonded metal rails replaced
immediately by our Customer Service Department.
B-586-0493
Fig. 519
Checking the rubber buffers

To check the rubber buffers on the right-hand side,
the drum has to be moved one revolution in three
steps.
5. Check the rubber buffers that are visible for a tight fit, cracks
and tear-offs.
Then start the engine and move the machine forward
approx. 1.50 m (5 ft).
Shut the engine down and perform the check once again.
6. Repeat these activities until the drum has been moved one
revolution.
7. Have any damaged rubber buffers replaced immediately by
B-586-0494 our Customer Service Department.
Fig. 520
BW 220 D-5 523

6.2.8.2.2 Checking the oil level in the exciter housing
NOTICE!
– Use only gear oil of the permitted specification
Ä Chapter 2.4.5 ‘Gear oil SAE 75W-90’
on page 77.

n Protective gloves
1. Before checking the oil level, run the machine warm with
vibration for about 1/2 hour.
2. Move the drum, until the oil level inspection plug is in bottom
position.
4. Clean the area around the level inspection plug and unscrew
the plug.
ð The oil level must reach the bottom edge of the level
bore.
Fig. 521
5. Clean the area around the filler plug and unscrew the filler
plug.
6. Fill in oil through the filler bore, until it starts to run out
through the level inspection bore.
8. Retighten the filler and level inspection plugs.

9. Repeat this inspection on the other side.
10. If a loss of oil is found, perform trouble shooting, repair the
drum if necessary.
Fig. 522
6.2.8.2.3 Checking the oil level in the drum drive reduction gear
NOTICE!
on page 77.
524 BW 220 D-5


n Protective gloves
1. There are 3 inspection plugs arranged around the circumfer-
ence of the reduction gear, always offset to each other by
90°.
Move the machine until one level inspection plug is in hori-
zontal position and one inspection plug points vertically up.
3. Clean the area around the horizontal level inspection plug
and unscrew the plug.
Fig. 523 bore.
4. If necessary clean the area around the upper level inspection
plug and unscrew the plug.
5. Fill in oil through the opening of the upper level inspection
plug, until it starts to run out through the horizontal inspection
plug.
6. Retighten both inspection plugs again.

6.2.8.3.1 Change the oil in the exciter housing
NOTICE!
– Drain gear oil only at operating temperature.
on page 77.

one year.
BW 220 D-5 525


n Protective gloves
1. Before changing the oil level run the machine warm for about
1/2 hour with vibration.
2. Move the drum, until the drain plug is in bottom position.
4. Clean the area around the drain plug.
WARNING!
Fig. 524 – Avoid touching hot components.
5. Unscrew the drain plug and catch any oil running out.
6. Turn the drain plug tightly back in.
7. Clean the area around the oil level inspection plug.
8. Unscrew the oil level inspection plug.
Fig. 525
9. Unscrew the oil filler plug and fill in new oil through the oil
filler bore, until oil starts to drip out through the inspection
bore.
10. Retighten the filler and level inspection plugs.
11. Change the oil on both sides.
12. Dispose of oil in an environmentally friendly way.
Fig. 526
526 BW 220 D-5

6.2.8.3.2 Change the oil in the drum drive reduction gear
NOTICE!
on page 77.

one year.

n Protective gloves
1. There are three plugs arranged around the circumference of
the reduction gear, always offset to each other by 90°.
Move the machine so that one plug is in horizontal position
and the two other plugs are facing vertically upwards and
vertically downwards.
3. Clean the area around the plugs.
WARNING!
Fig. 527
6. Unscrew the filler and oil level inspection plugs.
7. Fill in oil through the filler plug, until it starts to run out
through the oil level inspection plug.
8. Retighten the filler and oil level inspection plugs.
BW 220 D-5 527

6.2.8.4 As required
6.2.8.4.1 Retightening the padfoot shell
n Safety shoes
n Protective gloves
After the installation of the padfoot shell segments, all fastening
screws must be retightened.
1. Run an approx. two minute test drive with vibration.
3. Retighten all fastening screws.
4. After approx. 60 minutes work, retighten all fastening screws
again.
Fig. 528
6.2.8.4.2 Adjusting the scrapers

Smooth drum scrapers
1. Check the setting and condition of the front and rear scra-
pers; if necessary, adjust or replace the scraper rubber.
2. In order to adjust the scrapers, loosen the fastening screws
(1) in the slots and push the scraper towards the drum until it
makes contact.
3. Fasten the fastening screws again.
Fig. 529
Scrapers on smooth drums with

padfoot shell
1. Check the setting and condition of the scrapers; adjust or
replace the teeth if necessary.
2. To adjust the scrapers loosen the clamping screws and push
the scrapers towards the drum, leaving a gap of about
25 mm.
3. Retighten the clamping screws.
Fig. 530
528 BW 220 D-5

Machine assemblies – Padfoot shell
6.3 Padfoot shell

6.3.1 Attaching the padfoot shells................................... 529
6.3.2 Removing the padfoot shells................................. 541
6.3.1 Attaching the padfoot shells

6.3.1.1 Preliminary remarks and safety notes
Loads are only to be attached and hoisted by an expert/qualified
person.
Do not use lifting points that are damaged or impaired in any other
way.
Only use lifting and lashing tackle with sufficient load bearing
Always use appropriate lifting and lashing tackle at the lifting and
lashing points.
Use lifting tackle only in the specified loading direction.
When lifting the machine, avoid uncontrolled movements of the
load. If necessary, hold the load with guide ropes.
At least two people are required when attaching and detaching the
segments.
Weights
Padfoot shell segment Scraper
Approx. 425 kg (937 lbs) each Approx. 138 kg (304 lbs) each
During production, 1, 2 or 3 weld seams are

applied to the individual segments as identification
in order to ensure that the individual segments stay
1 together.
B-586-0342
Fig. 531
1 Weld seam identification
BW 220 D-5 529

6.3.1.2 Preparations
n Safety shoes
n Protective gloves
n Safety goggles

drum.
2. Apply the parking brake.

4. Clean the drum.
B-ELE-0069
Fig. 532
5. Check all three segments for damage to the lifting points.

ð Do not use lifting points that are damaged or impaired in
any way.
6. Check all three segments for deformation.
ð Do not use damaged or badly bent segments.
7. Clean all three segments.
8. Clean screw connection points of disconnected bolts, nuts
B-586-0339 and dirt.
Fig. 533
If necessary, use a drill with wire brush
attachment to clean the screw connection
points.
530 BW 220 D-5


n Safety shoes
n Protective gloves
Front scraper
1. Remove all nuts (1) from the fastening bolts between the
1 front scraper and drum.
WARNING!
crossbar.
B-586-0272
Fig. 534
2. Remove the rear bolts (1) on both sides.

1
B-586-0368
Fig. 535

5. Lower the front scraper to the ground or onto a pallet and pull
to the side.
B-586-0273
Fig. 536
BW 220 D-5 531

Rear scraper
6.
NOTICE!
stand get damaged.
get damaged.
7. Remove all nuts (1) from the fastening bolts between the rear
1 scraper and drum.
WARNING!
crossbar.
B-586-0274
Fig. 538
8. Remove the front bolts on both sides.

1
to the side.
B-586-0369
Fig. 539
532 BW 220 D-5

6.3.1.4 Attaching segments

n Safety shoes
n Protective gloves
1 To fasten the segments together first use

M20 x 135 bolts.
Once all segments are attached to the drum,
replace those bolts with M20 x 85 bolts.
Use new bolts and nuts!
2
B-586-0343
NOTICE!
Fig. 540 – When fastening, always turn the screw itself.
1 Hexagon bolt M20 x 85 (BOMAG – The cap nut is fitted with a knurl which holds
071 320 37) the nut in the retainer.
2 Cap nut M20 with knurl (BOMAG If the retainer on the cap is turned, the knurl
580 038 44) may get damaged which means the required
tightening torque cannot be achieved.
1. Segment
1. Attach suitable lifting tackle to the lifting eyes of the first seg-
ment.
CAUTION!
Danger of crushing when positioning the indi-
vidual segments!
– Never put your hands between the segment
and drum or machine parts.
B-586-0340
Fig. 541
2. Lift the first segment using suitable lifting tackle, position as

centrally as possible on the drum and set down.
B-586-0341
Fig. 542
BW 220 D-5 533

3. Fix the segment to the drum both right and left with a vice.
If there are four vices available, it is useful to

fix the segment front and back with a vice.
4. Start the engine and move the machine back as far as nec-
essary to be able to set down the next segment on the drum
from above.
B-586-0275
Fig. 543
B-ELE-0069
Fig. 544
2. Segment 6. Select the right segment.
CAUTION!
vidual segments!
7. Lift the second segment using suitable lifting tackle, position

as centrally as possible on the drum and set down.
8. Loosely connect the two segments using bolts of length
M20 x 135 (4 to 5 thread turns).
B-586-0341
Fig. 545
534 BW 220 D-5

9. Fix the second segment to the drum both right and left with a
vice.
essary to be able to set down the next segment on the drum
from above.
B-586-0276
Fig. 546
B-ELE-0069
Fig. 547
3. Segment
CAUTION!
vidual segments!
12. Lift the third segment using suitable lifting tackle, position on
the drum and set down.
13. Loosely connect the segments using bolts of length
M20 x 135 (4 to 5 thread turns).
B-586-0344
Fig. 548
BW 220 D-5 535

Tightening segments 1 and 3

14. Replace bolts of length M20 x 135 with length M20 x 85 and
tighten using tightening torque: 578 Nm (426 ft·lbf).
15. Start the engine and move the machine forward as far as
necessary to allow the bolts in the next segment to be
replaced and tightened.
Fig. 549
B-ELE-0069
Fig. 550

18. Start the engine and move the machine forward as far as
necessary to allow the bolts in the next segment to be
replaced and tightened.
Fig. 551
B-ELE-0069
Fig. 552
536 BW 220 D-5


21. Start the engine and test drive for approx. two minutes with
vibration.
Fig. 553
23. Retighten all fastening screws.
24. After approx. 60 minutes work, retighten all fastening screws
again.
B-ELE-0069
Fig. 554

n Safety shoes
n Protective gloves
Front scraper
1. Attach both of the upper half shells of the padfoot scraper to
the front right and left of the machine.
B-586-0345
Fig. 555
BW 220 D-5 537


4. Carefully lift the scraper until it is in the upper retainer half.
B-586-0346
Fig. 556
B-586-0347
Fig. 557

463 Nm (341 ft·lbf).
B-586-0348
Fig. 558
Rear scraper
8. Attach both of the upper half shells of the scraper rear right
and left.
B-586-0349
Fig. 559
538 BW 220 D-5


10.
NOTICE!
stand get damaged.
get damaged.
B-586-0360

11. Carefully lift the scraper until it is in the upper half shells.
B-586-0361
Fig. 561
463 Nm (341 ft·lbf).
B-586-0348
Fig. 562
BW 220 D-5 539

6.3.1.6 Installing the access steps

n Safety shoes
n Protective gloves
Repositioning the steps
1. Remove all four nuts of the upper step.
1
2. Remove the screws and position the step one bore higher
(1).
3. Insert the bolts, screw the nuts on and tighten them.
4. Likewise, install the lower step one bore higher.
1
B-586-0420
Fig. 563
Installing an additional step

5. Place two rubber plates with profiles on the lower bores.
B-586-0422
Fig. 564
7. Position the step with the profiles on the rubber plates.

B-586-0423
Fig. 565
540 BW 220 D-5

6.3.2 Removing the padfoot shells

6.3.2.1 Preliminary remarks and safety notes
Loads are only to be attached and hoisted by an expert/qualified
person.
Do not use lifting points that are damaged or impaired in any other
way.
Only use lifting and lashing tackle with sufficient load bearing
Always use appropriate lifting and lashing tackle at the lifting and
lashing points.
Use lifting tackle only in the specified loading direction.
When lifting the machine, avoid uncontrolled movements of the
load. If necessary, hold the load with guide ropes.
At least two people are required when attaching and detaching the
segments.
n Safety shoes
n Protective gloves

drum.
2. Apply the parking brake.

B-ELE-0069
Fig. 566
BW 220 D-5 541


n Safety shoes
n Protective gloves
Front scraper
B-586-0363
Fig. 567
sides.
3. Carefully set the scraper down on the floor.
1
B-586-0370
Fig. 568

1
2
B-586-0364
Fig. 569
542 BW 220 D-5

Rear scraper
6.
NOTICE!
stand get damaged.
get damaged.
sides.
out from under the machine.
1
B-586-0371
Fig. 571

1
2
B-586-0362
Fig. 572
BW 220 D-5 543

6.3.2.4 Removing segments

n Safety shoes
n Protective gloves
n Safety goggles
1. Attach suitable lifting tackle to the lifting eyes of the first seg-
ment.
2. Secure the segment with suitable lifting tackle.
3.
CAUTION!
Danger of eye injuries caused by particles
flying around!
B-586-0344 (safety gloves, protective working
clothes, goggles).
Fig. 573
Sever the fastening screws from the segments using a flame
cutter or cutting disc.
4. Lift the segment and set aside safely.
essary to attach lifting tackle to the next segment.
B-586-0340
Fig. 574
B-ELE-0069
Fig. 575
544 BW 220 D-5

7. Attach suitable lifting tackle to the lifting eyes of the second

segment.
9. Sever the fastening screws from the segments using a flame
cutter or cutting disc.
B-586-0344
Fig. 576
B-586-0340
Fig. 577
11. Fix the third segment to the drum both right and left with a
vice.
essary to attach lifting tackle to the next segment.
B-586-0275
Fig. 578
B-ELE-0069
Fig. 579
BW 220 D-5 545

14. Attach suitable lifting tackle to the lifting eyes of the third seg-
ment.
16. Undo the vices.
B-586-0340
Fig. 580

n Safety shoes
n Protective gloves
Front scraper
B-586-0273
Fig. 581

1
B-586-0272
Fig. 582
546 BW 220 D-5

Rear scraper
6.
NOTICE!
stand get damaged.
get damaged.
B-586-0338

1
B-586-0274
Fig. 584
6.3.2.6 Removing the access steps

n Safety shoes
n Protective gloves
Removing an additional step
1. Remove all four nuts of the lowest step.
2. Remove the screws and the remove the step with the pro-
files.
B-586-0423
Fig. 585
BW 220 D-5 547

3. Unscrew all four nuts on the frame.

4. Remove the screws and the remove the rubber plates with
the profiles.
B-586-0422
Fig. 586
Repositioning the steps

5. Remove all four nuts of the upper step.
1 6. Remove the screws and position the step one bore lower (1).
8. Likewise, install the lower step one bore lower.
B-586-0421
Fig. 587
548 BW 220 D-5

Machine assemblies – Oscillating articulated joint
6.4 Oscillating articulated joint

6.4.1 Overview................................................................ 549
6.4.2 Dismantling the oscillating articulated joint............ 550
6.4.3 Assembly of oscillating articulated joint................. 551
6.4.1 Overview

1 Oscillating articulated joint
2 Bearing cover
3 Housing
4 Cover
5 Carrier
6 Console
BW 220 D-5 549

6.4.2 Dismantling the oscillating articulated joint

1. Unscrew screw (1) and screws (2).
Fig. 589
2. Force the bearing cover (1) off using the thread (2).
3. Disassemble the opposite bearing cover in the same way.
Fig. 590
4. Remove the console (1).
Fig. 591
5. Unscrew screws (1).
Fig. 592
550 BW 220 D-5

6. Remove the housing (1).
Fig. 593
7. Take off the carrier (1).
Fig. 594
6.4.3 Assembly of oscillating articulated joint

1. Lay the cover (3) on a level base.
2. Apply anti-friction paint to the mating faces of cover and
rocker bearings (2).
3. Knock the rocker bearing into the bore hole.
4. Install the seal ring (1).
Fig. 595
5. Apply anti-friction paint to the mating faces of rocker bearings

(1) and carrier (2).
6. Assemble the rocker bearings.
Fig. 596
BW 220 D-5 551

7. Place the carrier (1) in mounting position on the cover (2).
Fig. 597

Fig. 598
10. Stand the housing (6) on a level base.

11. Insert shims (5) into the bearing bore as per spare parts cata-
logue.
12. Insert the backing disc (4) into the bearing bore.
13. Insert the Belleville springs (3) into the bearing bore. Ensure
correct alignment!
(2) and housing.
Fig. 599 16. Install the seal ring (1).
17. Position the housing (1) above the carrier (2).
18. Check whether the Belleville sprigs are correctly positioned.
If necessary, reposition the Belleville springs.
19. Lower the housing.
20. Bolt housing and cover together.
Fig. 600
552 BW 220 D-5


Fig. 601

Fig. 602

(2) and bearing cover (3).
Fig. 603
28. Stand the bearing cover (1) on a level base.

29. Insert shims (2) into the bearing bore as per spare parts cata-
logue.
30. Insert the backing disc (3) into the bearing bore.
31. Insert the Belleville springs (4) into the bearing bore. Ensure
correct alignment!
(5) and bearing housing.
Fig. 604
BW 220 D-5 553

35. Put the console (1) into place and align it to the carrier (2).
Fig. 605
36. Apply anti-friction paint to the mating faces of console (1) and
bearing cover (3).
37. Turn the guide pins (2) into the threaded bores.
38. Align and assemble the bearing cover.
39. Fasten the bearing cover.
40. Remove the guide pins.
41. Tighten the fastening screws on the bearing cover.
42. Repeat this procedure with two further bearing covers on the
opposite side.
Fig. 606
43. Assemble screws (2).
Fig. 607
554 BW 220 D-5

Machine assemblies – Drive axle
6.5 Drive axle


6.5.2.1 Checking wheels and tyres 556
6.5.3.1 Checking the oil level in the drive axle 557
6.5.3.2 Checking the oil level in the drive axle reduction gear 557
6.5.3.3 Checking the oil level in the wheel hubs 558
6.5.4.1 Change the oil in the drive axle 559
6.5.4.2 Changing the oil in the drive axle reduction gear 560
6.5.4.3 Changing the oil in the wheel hubs 561
6.5.4.4 Retightening the fastening of the axle on the frame 562
6.5.4.5 Retightening the wheel nuts 562
As required
6.5.5.1 Adjust the parking brake 562
BW 220 D-5 555

6.5.2 Checks prior to start up

6.5.2.1 Checking wheels and tyres
WARNING!
Danger of being injured by bursting tyres!
(safety shoes, gloves, goggles, hard hat).
– When checking the tyre pressure stand in the
extended path of the tyre track.
– Use an air hose with a length of min. 6 meters.
– Never exceed the permitted maximum pres-
sure.
The tire pressure can be adapted to the operating

conditions within the specified limits.
A reduced tire pressure improves the traction
especially on sandy soils.
Higher tires pressures improve the driving stability
of the machine.
The total height of the machine can also be influ-
enced by changing the tire pressure.

n Safety shoes
n Protective gloves
n Safety goggles
n Hard hat
1. Move the machine so that the tyre valve is in top position.

3. Check the wheels and tyres for cuts, bulges, damaged rims,
missing wheel studs or nuts.
bar 4. Have damaged wheels or tyres replaced immediately.
psi 5. Unscrew the valve caps and check the front and rear tyre
pressure, correct if necessary.
B-586-0086
Ensure equal pressure in all tyres.
Fig. 608
Tyre pressure nominal value Ä Chapter 2
‘Technical data’ on page 63
6. Screw the valve caps back on again.
556 BW 220 D-5


6.5.3.1 Checking the oil level in the drive axle
NOTICE!
on page 77.

n Protective gloves
2. Clean the area around the level inspection plug (1) and
unscrew the plug.
bore.
A second inspection plug is located on

the left front side of the drive axle.
3. If necessary clean the area around the filler plug (2) and
unscrew the filler plug.
Fig. 609
5. After filling in oil wait until the oil has evenly distributed inside
the axle.
6. Retighten level inspection and filler plugs.
6.5.3.2 Checking the oil level in the drive axle reduction gear
NOTICE!
on page 77.
BW 220 D-5 557


n Protective gloves
the plug.
3. The oil level must reach the bottom edge of the bore, top up
oil if necessary.
4. Turn the level inspection plug tightly back in.
Fig. 610
6.5.3.3 Checking the oil level in the wheel hubs
NOTICE!
on page 77.

n Protective gloves
1. Move the machine until the oil level inspection plug is in hori-
zontal position.
the plug.
4. The oil level must reach the bottom edge of the bore, top up
oil if necessary.
Fig. 611 6. Change the oil in both wheel hubs.
558 BW 220 D-5


6.5.4.1 Change the oil in the drive axle
NOTICE!
on page 77.

one year.

n Protective gloves
2. Clean the area around the drain plug.
WARNING!
Fig. 612
5. Clean the area around the filler plug (2) and the level inspec-
tion plug (1).
A second inspection plug is located on the

left front side of the drive axle.
7. Unscrew the filler plug.

Fig. 613 through the level inspection bore.
9. After filling in oil wait until the oil has evenly distributed inside
the axle, if necessary fill in some more oil.
10. Retighten level inspection and filler plugs.
BW 220 D-5 559

6.5.4.2 Changing the oil in the drive axle reduction gear
NOTICE!
on page 77.

one year.

n Protective gloves
2. Clean the area around drain plug and level inspection plug.
WARNING!
Fig. 614

6. Fill in oil through the inspection bore, until it starts to run out
Fig. 615
560 BW 220 D-5

6.5.4.3 Changing the oil in the wheel hubs
NOTICE!
on page 77.

one year.

n Protective gloves
1. Move the drum, until the oil level inspection plug is in bottom
position.
3. Clean the area around the oil level inspection plug.
WARNING!
Fig. 616
4. Unscrew the level inspection plug and catch any oil running
out.
5. Move the drive wheel, until the oil level inspection plug is in
horizontal position.
6. Fill in oil through the inspection bore, until it starts to run out
8. Change the oil in both wheel hubs.
Fig. 617
BW 220 D-5 561

6.5.4.4 Retightening the fastening of the axle on the frame

1. Check all fastening nuts on axle mounting bolts for tight fit,
retighten if necessary, tightening torque: 800 Nm (590 ft·lbf).
Fig. 618
6.5.4.5 Retightening the wheel nuts

n Protective gloves
1. Tighten the wheel nuts cross-wise, tightening torque: 550 Nm
(405 ft·lbf).
Fig. 619
6.5.5 As required
6.5.5.1 Adjust the parking brake
NOTICE!
Have adjustment work on the brakes only carried
out by a specialist! Always adjust both sides.
1. Secure the machine with wheel chocks against rolling.

2. Start the diesel engine to relieve the brake.
562 BW 220 D-5

1. Disengage the travel lever Ä Fig. 620 to the left, but do not
move to position "I" or "II".
The parking brake is released
Fig. 620
1. Unscrew locking plate 2 Ä Fig. 621.

2. Turn the square (1) in anti-clockwise direction against the
stop.
Fig. 621
1. In order to adjust the brake clearance turn the square 1

Ä Fig. 622 three turns back in clockwise direction.
2. Fasten the locking plate again.
3. Pull the plug off the brake solenoid valve and perform the
drive test.
The machine must be braked.
Fig. 622
BW 220 D-5 563

Machine assemblies – Air conditioning
6.6 Air conditioning

6.6.1 Overview of air conditioning system...................... 564
6.6.2 Physical principles................................................. 567
6.6.3 Refrigerant R134a................................................. 569
6.6.4 Compressor oil / refrigeration oil............................ 571
6.6.5 Working principle of the air conditioning system.... 573
6.6.6 Monitoring devices................................................. 574
6.6.7 Description of components.................................... 575
6.6.8 Compressor........................................................... 580
6.6.9 Emptying in case of repair..................................... 582
6.6.10 Drying and evacuation......................................... 583
6.6.11 Filling instructions................................................. 583
6.6.12 Steam table for R134a......................................... 586
6.6.13 Inspection and maintenance work....................... 590
6.6.1 Overview of air conditioning system
3 2 1
S-586-0456

1 Compressor
2 Condenser
3 Dryer/collector
4 HKL module
564 BW 220 D-5

Optional equipment
BW 220 D-5 565

Fig. 624
1 Compressor
2 Condenser
3 Drier / collector
4 HKL module
566 BW 220 D-5

6.6.2 Physical principles

In order to understand the working principle of an air conditioning
system one must first become familiar with the physical basics of
such a system.
The four well known physical conditions of water apply also for the
refrigerant in the air conditioning system.
1. gaseous (invisible)
2. vaporous
3. liquid
4. solid
If the water in a container is heated up (absorption of heat), the
rising steam is visible. If the steam is heated up further, due to the
absorption of heat, the visible steam will turn into invisible gas. This
process is reversible. When withdrawing the heat contained in gas-
eous water, the gas will turn into steam, then into water and finally
into ice.
Fig. 625
A - heat absorption
B- Heat dissipation
Heat always flows from the warmer to the colder matter. Any
matter consists of a mass of moving molecules. The rapidly moving
molecules or a warmer matter dissipate part of their energy to the
slower moving molecules with less heat. The movement of the mol-
ecules in the warmer matter becomes slower and the molecules in
the cooler matter are accelerated. This process continued, until all
molecules in the two matters move with identical speed. The mat-
ters have then reached an identical temperature and the transfer of
heat stops.
Fig. 626
Pressure and boiling point The boiling point is the temperature at which fluid changes to gas-
eous state.
Changing the pressure above a fluid also changes the boiling
point. It is a well known fact, that e.g. the lower the pressure
applied to water, the lower the boiling point.
When looking at water, the following values do apply:
n Atmospheric pressure, boiling point 100°C
n Overpressure 0.4 bar, boiling point 126°C
n Vacuum -0.6 bar, boiling point 71°C
For an optimal exchange of heat, liquid refrigerants must have a
low boiling point, so that they can absorb and dissipate heat
quickly.
BW 220 D-5 567

Steam pressure curve for refrigerant R134a

The steam pressure curve is a means for explaining the operation
principle of an air conditioning system.
A- liquid
B- gaseous
The diagram shows the evaporation curve of R134a. The diagram
for example shows, that R134a is liquid at 0°C and a pressure of 5
bar, but becomes gaseous at 40°C and 5 bar.
For better understanding one must also be aware of the following:
1. A gas heats up when being compressed (e.g. air pump, turbo
charger, ...).
2. When relieving gas it will cool down (e.g. white frost forms on
the valve when relieving air pressure from a car tire).
Fig. 627: Steam pressure curve 3. Condensing gas dissipates a lot of heat energy.
4. If a fluid evaporates it requires a lot of heat, i.e. the fluid thereby
cools down the surrounding environment (e.g. alcohol on skin)
At absolute pressure 0 bar correspond with an

absolute vacuum. The normal ambient pressure
(overpressure) corresponds with 1 bar absolute
pressure. On the scales of most pressure gauges
0 bar corresponds with an absolute pressure of 1
bar (indicated by the statement -1 bar below the 0).
In the pressure - temperature diagram for the refrigerant the drawn

in closed curve shows the cycle of the refrigerant. This cycle per-
manently continues in direction of the arrow.
The characters A, B, C, D stand for:
A - compression
B- condensation
C- relaxation
D- evaporation.
Fig. 628: Pressure - Temperature

Diagram
Excerpt from the wet steam table

R134aThis table is used for the determination of
evaporation and condensation temperature.
Saturation temperature Overpressure (pressure gauge Absolute pressure (pamb = 1 bar P

reading Pe in bar) in bar)
-20 0,33 1,33
-10 1,01 2,01
568 BW 220 D-5

Saturation temperature Overpressure (pressure gauge Absolute pressure (pamb = 1 bar P

reading Pe in bar) in bar)
0 1,93 2,93
10 3,15 4,15
20 4,72 5,72
6.6.3 Refrigerant R134a

General
The evaporation and condensation process is the method com-
monly used in mobile air conditioning systems. The system in this
case works with a substance that boils at low temperature, a sub-
stance referred to a refrigerant. The refrigerant used is tetrafluoro-
ethane R134a, which boils at a temperature of -26.5°C and under a
steam pressure of 1 bar.
Although the refrigerant circuit is a hermetically closed loop, the
system loses approx. 100g of refrigerant over the course of 1 year
by diffusion through hoses, pipes and seals, even though the
system is free of leaks. If too much refrigerant is lost the cooling
power of the system will drop.
Physical data of the refrigerant R134a
Chemical formula:
CH2F-CF3 or CF3-CH2F
Chemical designation:
Tetrafluoroethane
Boiling point at 1 bar:

- 26.5 °C
Solidification point:
-101.6 °C
Critical temperature:
100,6 °C
Critical pressure:
40.56 bar (absolute)
Critical point:
Critical point (critical temperature and critical pressure) means that
above this point there is no separating interface between liquid and
gas. Above its critical point any substance is gaseous. At tempera-
tures below the critical point all refrigerant types in pressure con-
tainers have a liquid and a gaseous phase, i.e. a gas cushion is
above the liquid. As long as gas is in the container, besides the
liquid, the pressure depends on the ambient temperature.
BW 220 D-5 569

Characteristics of the refrigerant R134a:

Refrigerant R134a is currently available under the following trade
marks. H-FKW 134a SUVA 134a KLEA 134a
Colour:
Refrigerant in form of vapour or liquid is colourless as water. The
gas is invisible. Only the bordering layer between gas and liquid is
visible. (Fluid level in rising pipe of filling cylinder or bubbles in
inspection glass). In the inspection glass the liquid refrigerant
R134a may appear coloured (milky). This turbidity results from par-
tially dissolved refrigeration oil and is no indicator for a fault.
Steam pressure:
In an incompletely filled, closed container, vaporous refrigerant will
volatilize from the surface in the same quantity that will turn liquid
in combination with steam particles. This state of equilibrium
occurs under pressure and is frequently referred to as steam pres-
sure. The steam pressure is independent from the temperature.
Physical properties of R134a:

The steam pressure curves of R134a and other refrigerants are
partly very similar, making a clear differentiation solely by pressure
impossible. With R 134a the compressor is lubricated by special
synthetic refrigeration oils, e.g. PAG-oils (polyalkylene glycol oils).
Behaviour with metals:

In pure condition refrigerant R134a is chemically stable and does
not attack iron and aluminium. However, contamination of the
refrigerant, e.g. with chlorine compounds, leads to aggressiveness
against certain metals and plastics. This can cause clogging, leaks
or deposits on the pistons of the compressor.
Critical temperature / critical pressure:

Up to a gas pressure of 39.5 bar overpressure (this corresponds
with a temperature of 101 °C) the refrigerant R134a remains chem-
ically stable, above this temperature the refrigerant decomposes
(see combustibility).
Water content:
In liquid refrigerant water can only be dissolved in very low quanti-
ties. In contrast to this refrigerant steam mixes with water steam at
any ratio. If the dryer in the liquid container has absorbed approx. 8
gr. of water, the refrigerant circuit transports possibly existing water
in form of droplets. This water flows to the nozzle of the expansion
valve and turns to ice. The air conditioning system stops cooling.
Water destroys the air conditioning system, because under high
pressures and temperatures and in connection with other contami-
nants it forms acids.
Inflammability:
570 BW 220 D-5

Refrigerant is not inflammable. On the contrary, it has fire inhibiting

or fire extinguishing properties. Refrigerant is decomposed by
flames or glowing surfaces. Ultraviolet light also cracks refrigerant
(caused by electric welding). This results in toxic fission products,
these must not be inhaled. However, irritation of the mucous mem-
branes is an early and in-time warning.
Filling factor:
In a container there must be a steam space above the liquid space.
The liquid expands with increasing temperature. The steam filled
space becomes smaller. From a certain time on the container will
be filled with just liquid. After this only a minor temperature
increase is enough to generate very high pressures in the con-
tainer, because the liquid would like to expand, but there is no
more room. The related forces are high enough to cause the con-
tainer to burst. In order to avoid overfilling of a container the pres-
sure gas directive clearly specifies how many kilograms of refrig-
erant may be filled into the container per litre volume. Multiplied
with the internal volume this "filling factor" determines the permis-
sible filling capacity For refrigerants used in motor vehicles it is
1.15 kg/l.
Environmental aspects The contribution of R134a to the greenhouse effect is by factor 10

smaller than the contribution of R12.
Since approx. 1992 the air conditioning systems for newly pro-
duced construction equipment were successively converted to
refrigerant R134a. This refrigerant does not contain any chlorine
and is thus harmless for the ozone layer. Until approx. 1992 air
conditioning systems were filled with refrigerant R12. Due to its
chlorine atoms this CFC has a high ozone decomposition potential
and also a potential to amplify the greenhouse effect. Conversion
programs for existing old systems with the ozone damaging R12
are in effect. For reasons of protecting the environment refrigerant
must not be discharged into the atmosphere.
6.6.4 Compressor oil / refrigeration oil

General
The compressor oil lubricates the movable parts in the compressor,

seals e.g. the gap between piston and cylinder inside the com-
pressor to prevent refrigerant loss and prevents other seals in the
system from drying up.
Part of the compressor oil dissolves in the refrigerant until satura-
tion is reached, so that a gas mixture of refrigerant, water steam,
compressor oil and contrast agent circulates through the system.
Compressor oil (the oil quantity should be 10 % of the refrigerant
weight) mixes with the refrigerant and circulates permanently
through the system.
BW 220 D-5 571

In connection with R134a- air conditioning systems special syn-

thetic compressor oils, e.g. polyalkylene glycol (PAG) oils, are
used. This is necessary, because e.g. mineral oil does not mix with
R134a. Apart from this, the materials in the R134a air conditioning
system may be attacked when the mixture is flowing through the
refrigerant circuit under high pressure and at high temperatures or
if the lubrication film in the compressor tears off. The use of non-
permitted oils can cause damage to the air conditioning system,
you should therefore only used the approved oils.
Properties of compressor oil / The most important properties are high solvency in connection with
refrigeration oil refrigerants, good lubrication characteristics, that they are free of
acids and their low water content. For this purpose only certain oils
can be used. PAG-oils suitable for use with refrigerant R134a are
highly hygroscopic and will not mix with other oil. As a protection
against the invasion of moisture drums must immediately be closed
again after they had been opened. Compressor oil ages under the
effect of moisture and acids, becomes dark, viscous and aggres-
sive against metals.
Compressor oil level / refrigeration

oil level in the compressor NOTICE!
The refrigeration oil level in the compressor must
be checked after replacing a system component or
if a leak in the system is suspected. Use only
refrigeration oil PAG SP-20 (H14-003-404).
When replacing a heat exchanger, e.g. evaporator
or condenser, any compressor oil / refrigeration oil
lost by exchanging the components, must be
replaced with fresh oil.
The actual quantity depends on the amount of oil
that may have been lost in connection with the
possible replacement of other components.
ENVIRONMENT!
Used compressor oil / refrigeration oil must be dis-
posed of as hazardous waste.
The following table shows how much compressor oil / refrigeration

oil will be lost in connection with various types of work on the air
conditioning system.
Reason of oil loss Amount of oil lost

Loss when emptying approx. 15 gr
Defective A/C hose approx. 30 gr
Hose change approx. 15 gr
Replacement of condenser approx. 30 gr
572 BW 220 D-5

Reason of oil loss Amount of oil lost

Replacement of evaporator approx. 30 gr
Replacement of liquid container approx. 30 gr
Replacement of expansion valve approx. 15 gr
NOTICE!
Compressor replacement
New compressors are delivered with an approx.
250 gr.compressor oil filling. To avoid excessive oil
in the A/C-system and thus a poor cooling effect,
the oil level in the A/C-system must be adjusted
accordingly.
The quantity depends on the amount of oil that
may have been lost in connection with the possible
replacement of other components.
The compressor oil quantity must be 10% of the
refrigerant quantity in the complete system.
With a refrigerant filling of 1100 gr. the system
requires a compressor oil / refrigerant oil filling of
110 gr.
Procedure
– Drain and measure the compressor oil from the

old compressor.
– Drain the compressor oil from the new com-
pressor and only fill in the exact quantity that
had been drained out of the old compressor.
The compressor oil from the new compressor
can be used for this purpose.
Topping up compressor oil / refrigeration oil is pos-

sible on a pressureless compressor directly into
the oil pan, in a pressureless refrigeration system
directly into the pressure side, but it is also pos-
sible to draw it into the pressure side of the refrig-
eration system during the evacuation process.
6.6.5 Working principle of the air conditioning system

All air conditioning systems are based on the same principle. They
extract heat from the surrounding environment. Everybody knows
the effect: if a sweating body is exposed to wind it will cool down,
because heat is extracted. For this purpose a refrigerant circulates
in a closed circuit inside the vehicle. This refrigerant thereby con-
tinuously changes its physical state between liquid and gaseous.
BW 220 D-5 573

An engine driven compressor (1) draws in gaseous refrigerant from

the evaporator (5) and compresses it. During this process the tem-
perature of the refrigerant increases tremendously.
The refrigerant vapour is then pumped to the condenser (2). This
condenser is arranged directly in front of the vehicle radiator, so
that a sufficient air flow is assured. In the condenser (2) the gas is
cooled down and consequently liquefied.
In the dryer / liquid container (3) the refrigerant is then collected
and freed of moisture and contaminants.
Fig. 629: Principle sketch of an air The expansion valve (4) regulates the flow rate from the dryer /
conditioning system liquid container (3) back to the evaporator (5) and the circuit starts
again.
6.6.6 Monitoring devices

Pressure switch, B105 The pressure switch (8) is used as monitoring feature for too high
and too low pressures. The switching contacts (4 and 5) effect the
magnetic clutch of the compressor via a relay (6).
If the system pressure increases excessively, e.g. because of a
excessively soiled condenser, a failed fan or a defective expansion
valve, the high pressure contact (5) will cut off the electric power
supply to the magnetic clutch when the set pressure is reached.
When the system pressure drops below the cut-off pressure by the
set differential pressure, the magnetic clutch of the compressor is
switched on again.
The low pressure contact (4) interrupts the electric power supply to
the magnetic clutch when the set pressure is fallen short of (pos-
sible causes: lack of refrigerant, defective expansion valve, too low
heat load, defective evaporator fan, ...). Since the refrigerant
R134a has an evaporation temperature of 0 °C at an overpressure
of 2 bar, the low pressure contact (4) is set to approx. 1.5 bar to
avoid icing. The switch on pressure is 0.5 to 2 bar higher than the
shut-off pressure (depending on system, see description of compo-
nents).
Thermostat A frost protection thermostat (3) protects the evaporator against

icing. Similar to the pressure switch, the thermostat activates or
deactivates the magnetic clutch for the compressor. Depending on
the design, the feeler of the temperature control is mounted
between the fins of the evaporator or attached to the evaporator
outlet (suction side). With fixed temperature controls the control
switches the compressor off at about 1 °C and back on again at
about 2.5°C to 5.5 °C (depending on system, see description of
components.)
With adjustable temperature regulators the switching point can be
changed so that the compressor is already shut down at higher
temperatures. This enables regulation of the air temperature.
574 BW 220 D-5

Monitoring chain
1 Switches
2 Fuse
3 Thermostat
4 Low pressure switch contact
5 High pressure switch contact
6 Relays
7 Connection for magnetic clutch
8 Pressure switch
Fig. 630: Monitoring chain
6.6.7 Description of components

Condenser
The condenser is located in front of the radiator for the machine. It
emits heat energy from the system into the surrounding air and liq-
uefies the gaseous refrigerant.
WARNING!
Danger of injury caused by exploding compo-
nent!
– Do not clean the condenser in the air condi-
tioning system with a hot water jet.
Fig. 631
The fins must be free of dirt and damage.
NOTICE!
or condenser, any compressor oil lost by
exchanging the components, must be replaced
with fresh oil.
Dryer / filter / fluid container /

inspection glass
Dryer / filter
The fluid container collects the fluid drops and passes these then
as a constant flow to the expansion valve. Moisture that has
entered during assembly of the refrigerant circuit is absorbed by a
dryer in the fluid container.
At evaporation temperatures below zero the refrigerant will deposit
previously absorbed moisture on the expansion valve, where this
water turns into ice and thus adversely affects the controllability of
the expansion valve. Moreover, moisture in the refrigerant circuit
causes corrosion, forms acids and enters into chemical composi-
tions.
Fig. 632
BW 220 D-5 575

Inside the refrigerant container the heavy liquid refrigerant collects

in the lower part of the container, flows through a rising pipe to the
outlet marked "A" and thus ensures bubble free operation of the
expansion valve.
Since the absorbing capacity of this filter/dryer is

limited, it must be changed within certain service
intervals. We recommend to replace it 1 x per
years, before the start of the season.
NOTICE!
The filter/dryer must generally be replaced when-
ever opening the refrigerant circuit, because mois-
ture will enter in such a case.
This requires emptying the air conditioning system!
Installation position:
The arrow marks on the filter/dryer must point in
flow direction, i.e. towards the expansion valve.
Filter/dryer cannot be treated for further use!
Pressure relief valve

The fluid container is equipped with a safety valve.
Response pressure 32 +/- 4 bar
Tightening torque 10 - 15 Nm
Fig. 633
Inspection glass
During operation the refrigerant must flow through the inspection
glass without air bubbles. In most cases the presence of air bub-
bles is a sign for a too low refrigerant level in the system. Apart
from this, the refrigerant may not sufficiently condense as a result
of a soiled evaporator or a defective condenser fan and the fluid
level in the refrigerant container may drop down to a level, at which
gaseous refrigerant could flow through the rising tube to the
inspection glass. This results in abnormally high temperatures in
and on the fluid lines (between refrigerant container and expansion
valve), as well as very high pressures in the pressure side.
However, incorrect evacuation or filling may also be the reason for
Fig. 634 air entering into the system and since air cannot be condensed,
one will not be able to get rid of these bubbles by topping up refrig-
erant. In this case the air conditioning system needs to be evacu-
ated and refilled.
576 BW 220 D-5

Air in the system is characterized by high pres-

sures and temperatures.
On R134a refrigeration systems from KONVEKTA the inspection

glasses are equipped with moisture indicators. In addition to the
float, the dryer/collector/inspection glass combination has an indi-
cator pearl integrated in the inspection glass, which changes its
colour when absorbing moisture.
The refrigerant level should be inside the inspection glass and
should only be checked after approx. 5 minutes continuous opera-
tion, because the refrigerant must first evenly distribute all over the
system.
WARNING!
In case of mechanical damage or corrosion on this
pressure container this collector unit must be
replaced, to avoid bursting and further damage.
Expansion valve
The expansion valve is mounted inside the HKL-module in the

cabin. The expansion valve always allows a small amount of the
high pressure liquefied refrigerant to flow into the evaporator, which
has a much lower pressure. This lower pressure causes these
liquid refrigerant to expand and to evaporate to gaseous state. The
heat required for this evaporation process is taken from the
ambient air through the lamellas and supplied to the refrigerant.
This is the so-called cooling effect.
The thermostatic expansion valve operates with an external pres-
sure compensation. This type of expansion valve works with high
accuracy, because it uses pressure and temperature at the evapo-
rator outlet and adjusts and overheating of approx. 7 K. The
already installed expansion valves and the ones delivered as spare
parts have this overheating value pre-set. In order to prevent a loss
Fig. 635 in performance or compressor damage you should only use orig-
inal expansion valves, because adjusting expansion valves takes a
lot of time and care.
In case of dirt in the refrigerant system you should

also check or clean the screen at the expansion
valve inlet.+
BW 220 D-5 577

Evaporator
The evaporator is mounted inside the HKL-module in the cabin. It

consists of a heat exchanger (inside air - refrigerant), with refrig-
erant flowing to a pipe system with cooling flanges.
As with the condenser, correct operation of all fans and cleanliness
of the fins must be assured.
Air conditioning systems have a circulation air filter mounted in the
air flow in front of the evaporator, which should be cleaned or
changed by the operator after each third trip, depending on the
amount of dirt.
A condensation water filter is mounted in the air flow after the
evaporator. This filter has the function to collect the water that has
condensed from the air in the evaporator block and to discharge
this water into the water pan With a defective condensation water
Fig. 636 filter condensation water may flow into the inside of the vehicle.
NOTICE!
or condenser, any compressor oil lost by
exchanging the components, must be replaced
with fresh oil.
Thermostat
Thermostat with fixed setting

The feeler of a defroster thermostat to switch off the magnetic
clutch in case of icing up or to switch the clutch back on after
defrosting, is mounted on the evaporator.
With fixed temperature controls the control switches the com-
pressor off at about +1 °C and back on again at about +2.5°C to
+5.5 °C.
Fig. 637
Adjustable thermostat
With adjustable temperature regulators the switching point can be
changed so that the compressor is already shut down at higher
temperatures. This enables regulation of the air temperature.
578 BW 220 D-5

The adjusted temperature must be below the

actual temperature inside the cabin, so that the
compressor will be switched on.
Fig. 638: adjustable temperature con-

troller
Pressure switch
Pressure switch B104

After a minimum pressure is reached on the low pressure side or a
maximum pressure on the high pressure side, the pressure switch
will switch off the magnetic clutch of the compressor to avoid
destruction of system components caused either by excessive
pressure or by drawing in external gases and foreign matter due to
a pressure which is too low.
Working pressure:
Low pressure off: 1.5 ± 0.5 bar
Low pressure on: 3.5 bar
Overpressure off: 25.0 ± 1.5 bar
Fig. 639
Overpressure on: 18.0 ± 1.5 bar
Pipes and hoses
Pipes and hoses in air conditioning systems must meet very high
requirements with respect to resistance against heat and pressure.
The requirements concerning leak tightness and, in case of hoses,
against diffusion, i.e. seepage of refrigerant through the hose
material, are very high. Pipes and hoses to be used must therefore
be specially made for air conditioning purposes. For this reason the
hoses have an inside lining of butyl rubber and an outside coating
of EDPM rubber. Hose sections exposed to heat are provided with
a special heat insulation.
O-rings are made of a special type of chloroprene rubber (neo-
prene). Before assembly of the air conditioning system these O-
rings must be lubricated with compressor oil / refrigeration oil. The
O-rings must always be replaced when assembling A/C-compo-
nents.
Recommended tightening torques for O-ring sealed fittings
BW 220 D-5 579

Thread Spanner width Torque

5/8“ 17 or 19 13.6 - 20.3 Nm
3/4“ 32.5 - 39.3 Nm
7/8“ 27 35.3 - 42.0 Nm
1 1/16“ 32 40.7 - 47.5 Nm
M30X2 36 105.0 - 115.0 Nm
M36X2 41 165.0 - 175.0 Nm
Bending radii for air conditioning hoses
Hose type Nominal width Bending radius

GH 134 NW8 min. 50 mm
GH 134 NW16 min. 100 mm
GH 494 NW20 min. 160 mm
GH 494 NW25 min. 194 mm
GH 494 NW32 min. 225 mm
6.6.8 Compressor
Structure
Fig. 640: Refrigerant compressor
580 BW 220 D-5

1 Refrigerant compressor 7 Pressure plate

2 Belt pulley 8 Driver disc
3 Melting fuse 9 Swash disc
4 Refrigerant compressor shaft 10 Piston (7 pieces, uniformly distributed over the entire circumference)
5 Ball bearing 11 Slipper pad
6 Magnetic coil 12 Swash plate chamber
A Suction valve B Pressure valve
Magnetic clutch The belt pulley (2) runs on a bearing on the refrigerant compressor
housing. It is driven by the ribbed V-belt and rotates on the ball
bearing (5) around the magnetic coil (6), which is mounted to the
refrigerant compressor housing. The pressure plate (7) is con-
nected to the shaft of the refrigerant compressor (4) by means of a
splined connection. It consists of 2 rings, which are connected by a
resilient plate.
The magnetic coil (6) is energized to start up the refrigerant com-
pressor (1). The magnetic force pulls the outer ring of the pressure
plate (7) against the belt pulley (2) and holds it in position. This
causes a positive connection between pressure plate (7) and belt
pulley (2).
Once the magnetic coil (6) is de-energized, spring force will return
the outer ring of the pressure plate (7) back to its rest position and
the flow of force is interrupted. This ensures switching off of the
refrigerant compressor in case of a mechanical defect.
Delivery process Once the magnetic coupling of the refrigerant compressor (1) has
caused the frictional connection, the shaft of the refrigerant com-
pressor (4) will drive the swash plate (9) via the driver disc (8). The
revolving slanted swash plate (9) causes a stroke movement of the
7 pistons (10), which are evenly distributed along the circumfer-
ence.
The pistons (10) are thereby actuated by slipper pads (11).
During the suction stroke gaseous refrigerant flows through the
suction valve (A) into the corresponding cylinder. When the stroke
of the piston (10) is reversed, it compresses the gaseous refrig-
erant, until the pressure inside the cylinder becomes so high, that
the pressure valve (B) opens and allows the refrigerant to flow
through the compressor outlet and thus into the refrigerant circuit.
The refrigerant compressor (1) has integrated chambers both on
the suction and on the pressure side, which have the function to
dampen resonances, which are generated by suction and com-
pression.
Displacement control The refrigerant compressor (1) is designed in such a way, that
already has sufficient flow rate to keep up the refrigerant circuit,
even at a slow vehicle speed and low engine speed.
BW 220 D-5 581

Since the flow rate of the refrigerant compressor (1) rises with
increasing engine and travel speed, the flow rate needs to be
reduced or regulated.
This is to avoid that the refrigerant compressor (1) unnecessarily
uses engine power.
The flow rate is controlled by switching the magnetic coupling on
and off.
Safety contgrol of the refrigerant To prevent the ribbed V-belt jumping off in case of a mechanical
compressor (1) defect of the refrigerant compressor (1), the magnetic coupling will
disengage automatically.
In case of a mechanical defect the refrigerant compressor (1) will
be harder to turn or may even block completely. The heat created
on the friction surface of the V-belt (2) blows a meting fuse (3) in
the magnetic coil (6). This interrupts the power supply to the mag-
netic coil (6) and releases the frictional connection.
Service valves The service valves are installed directly on the compressor. These
are used to e.g. evacuate and fill the system.
6.6.9 Emptying in case of repair

For repair work the air conditioning systems must very often be
emptied of all refrigerant.
Especially with expensive refrigerants and larger amounts of oil it
may be necessary to keep the refrigerant for later use.
For later use these refrigerants must be drawn out with suitable
equipment and intermediately stored in collecting containers.
ENVIRONMENT!
Contaminated refrigerant must be disposed of
environmentally
Releasing refrigerant into the atmosphere is pro-
hibited (see restrictive injunction concerning CFC,
day of enforcement 01. 08. 1991, § 8)
WARNING!
For draining refrigeration systems you should not
simply use any delivery containers, but only appro-
priate pressure bottles, which must be specially
marked and should comply with the pressure gas
directive.
When transferring refrigerant you must make sure
that the bottle does not contain more than the per-
mitted amount of refrigerant in litres and has suffi-
cient gas space for expansion (filling factor: 0,7).
582 BW 220 D-5

In order to reduce the evacuation period in case of short repairs,

you may fill the refrigerant circuit with approx. 0.5 bar nitrogen
when opening. This ensures that nitrogen will flow out of the refrig-
erant circuit while it is open and no air or moisture can enter. How-
ever, the necessity for vacuum generation and a dryer change
remains.
6.6.10 Drying and evacuation

Evacuation of air conditioning systems using R-type refrigerants
not only has the purpose of emptying the system of all air before
filling in refrigerant, but also to verify the leak tightness over a
longer lifetime in the achieved vacuum. However, the most impor-
tant factor in this work step is the drying of the system.
Any water residues in the refrigerant circuit will combine with the
refrigerant, which will lead to the previously described consequen-
tial damage.
Vacuum pumps with a capacity of more than 100 l/min and a final
pressure of less than 30 micron, i.e. 0.039 mbar should be used to
evacuate the refrigeration system.
The refrigerant compressor is not suitable for the purpose of evac-
uation, because it is not able to achieve a sufficient final vacuum
and, apart from this, may be mechanically damaged because of a
lack of lubrication when running empty during evacuation.
It is common practice to evacuate the refrigeration system to a final
vacuum of 1 Torr, i.e. 1.33 mbar.An exact time for evacuation and
drying cannot be predicted. It can only be determined by means of
a vacuum meter. However, if there is no vacuum meter at hand it is
generally better to evacuate 1 hour longer than 1 hour too less.
Function drying:
Under normal ambient pressure (1.013 mbar) evaporates absolute
at 100° C. If the pressure is reduced, water will already evaporate,
e.g. under a pressure of 10 mbar, at an ambient temperature of
almost 7°C, but the water will not evaporate all at once. Since it is
very difficult to separate the steam from the vacuum in the system,
the evacuation process is supported by the co-called vacuum
breaking (filling the circuit with dried nitrogen). With vacuum
breaking the filled in dried nitrogen absorbs the moisture in the
refrigerant circuit, which can then be easily discharged together
with the nitrogen.
6.6.11 Filling instructions

Filling of refrigerant into the dried, vented and oil filed machines
takes place under various conditions.
In most large series production facilities highly complicated equip-
ment is available for this purpose, whereas individual machines at
the place of installation must be filled directly from the refrigerant
container.
BW 220 D-5 583

Liquid refrigerant is only used to pre-fill the pressure side of the

evacuated refrigeration system (protective filling).
After switching the refrigeration system on and watching the
inspection glass, gaseous refrigerant can be filled into the system
while the engine is running, if the refrigerant level is found to be too
low (gas bubbles in the inspection glass).
NOTICE!
Liquid refrigerant in the suction side of the com-
pressor should generally be avoided during filling
and operation of the refrigeration system, since
this could damage the compressor..
When filling the air conditioning system directly from the refrigerant
bottle care must be taken not to overfill the system. As an addi-
tional control and for statistical purposes, e.g. for refilling, it is
important to write down the weight of the filled in refrigerant.
With correct operation of the air conditioning the refrigerant con-
tainer should be about 1/3 filled with liquid refrigerant, the evapo-
rator should be maximally filled at the calculated evaporation tem-
perature, i.e. the suction line should only be a few degrees warmer
than the evaporation temperature indicated by the pressure gauge.
White frost on the suction line is no measure for

assessing the filling.
584 BW 220 D-5

Fig. 641
Pos Designation Pos Designation

1 High pressure - gaseous 13 Manual shut-off valve (not used)
2 High pressure - liquid 14 Pressure switch with high and low pressure contacts
3 Low pressure - gaseous 15 Defroster thermostat
4 Compressor 16 Vacuum meter
5 Compressor pressure switch (not used) 17 Low pressure gauge
6 not used 18 High pressure gauge
7 Evaporator 19 Pressure reducing valve
8 Expansion valve 20 Vacuum pump
9 Inspection glass 21 Nitrogen bottle
10 Filter drier 22 Refrigerant bottle
BW 220 D-5 585

Pos Designation Pos Designation

11 Collecting container 23 Pressure gauge bar
12 Capacitor
Filling instructions
6.6.12 Steam table for R134a

Tempera- Pressure Density spec. volume spec. enthalpy Evapora-
ture tion heat
of the of the of the of the of the of the
fluid steam fluid steam fluid steam
t p p' p'' v' v'' h' h'' r
°C bar kg/dm3 kg/dm3 dm3/kg dm3/kg kJ/kg kJ/kg kJ/kg
-60 0.16 1.469 0.92 0.681 1082.6 123.17 359.85 236.68
-55 0.22 1.456 1.24 0.687 803.83 129.49 362.99 233.5
-50 0.29 1.443 1.65 0.693 606.45 135.75 366.14 230.39
-45 0.39 1.429 2.15 0.7 464.29 141.98 369.28 227.3
-40 0.51 1.415 2.78 0.707 360.3 148.21 372.41 224.19
-35 0.66 1.401 3.53 0.714 283.08 154.47 375.52 221.05
-30 0.84 1.387 4.45 0.721 224.97 160.78 378.61 217.84
-25 1.06 1.373 5.53 0.728 180.67 167.14 381.68 214.55
-24 1.11 1.37 5.78 0.73 173.12 168.42 382.29 213.88
-23 1.16 1.367 6.03 0.732 165.95 169.7 382.9 213.2
-22 1.22 1.364 6.28 0.733 159.14 170.98 383.51 212.53
-21 1.27 1.361 6.55 0.735 152.66 172.27 384.12 211.85
-20 1.33 1.358 6.83 0.736 146.5 173.56 384.72 211.16
-19 1.39 1.355 7.11 0.738 140.64 174.86 385.33 210.47
-18 1.45 1.352 7.4 0.74 135.06 176.15 385.93 209.78
-17 1.51 1.349 7.71 0.741 129.75 177.45 386.53 209.08
-16 1.57 1.346 8.02 0.743 124.68 178.75 387.13 208.38
-15 1.64 1.343 8.34 0.745 119.86 180.06 387.73 207.67
-14 1.71 1.34 8.68 0.746 115.26 181.37 388.33 206.96
-13 1.78 1.337 9.02 0.748 110.87 182.68 388.93 206.25
-12 1.85 1.334 9.37 0.75 106.68 183.99 389.52 205.53
586 BW 220 D-5


ture tion heat
t p p' p'' v' v'' h' h'' r
-11 1.93 1.331 9.74 0.752 102.68 185.31 390.11 204.8
-10 2.01 1.328 10.12 0.753 98.86 186.63 390.71 204.07
-9 2.09 1.324 10.5 0.755 95.21 187.96 391.3 203.34
-8 2.17 1.321 10.9 0.757 91.73 189.28 391.88 202.6
-7 2.26 1.318 11.31 0.759 88.39 190.61 392.47 201.86
-6 2.34 1.315 11.74 0.76 85.21 191.94 393.06 201.11
-5 2.43 1.312 12.17 0.762 82.16 193.28 393.64 200.36
-4 2.53 1.309 12.62 0.764 79.24 194.62 394.22 199.6
-3 2.62 1.305 13.08 0.766 76.44 195.96 394.8 198.84
-2 2.72 1.302 13.56 0.768 73.77 197.3 395.38 198.08
-1 2.82 1.299 14.04 0.77 71.2 198.65 395.96 197.31
0 2.93 1.296 14.55 0.772 68.75 200 396.53 196.53
28 7.27 1.196 35.66 0.836 28.04 238.96 411.71 172.75
29 7.48 1.192 36.73 0.839 27.22 240.4 412.21 171.81
30 7.7 1.189 37.83 0.841 26.44 241.83 412.71 170.87
31 7.93 1.185 38.95 0.844 25.67 243.28 413.2 169.92
32 8.16 1.181 40.1 0.847 24.94 244.72 413.69 168.97
33 8.39 1.177 41.28 0.85 24.22 246.17 414.18 168
34 8.63 1.173 42.49 0.853 23.53 247.63 414.66 167.03
35 8.87 1.169 43.74 0.856 22.86 249.08 415.14 166.05
36 9.12 1.164 45.01 0.859 22.22 250.55 415.61 165.07
37 9.37 1.16 46.31 0.862 21.59 252.01 416.08 164.07
38 9.63 1.156 47.65 0.865 20.99 253.48 416.55 163.07
39 9.9 1.152 49.02 0.868 20.4 254.96 417.01 162.05
40 10.17 1.148 50.43 0.871 19.83 256.44 417.47 161.03
41 10.44 1.143 51.87 0.875 19.28 257.92 417.92 160
42 10.72 1.139 53.35 0.878 18.74 259.41 418.37 158.96
43 11.01 1.135 54.87 0.881 18.23 260.9 418.81 157.9
44 11.3 1.13 56.42 0.885 17.72 262.4 419.24 156.84
45 11.6 1.126 58.02 0.888 17.24 263.91 419.68 155.77
BW 220 D-5 587


ture tion heat
t p p' p'' v' v'' h' h'' r
46 11.9 1.121 59.65 0.892 16.76 265.42 420.1 154.68
47 12.21 1.117 61.33 0.895 16.3 266.94 420.52 153.58
48 12.53 1.112 63.06 0.899 15.86 268.46 420.93 152.47
49 12.85 1.108 64.82 0.903 15.43 269.99 421.34 151.35
50 13.18 1.103 66.64 0.907 15.01 271.53 421.74 150.21
51 13.51 1.098 68.5 0.91 14.6 273.07 422.14 149.06
52 13.85 1.094 70.41 0.914 14.2 274.62 422.52 147.9
53 14.2 1.089 72.38 0.919 13.82 276.18 422.9 146.72
54 14.55 1.084 74.39 0.923 13.44 277.75 423.28 145.53
55 14.91 1.079 76.47 0.927 13.08 279.32 423.64 144.32
56 15.28 1.074 78.59 0.931 12.72 280.91 424 143.09
57 15.66 1.069 80.78 0.936 12.38 282.5 424.35 141.85
58 16.04 1.064 83.03 0.94 12.04 284.1 424.69 140.58
59 16.42 1.059 85.34 0.945 11.72 285.71 425.02 139.3
60 16.82 1.053 87.72 0.949 11.4 287.34 425.34 138
61 17.22 1.048 90.16 0.954 11.09 288.97 425.65 136.68
62 17.63 1.043 92.68 0.959 10.79 290.61 425.95 135.34
63 18.04 1.037 95.27 0.964 10.5 292.26 426.24 133.97
64 18.47 1.032 97.94 0.969 10.21 293.93 426.51 132.58
65 18.9 1.026 100.69 0.975 9.93 295.61 426.78 131.17
66 19.34 1.02 103.53 0.98 9.66 297.3 427.03 129.74
67 19.78 1.014 106.45 0.986 9.39 299 427.27 128.27
68 20.24 1.009 109.46 0.992 9.14 300.72 427.5 126.78
69 20.7 1.003 112.58 0.997 8.88 302.45 427.71 125.26
70 21.17 0.996 115.79 1.004 8.64 304.19 427.9 123.71
71 21.65 0.99 119.11 1.01 8.4 305.95 428.08 122.13
72 22.14 0.984 122.55 1.016 8.16 307.73 428.25 120.52
73 22.63 0.977 126.11 1.023 7.93 309.52 428.39 118.87
74 23.13 0.971 129.79 1.03 7.7 311.33 428.51 117.19
75 23.65 0.964 133.6 1.037 7.48 313.15 428.62 115.46
588 BW 220 D-5


ture tion heat
t p p' p'' v' v'' h' h'' r
76 24.17 0.957 137.56 1.045 7.27 315 428.7 113.7
77 24.7 0.95 141.67 1.052 7.06 316.86 428.76 111.9
78 25.23 0.943 145.95 1.06 6.85 318.74 428.79 110.05
79 25.78 0.936 150.4 1.069 6.65 320.64 428.8 108.15
80 26.34 0.928 155.03 1.078 6.45 322.57 428.77 106.21
81 26.9 0.92 159.87 1.087 6.26 324.51 428.72 104.21
82 27.48 0.912 164.92 1.096 6.06 326.48 428.63 102.15
83 28.06 0.904 170.22 1.106 5.87 328.47 428.5 100.04
84 28.66 0.895 175.77 1.117 5.69 330.48 428.34 97.86
85 29.26 0.887 181.6 1.128 5.51 332.52 428.12 95.61
86 29.88 0.878 187.75 1.14 5.33 334.58 427.86 93.29
87 30.51 0.868 194.25 1.152 5.15 336.67 427.55 90.88
88 31.14 0.858 201.14 1.165 4.97 338.78 427.17 88.39
89 31.79 0.848 208.48 1.179 4.8 340.92 426.72 85.8
90 32.45 0.837 216.31 1.195 4.62 343.09 426.2 83.1
91 33.12 0.826 224.73 1.211 4.45 345.29 425.58 80.29
92 33.8 0.813 233.84 1.229 4.28 347.53 424.86 77.33
93 34.49 0.801 243.77 1.249 4.1 349.79 424 74.21
94 35.19 0.787 254.71 1.271 3.93 352.08 422.99 70.91
95 35.91 0.771 266.92 1.296 3.75 354.41 421.78 67.37
96 36.64 0.755 280.84 1.325 3.56 356.77 420.3 63.53
97 37.39 0.736 297.17 1.359 3.37 359.17 418.44 59.27
98 38.14 0.714 317.43 1.4 3.15 361.6 415.97 54.37
99 38.92 0.687 346.24 1.455 2.89 364.07 412.16 48.09
100 39.71 0.65 636.32 1.537 1.57 366.58 375.04 8.46
101.06 40.56 0.515 515.3 1.941 1.94 390.05 390.05 0
BW 220 D-5 589



6.1.9.3.2 Checking, tensioning the V-belt of the air conditioning compressor 445
6.6.13.2.2 Changing the fresh air filter in the cabin 592
6.6.13.3.1 Servicing the air conditioning system 593
6.1.9.5.2 Replacing the air conditioning compressor V-belts 452
6.6.13.4.2 Cleaning the circulation air filter of the heating 596
As required
6.6.13.5.1 Checking the compressor oil level / refrigeration oil level 597

6.6.13.2.1 Checking, tensioning the V-belt of the air conditioning compressor
Checking the condition of the V-belt

n Safety shoes
n Protective gloves
1. Check the entire circumference of the belt for damage and
cracks.
2. Replace a damaged or torn V-belt Ä Chapter 6.1.9.5.2
‘Replacing the air conditioning compressor V-belts’
on page 452.
B-870-0278
Fig. 642
590 BW 220 D-5

Checking the V-belt tension

n Protective gloves
Tool: n Belt tension tester
1. Press the indicator arm (a) of the tester into the gap of the
measuring scale.
2. Place the meter in the middle between the V-belt pulleys on
the back of the belt.
Fig. 643
3. Actuate the push button (b) evenly with a finger under a right
angle to the belt, until the pressure spring disengages audibly
and noticeably.
ð The indicator arm remains in the measured position.
4. Take the measuring unit carefully off, without moving the indi-
cating arm.
Fig. 644
5. Read the belt tension where the upper edge of the indicating
arm intersects with the measuring scale.
Belt tension nominal value
during initial assembly (new 400 N (90 lbf) (cold)
belt)
after a running-in time, in 300 N (67 lbf)
case of reassembly
6. Tighten the belt, if necessary.
Fig. 645
BW 220 D-5 591

Tightening the V-belt

n Safety shoes
n Protective gloves
2 specified value.
1 3. Retighten the screw (1).
B-870-0279
Fig. 646
6.6.13.2.2 Changing the fresh air filter in the cabin

n Protective gloves
2. Pull the fastening pins out of the left cover and remove the
cover.
Fig. 647
3. Loosen the fastening screw.

4. Also remove the cover from the right hand side and loosen
the fastening screw.
Fig. 648
592 BW 220 D-5

5. Tilt the console towards the front screen and hold it.
Fig. 649
6. Take out the filter.

7. Insert the new filter and fold the console down again.
8. Tighten the left and right fastening screws and reinstall the
covers.
Fig. 650

6.6.13.3.1 Servicing the air conditioning system
Cleaning the condenser
n Protective gloves
n Safety goggles
BW 220 D-5 593

The air conditioning condenser is located in front of

the radiator.
LUFT 3.
CAUTION!
AIR Danger of eye injuries caused by particles
flying around!
(safety gloves, protective working
clothes, goggles).
Clean the condenser fins with compressed air or water.

B-586-0134
Fig. 651
Air conditioning function test

2. Switch the fan to the highest stage.
3. Choose the lowest cabin temperature.
4. Switch the air conditioning on.
5. Direct the air flow into the cabin and check, that the flowing
out air is considerably cooler.
ð If the outflowing air is considerably cooler, the air condi-
tioning system is in good working order.
Fig. 652
a Adjust the air distribution
b Regulate the cabin temperature
c Air conditioning on/off
d Fan on/off
Checking the condition of the drier/collector unit
Have the drier/collector unit replaced by our cus-

tomer service once every year before the operating
season.
594 BW 220 D-5

1. Check the drier/collector unit for mechanical damage or rust.

2. In case of mechanical damage or rust, have the drier/
collector unit immediately replaced by our customer service.
4. Switch the air conditioning on.
B-920-0067
Fig. 653
5. Check the moisture indication pearl inside the inspection

glass of the drier/collector unit.
orange The degree of moisture in the drying

agent is correct.
colourless Moisture level of drying agent too
high
6. If the moisture level of the drying agent is too high, have the
drier/collector unit replaced by our customer service.
B-920-0068
Fig. 654
7. Check the white floating ball inside the inspection glass of the
drier/collector unit.
Ball floats right on top The refrigerant level is cor-

rect.
Ball floats at bottom The refrigerant level is not
correct.
8. If the refrigerant level is too low, have the air conditioning

system inspected by our customer service.
B-920-0069
Fig. 655

6.6.13.4.1 Replacing the air conditioning compressor V-belts

two years.

n Protective gloves
BW 220 D-5 595

3. Loosen the screws (2, 3, 4) on the air conditioning com-

pressor.
4. Relieve the V-belt with the tensioning screw (1) and take it
off.
5. Install the new V-belt for the air conditioning compressor.
specified value Ä Chapter 6.1.9.3.2.2 ‘Checking the V-belt
tension’ on page 445.
7. Tighten screws (2, 3, 4) again.
Fig. 656
6.6.13.4.2 Cleaning the circulation air filter of the heating

n Safety shoes
n Protective gloves
2. Loosen the locks and remove the cover.
3. Take out the filter.
4. Clean the filter, replace if necessary.
5. Insert the filter and reinstall the cover.
B-GEN-0073
Fig. 657
596 BW 220 D-5

6.6.13.5 As required
6.6.13.5.1 Checking the compressor oil level / refrigeration oil level
NOTICE!
The compressor oil level must be checked after
replacing a system component or if a leak in the
system is suspected. Use only compressor oil /
refrigeration oil PAG SP-20 (H14-003-404).
1. Run the compressor for 10 minutes at engine idle speed.

2. remove the refrigerant from the air conditioning system.
3. Turn the compressor, as shown in Ä Fig. 658, if necessary
remove V-belt and hoses.
4. Remove the oil plug (the oil level must reach the bottom edge
of the bore, top up or drain off oil if necessary).
5. Turn the oil plug back in (tightening torque 15 to 25 Nm).
6. Refill the air conditioning system.
Fig. 658
BW 220 D-5 597

Machine assemblies – Auxiliary heating, AIRTRONIC
6.7 Auxiliary heating, AIRTRONIC

6.7.1 Description of function........................................... 599
6.7.2 Fuse assignment................................................... 602
6.7.3 Control panel......................................................... 603
2 3
1
S-586-0459

1 Heater unit, E30
2 Air filter
3 Timer (S28) and fuses (F320 and F321)
4 Fuel filter and pump for heating unit, Y14/M57
Optional equipment
598 BW 220 D-5

6.7.1 Description of function
9
8
1 2 3 4 5 6 7
10
W
F
B
19 15 14 13
12 11
V 17
18
A
16
S-586-0260
Fig. 660
1 Hot air fan wheel
2 Control unit
3 Combustion air fan wheel
4 Glow plug
5 Cover
6 Heat exchanger
7 Combined sensor (overheating/flame sensor)
8 Control element, module clock (S28)
9 Fuses (F320 & F321)
10 Air outlet
11 Cup filter, installed in fuel dosing pump
12 Fuel dosing pump (Y14)
13 Air outlet hood
14 Combustion chamber
15 Flange gasket
16 Exhaust silencer
17 Exhaust pipe
18 Combustion air hose
19 Fan motor
A Exhaust gas
B Fuel
BW 220 D-5 599

F Fresh air
V Combustion air
W Heating air
n The fan motor (19) Ä Fig. 660 and the combustion air impeller
(3) deliver combustion air into the combustion chamber (14).
n Fuel is pumped out of the vehicle’s tank.
n The fuel dosing pump (12) delivers fuel into the combustion
chamber (14).
n The glow pin (4) evaporates this fuel as it enters the combus-
tion chamber (14) and, in combination with the combustion air
(V), a combustible fuel-air mix is generated.
n Once a flame is present, the glow pin (4) is switched off, the
heat exchanger (6) transfers the heat to the heating air (W) and
exhaust gas (A) is discharged through the exhaust gas silencer
(16).
n The fan motor (19) and the heating air impeller (1) supply the
heating with cool fresh air (F), which is then heated up by the
heat exchanger (6) and finally blown into the inside of the
vehicle.
Switching on
DANGER!
Danger of suffocation caused by exhaust
fumes!
– Always ensure sufficient ventilation and extrac-
tion.
When switching on, the operation indicator in the control element

(8) Ä Fig. 660 lights up. The glow pin (4) is switched on and the
fan motor (19) starts with low speed.
Residual heat
If the heat exchanger (6) still contains too much
residual heat from the previous heater operation,
only the fan motor (19) will initially run (blow out of
cold air). Once the residual heat has dissipated,
the system will start.
Start The delivery of fuel starts approx. 60 seconds later and the fuel-air
mix in the combustion chamber (14) Ä Fig. 660 is ignited. Once
the combined sensor (7) has sensed the flame, the glow pin (4) is
switched off after 60 seconds. 120 seconds later, the AIRTRONIC
has reached the control stage “POWER” (maximum fuel quantity
and maximum fan speed).
Temperature selection with the The desired inside temperature is pre-selected with the control
control element knob; depending on the heater unit, the size of the room to be
heated and the prevailing outside temperature it may be between
+10° to +30°.
600 BW 220 D-5

Control of heater operation During heater operation the room temperature or the temperature
of the drawn in heated air is permanently measured. If the temper-
ature is higher than the temperature pre-selected by the control
element, the control process starts. The system has been designed
with 4 control stages, so that the heat flow provided by the heater
can be accurately adapted to the heat requirements. Fan speed
and fuel quantity thereby match the corresponding control stage.
Should the adjusted temperature still be exceeded in the lowest
control stage, the AIRTRONIC will change to control stage “OFF”
with the fan running on for another 4 minutes for cooling. After this
the fan will continue to run with minimum speed (circulation air
operation) or is switched off (fresh air operation), until the next
start.
Fan operation For fan operation you must first operate the change over switch
“Heating / Ventilation” and then switch on the AIRTRONIC.
Switching off When switching off the AIRTRONIC, the control light will go out
and the fuel supply is shut off.
The fan will continue running for approx. 4 minutes for cooling rea-
sons.
While the fan is still running, the glow pin is switched on for
cleaning, either for 40 sec. (AIRTRONIC D2) or 30 sec. (AIR-
TRONIC D4 / D4S).
Exceptional case
If no delivery of fuel (start phase) takes place until
the system is switched off, or if the AIRTRONIC is
in control stage “OFF”, the AIRTRONIC is shut
down without any overrun.
Heater operation at high altitudes n up to 1500 m: unlimited heater operation possible.

n above 1500 m: short term operation (e.g. crossing a pass or
having a rest) is generally possible. Longer periods require a
height adaptation of the fuel supply.
BW 220 D-5 601

6.7.2 Fuse assignment
B-586-0424
Fig. 661

602 BW 220 D-5

6.7.3 Control panel
1 4
2
3 17:30 21°C
6 5
B-DIS-0523
Fig. 662

1 [◀] button Navigating in the menu levels
Setting/changing numerical values
2 Menu bar Display of available menus
3 Status section Time
Cabin temperature
Information on active functions
Fault indicator
4 [▶] button Navigating in the menu levels
5 [ ] button Selecting menu levels and functions
Switching functions on
6 [ ] button Switching functions on and off
Returning to the main menu
Optional equipment
BW 220 D-5 603

In case of malfunctions you should The electronic control unit is able to store up to 5 faults, which can
check the following then be read out with the control panel and displayed.
If the AIRTRONIC does not start after being switched on:
n Switch the AIRTRONIC off and on again, but not more than 2
times in succession.
If the AIRTRONIC still does not start, please check if:
n Fuel in tank?
n Fuses ok?
n Electric cables, connections, terminals ok?
n Hot air duct, combustion air duct or exhaust duct congested?
n If the AIRTRONIC remains in “Ventilation” condition after
switching on, check the control element for short circuits.
In this case no fault code will be submitted.


Monthly
6.7.4.2.1 Notes on maintenance 604
Heating season
6.7.4.3.1 Notes on maintenance 605
6.7.4.4.1 Servicing the auxiliary heating 605
6.7.4.2 Monthly
6.7.4.2.1 Notes on maintenance
n Switch the auxiliary heating on every month for about ten
minutes.
After longer periods of rest one check and prob-

ably clean the openings on heating air duct, the
combustion air duct and the exhaust duct.
604 BW 220 D-5

6.7.4.3 Heating season

6.7.4.3.1 Notes on maintenance
n Before the heating season the heater should be thoroughly
tested.
NOTICE!
In case of excessive of smoke over a longer period
of time or unusual combustion noises or if a dis-
tinct smell of fuel can be noticed, or electric / elec-
tronic components are overheating, the heater
must be switched off and taken out of service by
removing the fuse.

6.7.4.4.1 Servicing the auxiliary heating
Replacing the fuel filter for the auxiliary heating
n Safety shoes
n Protective gloves
2. Loosen the hose clamps (1) on the fuel filter (2) and pull the
1 hoses off the fuel filter.
3. Take off the fuel filter.
4. Install the new fuel filter by observing the flow direction.
5. Dispose of the used fuel filter environmentally.
2
B-586-0401
Fig. 663
BW 220 D-5 605

Replacing the air filter for the auxiliary heating

n Protective gloves
2. Unscrew the housing cover (1).
3. Take out the air filter (2).
4. Slide the new air filter carefully into the housing (3).
5. Close the housing cover again.
Fig. 664
606 BW 220 D-5

Machine assemblies – Cabin assembly
6.8 Cabin assembly

6.8.1 Safety..................................................................... 607
6.8.2 Preparations.......................................................... 608
6.8.3 Cabin assembly..................................................... 609
6.8.4 Final function tests and checks.............................. 614
6.8.1 Safety
General safety regulations for When installing the cabin to your BOMAG machine you must
assembly strictly comply with the valid accident prevention instructions
or the country specific regulations. However, dangers for per-
sons and property may still arise, if:
n the lifting gear used has a too low bearing capacity
n damaged or worn lifting tackle is used
n unqualified personnel is entrusted with the installation
Each person involved in the installation of the cabin must
therefore read and comply with these safety regulations. If
necessary, the customer must demand a written confirmation
with signature.
Moreover, the following instructions and regulations must obviously
also be adhered to:
n country specific safety regulations. It is the duty of the operator
to be acquainted with these instructions and to apply these
accordingly. This applies also for local regulations concerning
different types of handling work. Should the recommendations
in these instructions be different from the regulations valid in
your country, you must comply with the safety regulations valid
in your country.
Changes and conversions to the Unauthorized changes to the cabin are prohibited for safety rea-
cabin/machine sons.
this machine. We wish to make explicitly clear that we have not
tested or approved any parts or accessories not supplied by us.
effect on the active and/or passive driving safety.
The manufacturer explicitly excludes any liability for damage
caused by the use of non-original parts or accessories.
Notes on safety in the assembly

instructions WARNING!
Paragraphs marked like this highlight possible dan-
gers for persons.
BW 220 D-5 607

NOTICE!
gers for machines or parts of the machine.
Paragraphs marked like this contains technical

information and hints for optimal assembly.
ENVIRONMENT!
Paragraphs marked like this point out practices for
safe and environmental disposal of fuels and lubri-
cants as well as replacement parts.
Strictly observe the national regulations for the pro-
tection of the environment.
Information and safety stickers/ Keep stickers/decals in good and legible condition (see spare parts
decals on the cabin catalogue) and comply with their meaning.
Replace damaged stickers/decals
Working on electric parts of the Before starting to work on electric parts of the machine disconnect
machine the battery and cover it with insulating material.
Do not use fuses with higher ampere ratings and do not repair
fuses with a piece of wire. Fire hazard.
6.8.2 Preparations
WARNING!
Danger of accident!
For transport purposes the driver's seat must be
tied down with cable straps thus to operate the
seat contact switch. Before resuming operation of
the machine these cable straps must strictly be
removed to ensure safe and reliable function of the
seat contact switch.
Check the 4 lifting eyes on the cabin roof for tight
fit.
Fasten the lifting gear to all four lifting eyes.
Use lifting gear (chains or ropes) of sufficient load
bearing capacity. The minimum load bearing
capacity of the crane must be 1000 kg.
Do not stand or step under loads being lifted.
608 BW 220 D-5

1. Make sure that all fastening screws, washers, spacers and

nuts are available to fasten the cabin.
2. Check whether rear rack, foot mat, step plate and fastening
kit are available.
Fig. 665
3. Fasten the lifting tackle to the four lifting eyes 1.

4. Undo any fastenings on the transport pallet.
5. Slowly lift the cabin with a crane.
WARNING!
Danger of accident!
Fig. 666
6.8.3 Cabin assembly
WARNING!
Danger of accident!
NOTICE!
After the cabin installation the fault code “9109” will
no longer be displayed.
BW 220 D-5 609

1. Remove dirt, oil and moisture from the driver's stand.

2. Check the condition of the seals on the driver's stand.
Fig. 667
3.
NOTICE!
When lifting the cabin, observe the weight
distribution. In any case the cabin must be
lowered vertically onto the driver's stand.
Lower the cabin slowly and vertically onto the driver's stand
until only approx. 20 cm distance remains.
Fig. 668
4. Plug in the cables for the heating.

5. Set down the cabin completely on the driver's stand.
Fig. 669
6.
NOTICE!
Take care that none of the hoses and electric
cables become squashed .
Run cables and hoses from inside the cabin frame through
the driver's stand to the outside.
Fig. 670
610 BW 220 D-5

If the bores do not match, the cabin can be moved

into position by means of a crow bar.
7. Turn in the fastening screws (M 16x35) and tighten.

8. Repeat this measure on the opposite side.
Fig. 671
9. Insert screws from below and tighten the nuts (M10) with
washers.
Fig. 672
10. Attach the cover, insert expanding rivet and knock it in with a
plastic mallet.
Fig. 673
BW 220 D-5 611

11. Insert a distance plate between driver's stand and cabin and
tighten the fastening screw.
Fig. 674
13. Connect the hoses for the heating and, if available, for the air
conditioning.
Fig. 675
14. Insert the wiring loom into the control cabinet and install a
bulkhead bushing.
Fig. 676
15. Connect ground cable X8B (2), + potential 30 X8A (3) and
wiring loom plug X4E (1) to the circuit board.
Fig. 677
612 BW 220 D-5

16. Install the protective covering.
Fig. 678
17. Push the hoses for the front and rear windscreen washers
through the opening and connect them to the check valves.
Fig. 679
18. Fasten the wiring loom of the cabin and hoses with cable
ties.
Fig. 680
19. Turn nuts with washers onto both studs and tighten.
Fig. 681
BW 220 D-5 613

20. Assemble the guard.
Fig. 682
21. Remove the lifting tackle, unscrew the lifting eyes and close
the openings with plugs.
Fig. 683
6.8.4 Final function tests and checks
NOTICE!
Make sure that all screws have been tightened
with the specified torque.
After the cabin assembly the following tests must

be performed to assure that all cables and lines
are correctly connected.
1. Insert the ignition key and turn clockwise to position "1".

2. Operate the switches fpr headlights, direction indicators and
interior light to check their function.
If the function of the windscreen washer system is

reversed, the two washing water hoses must be
interchanged.
3. Operate the switches for front and rear windscreen washer

system and check their correct function.
5. Switch the air conditioning on by the switch. After a five
minute operation the cabin must become noticeably cooler.
6. Switch the air heater on by the switch. After a five minute
operation the cabin must become noticeably warmer.
614 BW 220 D-5

NOTICE!
The machine must not be operated if the seat con-
tact switch is not functioning correctly.
7. Function of the seat contact switch.

8. Check the adjustment of the doors, re-adjust if necessary
BW 220 D-5 615

Machine assemblies – ROPS FOPS
6.9 ROPS FOPS

6.9.1 ROPS/FOPS assembly
6.9.1.1 Safety.................................................................. 616
6.9.1.2 Preparations....................................................... 617
6.9.1.3 ROPS/FOPS assembly....................................... 618
6.9.1.4 Final work........................................................... 622
6.9.1.1 Safety
General safety regulations for When carrying out assembly work on your machine you must
Each person involved in such assembly work must therefore
read and comply with these safety regulations.
also be adhered to:
in your country.
Changes and conversions to the Unauthorized changes to the ROPS/FOPS or the machine are pro-
cabin/machine hibited for safety reasons.

gers for persons.
616 BW 220 D-5

NOTICE!

ENVIRONMENT!
WARNING!
Danger of accident!
Check the 4 lifting eyes on the ROPS/FOPS for
tight fit.
Fasten the lifting gear to all four lifting eyes of the
ROPS/FOPS.
BW 220 D-5 617

1. Make sure that all fastening screws, washers, and nuts are
available.
Fig. 684
2. Fasten the lifting gear to the four lifting eyes.

3. Loosen possible fastening on the transport pallet.
4. Slowly lift the ROPS/FOPS using a crane.
WARNING!
Danger of accident!
Fig. 685
6.9.1.3 ROPS/FOPS assembly
WARNING!
Danger of accident!
1. Remove dirt, oil and moisture from the driver’s stand.

2. Check the condition of the seals on the driver’s stand.
Fig. 686
618 BW 220 D-5

3.
NOTICE!
When lifting the ROPS/FOPS take care of
the weight distribution. In any case the
ROPS/FOPS must be lowered vertically onto
the driver’s stand.
Slowly lower the ROPS/FOPS vertically onto the driver’s

stand.
Fig. 687 If the bores do not match, the ROPS/FOPS can be

moved into position by means of a crow bar.
4. Turn in and tighten the fastening screws (M16x35).

Fig. 688
6. Insert the screws (M10x30) and tighten the nuts with

washers.
Fig. 689
7. Cover the fastening screws for the railings with screw reten-
tion agent and tighten them.
Fig. 690
BW 220 D-5 619

8. Tighten the fastening screws of the railings at the bottom.
Fig. 691
9. Insert the wiring loom into the control cabinet and install a
bulkhead bushing.
Fig. 692
10. Connect ground cable X8B (2), + potential 30 X8A (3) and
wiring loom plug X4E (1) to the circuit board.
Fig. 693
11. Install the protective covering.
Fig. 694
620 BW 220 D-5

12. Fasten the wiring loom of the cabin and hoses with cable
ties.
Fig. 695
13. Turn nuts with washers onto both studs and tighten.
Fig. 696
14. Remove the lifting tackle and unscrew the lifting eyes.
15. Turn in and tighten the fastening screws (M16x30) for the
FOPS plate.
Fig. 697
16. Place the roof shells on the FOPS plate.

10 x
17. Screw in the fastening screws (M10x25), tighten them and
press on the protective caps (1).
U-586-0263
Fig. 698
BW 220 D-5 621

18. Hook the safety catch (1) into the front of the FOPS plate.
U-586-0261
Fig. 699
19. Fasten the safety catch to the roof shells.
U-586-0262
Fig. 700
6.9.1.4 Final work

1. Function test of sockets and working lights.


6.9.2.2.1 Checking the ROPS 622

6.9.2.2.1 Checking the ROPS
On machines with cabin the ROPS (roll over pro-

tection structure) is an integral part of the cabin.
All bolted connections must comply with the specifications and

should be absolutely tight (observe the tightening torques).
622 BW 220 D-5

Screw and nuts must not be damaged, bent or deformed.

Unusual movements and noises (vibrations) during operation are
signs for damage or loosened fastening elements.
1. Inspect the cabin, especially the ROPS, for cracks, corrosion,
damage and missing fastening parts.
2. Check the fastening screws for the cabin (ROPS) to the oper-
ator’s stand for tight fit.
3. Check the rubber buffers of the operator’s platform suspen-
sion for condition and tight fit.
4. Check the condition and fastening of the seat belts.
BW 220 D-5 623

Machine assemblies – VM31 BCM/GPS installation
6.10 VM31 BCM/GPS installation

6.10.1 Safety................................................................... 624
6.10.2 Assembly work for holding fixture and cable of
BCM/GPS............................................................ 626
6.10.3 Concluding work.................................................. 632
6.10.1 Safety
General safety regulations for When carrying out assembly work on your machine you must
Each person involved in such assembly work must therefore
read and comply with these safety regulations.
also be adhered to:
in your country.
Changes and conversions to the Unauthorized changes to the cabin/machine are prohibited for
cabin/machine safety reasons.

gers for persons.
624 BW 220 D-5

NOTICE!

ENVIRONMENT!
BW 220 D-5 625

6.10.2 Assembly work for holding fixture and cable of BCM/GPS
Fig. 701
626 BW 220 D-5

Pos Quantity Part no. Designation

1 1 85001036 Spacer plate BCM
2 2 07510824 Stud M8x30
3 1 85001052 Holding fixture of BCM computer
4 2 08510817 Washer
5 2 08130813 Hexagon nut, self locking M8
6 1 05767750 Docking station
7 4 07210609 Fillister head screw Torx M6x12
8 1 85001041 Holding fixture of GPS Delux, assembled
9 1 05767708 Base plate
10 1 07321449 Countersunk screw M16x25
11 4 07210895 Fillister head screw Torx M8x16
12 2 06510175 Protective cap M8
1. Remove the protective cap on the cabin roof.

2. Attach GPS holding fixture (8) (figure 1) and fasten it with
countersunk screw (10).
3. Attach the base plate (9) and fasten it with 4 fillister head
screws (11).
4. Fasten the holding fixture (3) with 4 fillister head screws (7)
to the docking station (6).
5. Remove the expanding rivets from the covering of the A-pillar
and remove the covering.
Fig. 702
BW 220 D-5 627

6. Drill two holes with a 10 mm diameter at the mark.
Fig. 703
7. Insert studs (2).

8. Install spacer plate (1).
9. Assemble the covering of the A-pillar again.
Fig. 704
10. Fasten the docking station to the A-pillar with washers and
nuts (figure 2).
Then screw on the caps.
Fig. 705
12. Pull out the expanding rivets (2) of the covering above the
right door.
Disassemble the handle (1) and remove the covering.
Fig. 706
628 BW 220 D-5

13. Remove the operating console of the cabin.
Fig. 707
BW 220 D-5 629

Fig. 708
630 BW 220 D-5

Pos Quantity Part no. Designation

1 1 58260571 Wiring loom GPS Power WZ-5
2 1 58260570 Wiring loom BCM Supply + CAN 5
3 1 05767085 Interface
1.
NOTICE!
Install the cable in a curved manner and
fasten it with cable ties.
2. Install the cables in the direction of the operating console.

3. Connect the cables to the cabin and interface according to
illustration (figure 7).
4. Fasten the interface with cable straps.
Fig. 709
5. Remove the fastening screws of the left glove compartment.
Fig. 710
6. Pull out the expanding rivets of the left half of the cabin
ceiling.
Pull down half of the ceiling.
Fig. 711
BW 220 D-5 631

7. Remove the fastening screws for the lamp console and set
down the lamp holder.
Fig. 712
8. Drill a 25 mm hole for the cable gland.

Guide the cables through the hole and insert the grommet.
Connect the cable to the GPS base plate.
Fig. 713
9. Establish the plug-in connection and fasten the cables.

10. Install all coverings and lamp holders again.
Fig. 714
6.10.3 Concluding work

1. Insert BCMmobile into the docking station and switch it on.
2. Mount the GPS receiver and connect the plug.
3. Switch the ignition on.
632 BW 220 D-5

4. Check: does the charge LED on the BCM05mobile (1) and

the LED bar on the holding fixture (2) light up?
Fig. 715
5. Is the LED on the Starfire GPS receiver on/ is it flashing?
Fig. 716
6. The machine data (1) must appear after several seconds.

7. Select the system tab image (2).
Fig. 717
BW 220 D-5 633

8. The GPS data string (position of the machine) must appear

here (3).
9. The GPS receiver status must appear here (4).
Fig. 718
634 BW 220 D-5

Troubleshooting
7 Troubleshooting
BW 220 D-5 635

Troubleshooting – Preliminary remarks
7.1 Preliminary remarks............................................... 636

7.2 Emergency procedures.......................................... 638
7.2.1 Actuating the emergency stop switch.................... 638
7.2.2 Machine stops in case of faults.............................. 639
7.2.3 Disconnecting the battery...................................... 640
7.2.4 Emergency exit...................................................... 640
7.2.5 Towing the machine............................................... 641
7.2.6 After towing............................................................ 643
7.3 Troubleshooting, electrical systems..................... 646
7.3.1 Preliminary remarks............................................... 646
7.3.2 Starting the engine with jump leads....................... 649
7.3.3 Servicing the battery, checking the main battery
isolation.................................................................. 650
7.3.4 Fuse assignment................................................... 651
7.3.5 ESX, checking the electric power supply............... 655
7.3.6 Diagnostics concept............................................... 663
7.4 Trouble shooting, diesel engine............................ 666
7.4.2 Engine malfunctions.............................................. 667
7.4.3 Deutz DTC fault code list, EMR3........................... 670
7.5 Trouble shooting, hydraulics................................. 737
7.5.2 Insufficient hydraulic power................................... 738
7.5.3 Troubleshooting axial piston pumps...................... 741
7.5.4 Troubleshooting axial piston motors...................... 743
7.5.5 Troubleshooting table for hydraulic components... 745
7.6 Troubleshooting the air conditioning system...... 753
7.6.1 Basic principles...................................................... 753
7.6.2 Troubleshooting..................................................... 760
7.6.3 Leak test................................................................ 773
7.6.4 Checking the magnetic clutch ............................... 774
7.7 Troubleshooting the auxiliary heating.................. 775
7.7.1 Fuse assignment................................................... 775
7.7.2 Components.......................................................... 776
7.7.3 Control and safety elements.................................. 777
7.7.5 Diagnostics............................................................ 779
7.7.6 Check the fuel supply............................................ 782
7.7.7 Circuit diagram, AIRTRONIC D2/D4...................... 784
7.1 Preliminary remarks

Malfunctions are frequently caused by incorrect operation of the
machine or insufficient maintenance. Whenever a fault occurs you
should therefore thoroughly read these instructions on correct
operation and maintenance.
636 BW 220 D-5

Troubleshooting – Preliminary remarks
If you cannot locate the cause of a fault or rectify it yourself by fol-

lowing the trouble shooting chart, you should contact our customer
service department.
BW 220 D-5 637

Troubleshooting – Emergency procedures
7.2 Emergency procedures

7.2.1 Actuating the emergency stop switch
1. In events of emergency and in case of danger actuate the
emergency stop switch immediately.
ð The engine is shut down and the parking brake is closed.
Fig. 719
638 BW 220 D-5

7.2.2 Machine stops in case of faults

If serious faults occur during operation, the control unit prevents
further operation.
The machine is stopped and the parking brake is applied irrespec-
tive of the travel lever position (safe condition).
B-SYM-1054
The central warning light flashes and the warning buzzer sounds.
Fig. 720
1. Shift the travel lever to the “Middle” position and engage it to

the right.
NOTICE!
– Do not shut down the engine all of a sudden
from full load speed, but let it idle for about two
minutes.
B-ELE-0285
Fig. 721

B-ELE-0069
Fig. 722
4. Turn the main battery switch anticlockwise and pull it out.

5. Close the engine hood and lock it if necessary.
6. Inform our Customer Service Department.
7. Only operate the machine after it has been properly repaired.
B-SWI-0169
Fig. 723
BW 220 D-5 639

7.2.3 Disconnecting the battery

1. In events of emergency, e.g. in case of a cable fire, discon-
nect the battery from the vehicle network. For this purpose
turn the main battery switch anticlockwise and pull it out or
pull the battery terminal off the battery.
Fig. 724
7.2.4 Emergency exit

If a machine has turned over and the cabin door is jammed, the
cabin windows can be used as emergency exits.
1. Take the emergency hammer out of its bracket and smash
the cabin window.
Fig. 725
640 BW 220 D-5

7.2.5 Towing the machine

Tow the machine only in case of emergency or to prevent an acci-
dent.
Towing distance max. 500 m (1600 ft), towing speed max. 1 km/h
(55 ft/min).
Before towing make sure that:
n the tractor vehicle has sufficient traction and braking power for
the non-braking towed load;
n lifting tackle is of sufficient strength to withstand the load and is
fastened at the points provided for this purpose.
If no tow bar is used, towing is only permitted uphill.
n Safety shoes
n Protective gloves
WARNING!
Danger of injury caused by uncontrolled
machine movement!
– Always secure the machine against unintended
rolling.
Preparing for towing

1. Fasten the towing device reliably to the towing points.
Fig. 726
Access to the travel pumps

4. Loosen the clamp on the exhaust pipe.
B-586-0196
Fig. 727
BW 220 D-5 641

5. Unscrew four fastening screws (1) from the main fuse box
1 and lay the main fuse box to the side.
B-586-0166
Fig. 728
6. Unscrew the screws (1) from the engine oil filter bracket.
1 7. Lay the engine oil filter bracket to the side.
B-586-0201
Fig. 729
8. Unscrew the two screws (1) from the left side of the cross-
1 member.
B-586-0173
Fig. 730
9. Unscrew the two outer screws (1) from the right side of the
1 cross-member.
10. Tilt the cross-member to the right.
B-586-0172
Fig. 731
642 BW 220 D-5

Releasing the parking brake

11. Loosen the high pressure relief valves (1) on the travel pump
for approx. three turns in anticlockwise direction to open a
bypass.
Leakage!
1
– Do not back the valves out for more than
three turns!
B-586-0178
Fig. 732
12. Press the emergency operation button completely in.

13. Insert a suitable pump lever extension and operate the pump,
until the brake is released.
ð The machine can now be towed.
B-586-0097
Fig. 733
7.2.6 After towing
WARNING!
Danger of injury caused by uncontrolled
machine movement!
– Always secure the machine against unintended
rolling.
1. If the engine cannot be started, pull the emergency operation

button completely out after towing.
After starting the engine the emergency oper-

ation button is pushed out by hydraulic pres-
sure.
B-586-0098
Fig. 734
BW 220 D-5 643

2. Retighten the high pressure limiting valves (1) on the travel

pump again, tightening torque: 70 Nm (52 ft·lbf).
3. Return the cross-member to the installation position.
B-586-0178
Fig. 735
4. Tighten the two outer screws (1) on the right side of the
1 cross-member.
B-586-0172
Fig. 736
5. Tighten the two screws (1) on the left side of the cross-
1 member.
B-586-0173
Fig. 737
6. Attach the engine oil filter bracket in the installation position

1 and tighten both screws (1).
B-586-0201
Fig. 738
644 BW 220 D-5

7. Attach the main fuse box in the installation position and

1 tighten the four screws (1).
B-586-0166
Fig. 739
8. Attach the exhaust pipe in the installation position and tighten

the clamp.
B-586-0196
Fig. 740
BW 220 D-5 645

Troubleshooting – Troubleshooting, electrical systems
7.3 Troubleshooting, electrical systems

7.3.3 Servicing the battery, checking the main battery
isolation.................................................................. 650
7.3.4 Fuse assignment................................................... 651
7.3.5 ESX, checking the electric power supply............... 655
7.3.6 Diagnostics concept............................................... 663
7.3.1 Preliminary remarks

service department.
Due to the fast technical development electric and electronic

vehicle systems become more intelligent and more comprehensive
day by day, and can hardly be dispensed with in hydraulic and
mechanical vehicle systems.
Diagnostics according to plan
Well structured trouble shooting procedures can save time and
money.
Random tests have revealed that purely electronic components or
control units only very rarely are the actual cause of failures:
n In approx. 10 % of the examined cases the problems were
caused by control units.
n In approx. 15 % sensors and actuators were the cause of the
problems.
By far the highest proportion of all faults could be traced back to
wiring and connections (plugs, etc.).
General:
Before changing any expensive components, such as control units,
you should run a systematic trouble shooting session to eliminate
any other possible fault sources. Knowledge in basic electrics is
required for this purpose. If a fault was diagnosed without having
pulled the plug of the control unit or inspected the wiring, this
should be done before changing any parts.
Check for good cable and ground contacts, therefore keep all
mechanical transition points between electric conductors (termi-
nals, plugs) free of oxide and dirt, as far as this is possible.
646 BW 220 D-5

Always use the machine related wiring diagram for testing. If one
or more faults were detected, these should be corrected immedi-
ately.
Do not disconnect or connect battery or generator while the engine
is running.
Do not operate the main battery switch under load.
Do not use jump leads after the battery has been removed.
Sensors and electric actuators on control units must never be con-
nected individually or between external power sources for the pur-
pose of testing, but only in connection with the control unit in ques-
tion.
It is not permitted to pull plugs off while the voltage supply is
switched on (terminal 15 "ON")! Switch the voltage supply "OFF"
first and pull out the plug.
Even with an existing polarity reversal protection incorrect polarity
must be strictly avoided. Incorrect polarity can cause damage to
control units!
Plug-in connectors on control units are only dust and water tight if
the mating connector is plugged on! Control units must be pro-
tected against spray water, until the mating connector is finally
plugged on!
Unauthorized opening of control electronics (Microcontroller MC),
modifications or repairs in the wiring can cause severe malfunc-
tions.
Do not use any radio equipment or mobile phones in the vehicle
cab without a proper aerial or in the vicinity of the control elec-
tronics!
Switches, plugs, wiring looms Over the years corrosion and contamination can create high con-
tact resistances in plugs and switches, wiring looms affected by
“copper worm” (corrosion) are poor conductors. In extreme inci-
dents such a component will be absolutely dead, while minor
damage more or less reduces the performance of the affected con-
sumers to a noticeable extent.
In many cases it is enough to examine the components visually:
Green male connectors of plugs, neglected switch contacts must
be mechanically cleaned and reassembled with some contact
spray. Cables core showing green discolouration must be replaced.
A resistance measurement provides exact information about the
conductivity.
Leakage currents The machine has not been driven for a few days, and the battery is
almost empty? This may be caused by a “surreptitious consumer”
in the electrical network of the machine, of a leakage current
simply “draws” your battery empty. Such a leakage current can be
caused by e.g. the ignition lock, a defect switch, a relay or a
clamped or chafed cable.
BW 220 D-5 647

A leakage current can be located by a amperage

measurement with a multimeter.
Measuring fault Whenever the electrical system of the vehicle behaves in an unex-
pected way, one should first consider that there may be a ground
problem! The older the electrical system and the lower the voltage,
the more likely this will be the cause.
As we all know, being able to utilize electric current requires the
existence of a closed electric circuit, the electrons leaving the bat-
tery must be able to return to the battery. In vehicles numerous
existing metal parts can be used for this purpose. The negative
pole of the battery is connected with the metal of the frame. The
current then flows through an insulated cable to e.g. a lamp should
light, and instead of a return line, the socket of the lamp is also, in
some way, connected to the frame, through which the current can
flow back to the battery. However, should the connection between
lamp and frame corrode causing a high electrical resistance at that
point, the current will try to find a different way. If no other way can
be found, the component will simply not work, even if the meter
shows that voltage arrives. Very often the current finds a different
way back to the battery, sometimes through other consumers.
Measuring sensors and actuators

Sensor signals are best checked where they are
needed, i.e. on the control unit. If the correct signal
is received you can be sure that not only the
sensor, but also the wiring to the control unit is in
good working order.
It is a common procedure to pick up the signals
with a break-out-box, the Y-cable of which is fas-
tened between control unit and control unit plug. If
no break-out-box is available, the measurement
takes place directly on the sensor, or one must try
to gain access to the back of the plug.
Trouble shooting procedure:

n First check the corresponding actuator, in case of a faulty
signal the output signal must be checked directly on the control
unit.
n If the output signal is correct, check the wiring to the actuator.
n In case of an incorrect output signal, check the corresponding
input signals after.
n In case of incorrect input signals check the signal on the
sensor itself.
n If the sensor signal is correct, check the wiring to the control
unit for continuity and against ground (short circuit).
n If the sensor delivers a correct signal, the sensor itself may be
the cause of the problem, or the sensor may be affected by
other incorrectly working components.
648 BW 220 D-5

n However, the voltage supply and the ground connection of the

control unit as well as the power supply for sensors and actua-
tors must also be checked. Because an incorrect voltage value
can distort the input and output signals.
n If the action steps described above do not deliver a result, the
periphery is OK and the fault must be in the control unit, but be
cautious, most faults are caused by poor contacts in the plug
connections.
If the battery is empty If the battery is empty, the fault is normally quite quickly identified.
There are the following possibilities:
n because it is no longer charged by the generator
n because one of the consumers (light, radio, etc.) has not been
switched off
n because a hidden consumer “surreptitiously” empties the bat-
tery
n because the battery is defective
n generator or regulator are defective
n wiring between generator, starter and battery in poor condition
Check and measure the charge

system for faults It makes sense to be familiar with the working prin-
ciple of the charge system.
Necessary if:
n the battery is permanently discharged
n the battery has boiled over and acid has escaped
n the headlights light considerably brighter when accelerating
n light bulbs burn out frequently at irregular intervals
7.3.2 Starting the engine with jump leads
NOTICE!
battery.
BW 220 D-5 649

NOTICE!
Fig. 741

tive poles after.
7.3.3 Servicing the battery, checking the main battery isolation

7.3.3.1 Battery service

need to be checked.
ranty!
650 BW 220 D-5


n Protective gloves
n Safety goggles
2. Remove the battery and clean the battery compartment.
3. Clean the outside of the battery.
4. Clean battery poles and pole clamps and grease them with
pole grease (Vaseline).
5. Install the battery and check the battery fastening.
6. On serviceable batteries check the acid level, if necessary
top up to the filling mark with distilled water.
Fig. 742
7.3.3.2 Checking the main battery shutoff

1. Turn the main battery switch counter-clockwise and pull it
out.
2. Check by turning the ignition key, whether the battery is dis-
connected from the electric system of the machine.
Fig. 743

7.3.4.1 Notes on safety
WARNING!
Danger of injury by fire in the machine!
– Do not use fuses with higher ampere ratings
and do not bridge fuses.
7.3.4.2 Central electrics

F05 20 A 12-V socket
F07 10 A Hazard light
F08 10 A Direction indicators
BW 220 D-5 651


F09 10 A Parking and tail light, left
F10 10 A Parking and tail light, right
F11 15 A Head lights, front
F13 15 A Starter switch
F19 15 A Working head lights, front
F22 15 A Working head lights, rear
F23 15 A Warning horn
F24 10 A Instrument cluster
F29 15 A Compressor - air suspended seat, seat heating
F39 80 A Main fuse for cabin
F40 30 A Heating, air conditioning, fan
F84 10 A Control (contact 54)
F91 5A Sensors
F124 25 A Fuel pre-heating
F129 3A BOMAG TELEMATIC (MD+)
F157 30 A Starter
F169 5A Start current
F243 7.5 A BOMAG TELEMATIC (potential 30)
F244 5A BOMAG TELEMATIC (potential 15)
F268 20 A Fuel pump
FM1 1A Sensors
FM2 1A Sensors
652 BW 220 D-5

7.3.4.3 Main fuses

Fig. 744

Fig. 745

BW 220 D-5 653

7.3.4.4 Control console cabin
Fig. 746
Position Fuse Amperage Designation

1 F17 5A Radio
2 F264 10 A BCM
3 F271 10 A BCM net
4 F150 5A GPS
5 F266 10 A Radio/Tachograph
6 F143 20 A Rear windscreen heating
7 F28 15 A Rear windscreen wiper
8 F27 15 A Front windscreen wiper
9 F279 15 A Spare
10 F272 5A Control console cabin
654 BW 220 D-5

7.3.4.5 Auxiliary heating
B-586-0424
Fig. 747

7.3.5 ESX, checking the electric power supply

Power supply All electronic switching and control units require an electric power
supply to be able to work. If the plus or minus supply is faulty, the
control unit will work incorrectly or fail.
The following describes the electric power supply

for the ESX-control.
shows a simplified representation of how the con-
trol unit (ESX, 68 pole) is connected. The complete
representation can be found in the wiring diagram
of the machine.
The procedure can also be used for other controls.
Pin assignment and voltage supply may be dif-
ferent, but the procedures for line testing are gen-
erally the same.
BW 220 D-5 655

Fig. 748: Circuitry example

1 Engine block
ESX Control unit
F00 Main fuse
Fx,Fxx Fuses potential 30
Fxxx Fuses potential 15
G Generator
G01 Battery
GND Housing earth
H08 Charge control lamp
S00 Ignition switch
S01 Emergency stop switch
Pin 28 Voltage supply for control
Pin 54 if the signal (12/24 Volt) is applied, the control is
switched on
Pin 55 Ground supply for control
Pin 56 to 60 Voltage supply for outputs
GND Housing earth
Fault in current supply, general Clear interruptions in the plus or minus supply are relatively easy to
detect. However, the plus and minus sides of control units are in
most cases connected to the vehicle mains supply via several
cables, so that several parallel current branches exist. Checking
the power supply is therefore slightly more difficult than expected.
Another point is the fact that every current branch has several plug
connections, which could corrode over the years. Corroded points
are transition resistances and thus cause undesired voltage drops.
In case of undesired voltage drops the control unit is supplied with
a lower voltage. This can lead to faulty reactions or even failure of
the control unit.
656 BW 220 D-5

Fig. 749: Circuitry example

The arrows point to the contact locations, which may be the cause
if a control unit only receives a reduced supply voltage.
The following faults may occur:
n Line interruption in a plus supply line
n high voltage drop in a plus supply line
n line interruption on the minus side
Measuring principle for line testing When a line conducts an electric current, a voltage drop will occur
in the line (UV).
The size of this voltage drop UV depends on:
n the available amperage (I) and
n the electric resistance (RLine) of the current branch being
checked
In order to have reliable comparison possibilities at hand one
should always work with the same amperage. Identical marginal
conditions are therefore used in all of the following examples:
n 12 Volt – vehicle battery as voltage source or 24 Volt in a 24
Volt vehicle network
n 12 V / 21 W – lamp as load in a 12 Volt vehicle network
n 24 V / 21 W – lamp as load in a 24 Volt vehicle network
Test steps
1. Switch the ignition off
2. Unplug the control unit from wiring loom.
3. 3. If available connect the Pinbox Ä Fig. 750 to the plug of
the wiring loom, do not connect the control unit with the
Pinbox. If no Pinbox is available, provide measuring cables
with appropriate plug-in contacts, e.g. spade-type plugs.
BW 220 D-5 657

4. 4. Check with multimeter. If a setpoint is not reached, pro-

ceed step by step to identify the weak spot. Repair as neces-
sary. Repeat the measurement.
NOTICE!
The plug must not be pulled off or plugged on while
the ignition is switched on. Switch off the ignition
first and then pull off or plug on the plug.
Only plug the wiring loom onto the control unit,
when the actual value corresponds with the set-
point.
Fig. 750: Pinbox for 68 pole ESX control
658 BW 220 D-5

General measuring setup to check

a supply line (plus side)
Fig. 751: Measuring arrangement 12 Volt

1 Supply line, plus side
2 Plug contact in wiring loom plug on control or Pinbox
E Lamp, 12V / 21 Watt
P Multimeter
G01 Battery as voltage source, 12V
UV Voltage drop caused by the lamp current
Nominal value
The voltage incident UV should not exceed 0.5 V => UNominal ≤ 0.5
V.
BW 220 D-5 659

General measuring setup to check

a return line (minus side)
Fig. 752: Measuring arrangement 12 Volt

1 Return line, minus side
2 Plug contact in wiring loom plug on control or Pinbox
E Lamp, 12V / 21 Watt
P Multimeter
G01 Battery as voltage source, 12V
UV Voltage drop caused by the lamp current
Nominal value
The voltage incident UV should not exceed 0.5 V => UNominal ≤ 0.5
V.
660 BW 220 D-5

Connection example to check the

plus line between battery and plug
pin 28
Fig. 753
X Wiring loom plug disconnected from control unit or Pinbox
P Multimeter
S00 Ignition switched on. Nominal value: E is bright. UV max. 0.5
Volt
S00 Ignition switched off. Nominal value: E is dark. UV = 0.0 Volt
Connection example to check the

minus line between battery and
plug pin 55
Fig. 754
P Multimeter
X Wiring loom plug disconnected from control unit or Pinbox
E Nominal value: E is bright. UV max. 0.5 Volt
BW 220 D-5 661

Test protocol for ESX
Plug pin Note Nominal values

28 Ignition ON
E is bright,
E between plug pin 28 and battery minus
UV max. 0.5 Volt
P between battery plus and plug pin 28
28 Ignition OFF
E is dark,
E between plug pin 28 and battery plus
UV = 0 Volt
P between battery minus and plug pin 28
54 Ignition OFF, emergency stop not operated
E is bright,
UV max. 0.5 Volt
54 Ignition OFF, emergency stop operated
E is dark,
UV = 0 Volt
55 Ignition OFF
E is bright,
UV max. 0.5 Volt
56, 57, 58, 59, 60 Ignition OFF
E is bright,
E between plug pin 56, 57, 58, 59, 60 and battery minus
UV max. 0.5 Volt
P between battery plus and plug pin 56, 57, 58, 59, 60
If one or several setpoint(s) is (are) exceeded, one

must make considerations which are related to the
wiring diagram.
Example 1:
In all supply lines to the pins 56, 57, 58, 59 and 60 the voltage drop
is too high. There are two possible reasons. All contacts are either
corroded, or the supply line between battery and fuse Fxx has poor
contact.
Example 2:
Only one measuring value exceeds the setpoint. In this case the
fault must be located between the last branch and the corre-
sponding plug pin.
662 BW 220 D-5

7.3.6 Diagnostics concept

Introduction A correct and reliable diagnose is a general prerequisite for the
detection of faults in system. For this to count as a rule several
points must be fulfilled. One of these points is the ability of the
engine to run a systematic trouble shooting procedure. However,
this is only possible when a diagnostics concept is available and in
practice. Trouble shooting can generally be performed in various
ways.
Fault description and questioning After the customer has explained his complaint(s) the engineer has
of the customer to ask further questions to track down the cause of the fault. If the
complaint is additionally related to electric/electronic components,
the visual examination and a possible test drive must be subse-
quently followed by an interrogation of the error log. The further
procedure in this case depends on the outcome of this interroga-
tion.
Fig. 755
(1) Fault memorized in error log
Clear cause? If the fault message leaves no doubt, repair work may be started
immediately.
(2) No fault memorized in the error Even if the fault is in the electric/electronic part of the vehicle, a
log at the time of initial questioning control unit will very often not detect a fault. Right from the start
you should be aware of the fact that a high proportion of faults is
caused by contacts. This even gets worse in case of older and
neglected vehicles.
BW 220 D-5 663

In order to examine the electric/electronic part of an electronic

system it is recommended to check the incoming sensor informa-
tion and outgoing command values on a control unit. This requires
profound knowledge of system and components.
Consideration, if the error log has n What could be the cause of the complaint?
not recorded a fault n Which measuring possibilities are available?
Localizing faults
Line or component?
Fig. 756
n In most cases the fault message does not clarify whether the
fault is in the sensor or actor, or in one of the connecting lines
(2) between control unit and the mentioned component (1). For
this purpose it makes sense to check the component and the
connecting lines between control unit and component sepa-
rately.
n Checking the voltage supply for the control unit
n Checking the sensor lines
n Checking the actor lines
664 BW 220 D-5

Sequence after the fault is found
Fig. 757
BW 220 D-5 665

Troubleshooting – Trouble shooting, diesel engine
7.4 Trouble shooting, diesel engine
7.4.1 Starting the engine with jump leads
NOTICE!
battery.
NOTICE!
Fig. 758

tive poles after.
666 BW 220 D-5

7.4.2 Engine malfunctions

Malfunction Possible cause Remedy
Engine does not Temperature below starting limit Check
start or starts poorly
Cold starting facility Check/replace
Engine oil with wrong SAE viscosity class Change the engine oil
The fuel quality does not meet the Change the fuel
requirements
Battery defective or not charged Check
Cable to starter loose or oxidized Check cable connection
Starter defective or pinion does not Check starter
engage
Incorrect valve clearance Adjustment
Air filter clogged / exhaust turbocharger Check, replace if necessary
defective
Air in the fuel system Bleeding the fuel system
Compression pressure too low Check
Exhaust gas counter pressure too high Check
Injection line leaking Check
Engine does not Engine electronics prevent starting Check fault by fault code, repair as nec-
start and diagnostic essary
lamp is flashing
Engine starts, but V-belt/ribbed V-belt (fuel pump in belt Check, whether torn or loose
runs irregularly or drive)
misfires
Compression pressure too low Check
Air in the fuel system Bleeding the fuel system
Fuel pre-cleaner soiled Check, clean the water separator, replace
the fuel pre-cleaner
requirements
Injector defective Replace
Speed changes are Engine electronics detected a system Check fault by fault code, repair as nec-
possible and cen- fault and activates a substitute speed essary
tral warning lamp
lights
BW 220 D-5 667


The engine over- Cooling system ventilation line clogged Clean ventilation line
heats, the coolant
temperature Engine oil with wrong SAE viscosity class Change the engine oil
warning lamp lights Engine oil filter dirty Replace
Engine oil level too low or too high Check, top up or drain off as necessary
Radiator soiled Clean
Coolant pump defective (V-belt torn or Check, whether torn or loose
loose)
Lack of coolant Check the coolant level, top up if neces-
sary
Resistance in cooling system too high / Check the cooling system
flow quantity too low
Fan defective / V-belt torn or loose Check fan / V-belt, replace if necessary
Charge air pipe leaking Check
Intercooler soiled Clean
defective
Insufficient engine Engine oil level too high Check, top up or drain off as necessary
power
Fuel intake temperature too high Check the system
requirements
defective
Fan defective / V-belt torn or loose Check fan / V-belt, replace if necessary
Intercooler soiled Clean
Resistance in cooling system too high / Check the cooling system
flow quantity too low
Insufficient engine Engine electronics reduces the power Check fault by fault code, repair as nec-
power and diagnos- essary
tics lamp lights
Engine does not Injection line leaking Check
work with all cylin-
ders Injection valve defective Check, replace if necessary
668 BW 220 D-5


Engine oil level too high Check, drain off if necessary
Engine has too low Engine oil level too low Check, top up or drain off as necessary
or no oil pressure
Engine oil with wrong SAE viscosity class Change the engine oil
Engine has exces- Engine oil level too high Check, drain off if necessary
sive oil consump-
tion Crankcase ventilation Check/replace
Engine oil in the Engine is permanently operated with too Check the load factor
exhaust system low load (< 20-30%)
Blue engine Engine oil level too high Check, drain off if necessary
exhaust smoke
Check the engine oil level, drain off if
necessary
White engine Temperature below starting limit Check
exhaust smoke
requirements
Injector defective Check, replace if necessary
Black engine Air filter clogged / exhaust turbocharger Check, replace if necessary
exhaust smoke defective
Charge air pressure dependent full load Check
stop defective
No regeneration in Electric power supply to the air com- Check fuse and supply line, replace the
the diesel particu- pressor interrupted lock
late filter
Air compressor defective Check the air compressor, replace the
lock
Air filter clogged Clean/replace the air filter, check the air
compressor, if necessary replace the lock
Fuel supply interrupted Check the lines, check the dosing unit
Implausible sensor signal Check the exhaust counter pressure
sensor, check the differential pressure
sensor on the particulate filter, check the
pressure sensors in the dosing unit
Swirl vanes covered with soot Clean, look for reason of sooting
BW 220 D-5 669

7.4.3 Deutz DTC fault code list, EMR3
670 BW 220 D-5

referrenced ECU-Software
DTC-List P490_: 220, 310, 501 P492_: 213
Diagnosis- and Errorcodes P491_: 220, 310, 400, 501 P513_: 214, 300
Deutz-Code / SPN / Fehlername ...............................Seite Deutz-Code / SPN / Fehlername............................... Seite Deutz-Code / SPN / Fehlername...............................Seite
11 / 107 / AirFltSysReac.................................................... 3 56 / 110 / CTSCDSysReac ..............................................15 122 / 523607 / FrmMngTOTSC1DE................................ 27
12 / 91 / APP1.................................................................... 3 57 / 701 / Dummy1CD_Max.............................................15 123 / 523608 / FrmMngTOTSC1DR................................ 28
14 / 91 / APPPwm.............................................................. 3 58 / 701 / Dummy1CD_Min..............................................16 124 / 523609 / FrmMngTOTSC1PE ................................ 28
15 / 91 / APPPwmPer........................................................ 4 59 / 701 / Dummy1CD_SigNpl.........................................16 125 / 898 / FrmMngTOTSC1TE ...................................... 28
16 / 108 / APSCD .............................................................. 4 60 / 702 / Dummy2CD_Max.............................................16 126 / 520 / FrmMngTOTSC1TR ...................................... 29
17 / 729 / ArHt1.................................................................. 4 61 / 702 / Dummy2CD_Min..............................................17 127 / 523610 / FrmMngTOTSC1VE ................................ 29
18 / 730 / ArHt2.................................................................. 5 62 / 702 / Dummy2CD_SigNpl.........................................17 128 / 523611 / FrmMngTOTSC1VR................................ 29
19 / 676 / ArHtCD_NoLd.................................................... 5 69 / 2791 / EGRCD_Max .................................................17 131 / 523500 / FrmMngTxTO .......................................... 30
20 / 676 / ArHtCD_RlyErr .................................................. 5 70 / 2791 / EGRCD_Min ..................................................18 133 / 174 / FTSCD........................................................... 30
22 / 168 / BattCD ............................................................... 6 71 / 2791 / EGRCD_SigNpl..............................................18 134 / 174 / FTSCDSysReac ............................................ 30
23 / 168 / BattCDSysReac................................................. 6 72 / 2791 / EGRCDIntEGR ..............................................18 136 / 523618 / GOTSCD ................................................. 31
24 / 523561 / BIPCyl1........................................................ 6 74 / 923 / EngCDTrqCalcOut ...........................................19 137 / 523619 / GOTSCDSysReac................................... 31
25 / 523562 / BIPCyl2........................................................ 7 75 / 190 / EngMBackUp ...................................................19 138 / 29 / HdThrt ............................................................. 31
26 / 523563 / BIPCyl3........................................................ 7 76 / 190 / EngMCaS1.......................................................19 139 / 1638 / HOTSCD ..................................................... 32
27 / 523564 / BIPCyl4........................................................ 7 77 / 190 / EngMCrS1........................................................20 140 / 1638 / HOTSCDSysReac....................................... 32
28 / 523565 / BIPCyl5........................................................ 8 78 / 190 / EngMOfsCaSCrS.............................................20 141 / 523617 / HWEMonCom.......................................... 32
29 / 523566 / BIPCyl6........................................................ 8 79 / 190 / EngPrtSysReacFOC ........................................20 142 / 630 / HWEMonEEPROM........................................ 33
30 / 523567 / BIPCyl7........................................................ 8 80 / 190 / EngPrtSysReacORC........................................21 143 / 523612 / HWEMonRcyLocked ............................... 33
31 / 523568 / BIPCyl8........................................................ 9 81 / 703 / ESLpCD ...........................................................21 144 / 523612 / HWEMonRcySuppressed........................ 33
32 / 102 / BPSCD .............................................................. 9 82 / 1074 / ExFlCD...........................................................21 145 / 523612 / HWEMonRcyVisible ................................ 34
33 / 102 / BPSCDSysReac................................................ 9 83 / 975 / FanCD..............................................................22 146 / 523612 / HWEMonUMaxSupply............................. 34
BW 220 D-5
37 / 111 / CLSCDSysReac .............................................. 10 85 / 1639 / FanCDEval.....................................................22 147 / 523612 / HWEMonUMinSupply.............................. 34
38 / 1323 / CmbChbMisfire1............................................ 10 86 / 523602 / FanCDSysReac .........................................22 149 / 105 / IATSCD ......................................................... 35
39 / 1324 / CmbChbMisfire2............................................ 10 87 / 97 / FlFCD.................................................................23 150 / 105 / IATSCDSysReac........................................... 35
40 / 1325 / CmbChbMisfire3............................................ 11 89 / 97 / FlFCD_WtLvl......................................................23 153 / 523350 / InjVlvBnk1A ............................................. 35
41 / 1326 / CmbChbMisfire4............................................ 11 90 / 94 / FlPSCD ..............................................................23 154 / 523351 / InjVlvBnk1B ............................................. 36
42 / 1327 / CmbChbMisfire5............................................ 11 91 / 94 / FlPSCDSysReac................................................24 155 / 523352 / InjVlvBnk2A ............................................. 36
43 / 1328 / CmbChbMisfire6............................................ 12 94 / 523239 / FrmMngDecV1...........................................24 156 / 523353 / InjVlvBnk2B ............................................. 36
44 / 1450 / CmbChbMisfire7............................................ 12 95 / 523240 / FrmMngFunModCtl ....................................24 157 / 523354 / InjVlvChipA.............................................. 37
45 / 1451 / CmbChbMisfire8............................................ 12 106 / 523212 / FrmMngTOEngPrt....................................25 158 / 523355 / InjVlvChipB.............................................. 37
46 / 1322 / CmbChbMisfireMul ........................................ 13 110 / 523216 / FrmMngTOPrHtEnCmd............................25 159 / 651 / InjVlvCyl1A .................................................... 37
47 / 1346 / CmbChbSysReac .......................................... 13 112 / 523218 / FrmMngTORxCCVS ................................25 160 / 651 / InjVlvCyl1B .................................................... 38
48 / 1109 / CoEngShOffDemIgr....................................... 13 113 / 523604 / FrmMngTORxEngTemp...........................26 161 / 652 / InjVlvCyl2A .................................................... 38
52 / 1072 / CRERCD ....................................................... 14 117 / 523238 / FrmMngTOSwtOut...................................26 162 / 652 / InjVlvCyl2B .................................................... 38
53 / 1081 / CSLpCD......................................................... 14 118 / 523222 / FrmMngTOTCO1 .....................................26 163 / 653 / InjVlvCyl3A .................................................... 39
54 / 704 / CTLpCD........................................................... 14 120 / 523605 / FrmMngTOTSC1AE.................................27 164 / 653 / InjVlvCyl3B .................................................... 39
55 / 110 / CTSCD ............................................................ 15 121 / 523606 / FrmMngTOTSC1AR.................................27 165 / 654 / InjVlvCyl4A .................................................... 39
DEUTZ AG, TE-CE, Fi Seite 1 Rev. 2.1, 22.10.2008

671
672
DTC-List P490_: 220, 310, 501 P492_: 213
Deutz-Code / SPN / Fehlername ...............................Seite Deutz-Code / SPN / Fehlername............................... Seite Deutz-Code / SPN / Fehlername...............................Seite
166 / 654 / InjVlvCyl4B .................................................... 40 211 / 523613 / RailMeUn0 ...............................................52 255 / 523659 / FrmMngRapeOilVlv1 ............................... 64
167 / 655 / InjVlvCyl5A .................................................... 40 212 / 523613 / RailMeUn1 ...............................................52 256 / 523660 / FrmMngRapeOilVlv2 ............................... 65
169 / 656 / InjVlvCyl6A .................................................... 41 214 / 523613 / RailMeUn3 ...............................................53 258 / 523662 / FrmMngRapeOilVlv4 ............................... 65
171 / 657 / InjVlvCyl7A .................................................... 41 216 / 523613 / RailMeUn7 ...............................................54 260 / 523664 / FrmMngSTIN1RX.................................... 66
172 / 657 / InjVlvCyl7B .................................................... 42 218 / 523490 / SOPTst.....................................................54
173 / 658 / InjVlvCyl8A .................................................... 42 219 / 1079 / SSpMon1 .....................................................54
174 / 658 / InjVlvCyl8B .................................................... 42 221 / 1080 / SSpMon2 .....................................................55
175 / 523370 / InjVlvErrDet.............................................. 43 222 / 523601 / SSpMon3 .................................................55
176 / 523615 / MeUnCD_ADC ........................................ 43 223 / 677 / StrtCDHS .......................................................55
177 / 523615 / MeUnCDNoLoad ..................................... 43 224 / 677 / StrtCDLS........................................................56
178 / 523615 / MeUnCDSCBat........................................ 44 225 / 624 / SysLamp ........................................................56
179 / 523615 / MeUnCDSCGnd ...................................... 44 226 / 158 / T15CD............................................................56
182 / 2634 / MnRly1_SCB ............................................... 44 227 / 523550 / T50CD......................................................57
183 / 2634 / MnRly1_SCG............................................... 45 228 / 523550 / TPUMon...................................................57
184 / 523420 / Montr........................................................ 45 232 / 84 / VSSCD1...........................................................57
186 / 2634 / MRlyCD ....................................................... 45 235 / 523600 / WdCom ....................................................58
187 / 563 / MRlyCDMnRly2 ............................................. 46 236 / 523470 / PRVMonSysReac ....................................58
188 / 2634 / MRlyCDMnRly3 ........................................... 46 237 / 523006 / APPCDSwtnSel........................................58
189 / 523450 / MSSCD1.................................................. 46 238 / 523007 / FrmMng_TORxEngPress.........................59
BW 220 D-5
190 / 523451 / MSSCD2.................................................. 47 239 / 523008 / MplCtl.......................................................59
191 / 523452 / MSSCD3.................................................. 47 240 / 98 / OLSCD.............................................................59
192 / 639 / NetMngCANAOff ........................................... 47 241 / 98 / OLSCDSysReacHi...........................................60
193 / 1231 / NetMngCANBOff ......................................... 48 242 / 107 / ADPSCDAna..................................................60
194 / 1235 / NetMngCANCOff ......................................... 48 243 / 98 / OLSCDSysReacLo ..........................................60
195 / 705 / OPLpCD ........................................................ 48 244 / 523009 / PrvMonWear ............................................61
196 / 100 / OPSCD.......................................................... 49 245 / 523010 / RailMeUn8 ...............................................61

197 / 100 / OPSCD1........................................................ 49 246 / 523650 / FlSys_FLPFMSysReac............................61
198 / 100 / OPSCDSysReacHi ........................................ 49 247 / 523651 / FlSys_FTSFMSysReac............................62
199 / 100 / OPSCDSysReacLo........................................ 50 248 / 523652 / FlSys_FlushStateEngineOff.....................62
200 / 1237 / OSwCD........................................................ 50 249 / 523653 / FlSys_RapeOilHeatEx .............................62
201 / 175 / OTSCD .......................................................... 50 250 / 523654 / FrmMngDieselLvl .....................................63
203 / 175 / OTSCDSysReac............................................ 51 251 / 523655 / FrmMngFuelTemp....................................63
208 / 523470 / PRVMon .................................................. 51 252 / 523656 / FrmMngLowPressureDiesel.....................63
209 / 157 / RailCD ........................................................... 51 253 / 523657 / FrmMngRapeOilIn....................................64
210 / 157 / RailCDOfsTst................................................. 52 254 / 523658 / FrmMngRapeOilLvl ..................................64

DTC-List P490_: 220, 310, 501 P492_: 213
11 / 107 / AirFltSysReac 12 / 91 / APP1 14 / 91 / APPPwm

Error description AIR FILTER COND. Error description THROTTLE 1 Error description THROTTLE 1
Air filter differential pressure: the pressure difference of the intake Analog accelerator pedal sensor 1 or double accelerator pedal Digital accelerator pedal sensor (PWM): the signal received by
air between the filter inlet and outlet calculated by ECU is above sensor: the voltage measured by ECU is out of the target range ECU is defective or implausible or the pulse-duty factor is out of
the target range and the ECU activates a system reaction or the calculated pedal position is implausible compared with the the target range
Error codes position of the second pedal Error codes
DEUTZ-Errorcode: 11 Error codes DEUTZ-Errorcode: 14
BlinkCode (short-long-short): 1 - 3 - 6 DEUTZ-Errorcode: 12 BlinkCode (short-long-short): 2 - 2 - 2
SPN: 107 BlinkCode (short-long-short): 2 - 2 - 6 SPN: 91
possible FMI: SPN: 91 possible FMI:
0: data valid, but above normal working area possible FMI: 8: unusual frequency, pulse or period.
12. Errormode not identifiable 3: Voltage to high or short circuit to +Ubatt 8: unusual frequency, pulse or period.
12. Errormode not identifiable 4: Voltage to low or short circuit to -Ubatt 2: data stream is defective
12. Errormode not identifiable 12. Errormode not identifiable 8: unusual frequency, pulse or period.
Errordetection 2: data stream is defective Errordetection
Errorlamp shows permanent light. Entry in errormemory. Errordetection Errorlamp shows permanent light. Entry in errormemory.
Possible reason for error Errorlamp shows permanent light. Entry in errormemory. Possible reason for error
Pressure loss above target range with system reaction, air filter Possible reason for error Duty cycle outside target range, signal erroneous or implausible
clogged or defective, sensor not working, connection cable Voltage outside target range, signal implausible compared to (pedal 1), sensor defective, onnection cable demaged
demaged signal of redundant pedal (analog pedal 1), sensor defective, Take actions for error repair
Take actions for error repair connection cable demaged Check cabling, check accelator pedal sensor and if necessary
Check airfilter and if necessary clean or renew it, check cabling, Take actions for error repair replace it, check connection cable and if necessary repair or
BW 220 D-5
check air filter and if necessary replace the filter component, Check cabling, check accelator pedal sensor and if necessary replace it
check sensor and if necessary replace it, check connection cable replace it, check connection cable and if necessary repair or other error properties
and if necessary repair or replace it replace it System reaction: Warning, switching to substitute value
other error properties other error properties correspond to Priority-Chain or Limp Home
System reaction: Warning or Warning and power reduction System reaction: Warning, switching to substitute value Behaviour error lamp: permanent light
Behaviour error lamp: permanent light correspond to Priority-Chain or Limp Home Selfhealing: yes
Selfhealing: yes Behaviour error lamp: permanent light Signal Priority: 4
Signal Priority: 2 Selfhealing: no Measurement @ errortime: actual value
Measurement @ errortime: actual value Signal Priority: 4
Measurement @ errortime: actual value

673
674
DTC-List P490_: 220, 310, 501 P492_: 213
15 / 91 / APPPwmPer 16 / 108 / APSCD 17 / 729 / ArHt1

Error description THROTTLE 1 Error description BAROMETRIC PRESS. Error description AIR HEATER RELAY
digital accelerator pedal sensor (PWM): the frequence of the Ambient air pressure sensor (in ECU): the voltage measured by Air heater relay: the current drain measured by ECU is out of the
signal received by ECU is out of the target range ECU is out of the target range or the calculated ambient air target range
Error codes pressure is implausible compared with the charge air pressure Error codes
8: unusual frequency, pulse or period. possible FMI: 3: Voltage to high or short circuit to +Ubatt
8: unusual frequency, pulse or period. 3: Voltage to high or short circuit to +Ubatt 4: Voltage to low or short circuit to -Ubatt
12. Errormode not identifiable 4: Voltage to low or short circuit to -Ubatt 5: current to low or broken wire
12. Errormode not identifiable 12. Errormode not identifiable 12. Errormode not identifiable
Errordetection 2: data stream is defective Errordetection
Pulse frequency outside target range (pedal 1), sensor defective, Possible reason for error Cable break or short circuit at EDC output, relay defective,
connection cable demaged Ambient air pressure sensor defective, ECU defective connection cable demaged
Take actions for error repair Take actions for error repair Take actions for error repair
Check cabling, check accelator pedal sensor and if necessary Change ECU Check cabling, if sensor not working, check relay and if
replace it, check connection cable and if necessary repair or other error properties necessary replace it, check connection cable and if necessary
replace it System reaction: Warning, substitute value (0,85bar) repair or replace it
BW 220 D-5
other error properties Behaviour error lamp: permanent light other error properties
System reaction: Warning, switching to substitute value Selfhealing: yes System reaction: Warning, shutoff output
correspond to Priority-Chain or Limp Home Signal Priority: 4 Behaviour error lamp: permanent light
Behaviour error lamp: permanent light Measurement @ errortime: default value Selfhealing: yes
Selfhealing: yes Signal Priority: 2
Signal Priority: 4 Measurement @ errortime: shut off value

DTC-List P490_: 220, 310, 501 P492_: 213
18 / 730 / ArHt2 19 / 676 / ArHtCD_NoLd 20 / 676 / ArHtCD_RlyErr

Error description AIR HEATER VALVE Error description AIR HEATER Error description AIR HEATER
Air heater magnet valve: the current drain measured by ECU is Air heater relay: the ECU detects no switching operation at the Air heater relay: the ECU detects an implausible signal at the
out of the target range input of a readback process input of a readback process
Error codes Error codes Error codes
DEUTZ-Errorcode: 18 DEUTZ-Errorcode: 19 DEUTZ-Errorcode: 20
BlinkCode (short-long-short): 2 - 6 - 3 BlinkCode (short-long-short): 2 - 6 - 3 BlinkCode (short-long-short): 2 - 6 - 3
SPN: 730 SPN: 676 SPN: 676
possible FMI: possible FMI: possible FMI:
3: Voltage to high or short circuit to +Ubatt 12. Errormode not identifiable 5: current to low or broken wire
4: Voltage to low or short circuit to -Ubatt 4: Voltage to low or short circuit to -Ubatt 2: data stream is defective
5: current to low or broken wire 12. Errormode not identifiable 12. Errormode not identifiable
Errordetection Errordetection Errordetection
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory.
Possible reason for error Possible reason for error Possible reason for error
Cable break or short circuit, valve defective, connection cable Relay energized, but no feedback on sense line, relay defective Relay not energized, but working voltage on sense line, relay
demaged or wrong wired, preheat component defective, connection cable defective (can not disconnect or switch off), preheat component
Take actions for error repair demaged defective, connection cable demaged
Check valve and if necessary replace it, check connection cable Take actions for error repair Take actions for error repair
and if necessary repair or replace it Check cabling of preheat component, if relay not working,check Check cabling of preheat component, if relay not working,check
other error properties relay and if necessary replace it, check preheat component and if relay and if necessary replace it, check preheat component and if
BW 220 D-5
System reaction: necessary replace it, check connection cable and if necessary necessary replace it, check connection cable and if necessary
Behaviour error lamp: permanent light repair or replace it repair or replace it
Selfhealing: yes other error properties other error properties
Signal Priority: 2 System reaction: Warning System reaction: Warning
Measurement @ errortime: shut off value Behaviour error lamp: permanent light Behaviour error lamp: permanent light
Selfhealing: no Selfhealing: no
Signal Priority: 3 Signal Priority: 3
Measurement @ errortime: setpoint for output status Measurement @ errortime: setpoint for output status

675
676
DTC-List P490_: 220, 310, 501 P492_: 213
22 / 168 / BattCD 23 / 168 / BattCDSysReac 24 / 523561 / BIPCyl1

Error description BATTERY VOLTAGE Error description BATTERY VOLTAGE Error description INJECT. PERIOD ZYL.1
Battery voltage: the voltage measured by ECU is out of the target Battery voltage: the voltage measured by ECU is out of the target Begin of injection of cylinder 1: the ECU can not identify the
range range; the ECU activates a system reaction magnet valve or the injection pump with the measured value of
Error codes Error codes current drain at the begin of the injection
DEUTZ-Errorcode: 22 DEUTZ-Errorcode: 23 Error codes
BlinkCode (short-long-short): 3 - 1 - 8 BlinkCode (short-long-short): 3 - 1 - 8 DEUTZ-Errorcode: 24
SPN: 168 SPN: 168 BlinkCode (short-long-short): 5 - 3 - 1
possible FMI: possible FMI: SPN: 523561
0: data valid, but above normal working area 2: data stream is defective possible FMI:
1: data valid, but below normal working area 2: data stream is defective 2: data stream is defective
12. Errormode not identifiable 12. Errormode not identifiable 2: data stream is defective
Errordetection Errordetection 2: data stream is defective
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory. Errordetection
Possible reason for error Possible reason for error Errorlamp shows permanent light. Entry in errormemory.
Voltage below target range, battery defective, too high power Above target range with system reaction, too high power supply Possible reason for error
supply voltage, too high contact resistance, wiring demaged, voltage, parametering inaccurate, ECU defective Value outside target range or missing (cylinder 1), magnet valve
energie system overloaded, parametering inaccurate, ECU Take actions for error repair or injection pump defective
defective Check dataset of calibration of working voltage for application, Take actions for error repair
Take actions for error repair check LIMA? Check voltage of generator, check the parameters Check magnetic valve or injection pump and if
Check LIMA?, ECU, cabling, contact resistance, safety fuses, too and if necessary correct them, replace ECU necessary change them
BW 220 D-5
high load in energy system, check battery and if necessary other error properties other error properties
replace it, check battery pole and if necessary clean it, check System reaction: Warning System reaction: No function at the moment/ Allocation check
connection cable and if necessary repair or replace it, check volta Behaviour error lamp: permanent light cylinder!
other error properties Selfhealing: yes Behaviour error lamp: permanent light
System reaction: Warning, substitute value, dependent upon Signal Priority: 4 Selfhealing: yes
supply voltage (12V, 24V) Measurement @ errortime: actual value Signal Priority: 3
Behaviour error lamp: permanent light Measurement @ errortime: actual value

Selfhealing: yes
Signal Priority: 3

DTC-List P490_: 220, 310, 501 P492_: 213
25 / 523562 / BIPCyl2 26 / 523563 / BIPCyl3 27 / 523564 / BIPCyl4

Error description INJECT. PERIOD ZYL.2 Error description INJECT. PERIOD ZYL.3 Error description INJECT. PERIOD ZYL.4
Begin of injection of cylinder 2: the ECU can not identify the Begin of injection of cylinder 3: the ECU can not identify the Begin of injection of cylinder 4: the ECU can not identify the
magnet valve or the injection pump with the measured value of magnet valve or the injection pump with the measured value of magnet valve or the injection pump with the measured value of
current drain at the begin of the injection current drain at the begin of the injection current drain at the begin of the injection
SPN: 523562 SPN: 523563 SPN: 523564
2: data stream is defective 2: data stream is defective 2: data stream is defective
Value outside target range or missing (cylinder 2), magnet valve Value outside target range or missing (cylinder 3), magnet valve Value outside target range or missing (cylinder 4), magnet valve
or injection pump defective or injection pump defective or injection pump defective
Check magnetic valve or injection pump and if Check magnetic valve or injection pump and if d
necessary change them necessary change them other error properties
BW 220 D-5
other error properties other error properties System reaction: No function at the moment/ Allocation check
System reaction: No function at the moment/ Allocation check System reaction: No function at the moment/ Allocation check cylinder!
cylinder! cylinder! Behaviour error lamp: permanent light
Behaviour error lamp: permanent light Behaviour error lamp: permanent light Selfhealing: yes
Selfhealing: yes Selfhealing: yes Signal Priority: 3
Signal Priority: 3 Signal Priority: 3 Measurement @ errortime: actual value
Measurement @ errortime: actual value Measurement @ errortime: actual value

677
678
DTC-List P490_: 220, 310, 501 P492_: 213
28 / 523565 / BIPCyl5 29 / 523566 / BIPCyl6 30 / 523567 / BIPCyl7

Error description INJECT. PERIOD ZYL.5 Error description INJECT. PERIOD ZYL.6 Error description INJECT. PERIOD ZYL.7
Begin of injection of cylinder 5: the ECU can not identify the Begin of injection of cylinder 6: the ECU can not identify the Begin of injection of cylinder 7: the ECU can not identify the
magnet valve or the injection pump with the measured value of magnet valve or the injection pump with the measured value of magnet valve or the injection pump with the measured value of
current drain at the begin of the injection current drain at the begin of the injection current drain at the begin of the injection
SPN: 523565 SPN: 523566 SPN: 523567
Value outside target range or missing (cylinder 5), magnet valve Value outside target range or missing (cylinder 6), magnet valve Value outside target range or missing (cylinder 7), magnet valve
or injection pump defective or injection pump defective or injection pump defective
Check magnetic valve or injection pump and if Check magnetic valve or injection pump and if Check magnetic valve or injection pump and if
necessary change them necessary change them necessary change them
BW 220 D-5
other error properties other error properties other error properties
System reaction: No function at the moment/ Allocation check System reaction: No function at the moment/ Allocation check System reaction: No function at the moment/ Allocation check
cylinder! cylinder! cylinder!
Behaviour error lamp: permanent light Behaviour error lamp: permanent light Behaviour error lamp: permanent light
Selfhealing: yes Selfhealing: yes Selfhealing: yes
Signal Priority: 3 Signal Priority: 3 Signal Priority: 3
Measurement @ errortime: actual value Measurement @ errortime: actual value Measurement @ errortime: actual value

DTC-List P490_: 220, 310, 501 P492_: 213
31 / 523568 / BIPCyl8 32 / 102 / BPSCD 33 / 102 / BPSCDSysReac

Error description INJECT. PERIOD ZYL.8 Error description CHARGE AIR PRESS. Error description CHARGE AIR PRESS.
Begin of injection of cylinder 8: the ECU can not identify the Charge air pressure sensor: the measured voltage of sensor by Charge air pressure: the charge air pressure calculated by ECU
magnet valve or the injection pump with the measured value of ECU is out of the target range; the calculated charge air pressure is above the target range; the ECU activates a system reaction
current drain at the begin of the injection is implausible or the received value via CAN is defective Error codes
Error codes Error codes DEUTZ-Errorcode: 33
DEUTZ-Errorcode: 31 DEUTZ-Errorcode: 32 BlinkCode (short-long-short): 2 - 2 - 3
BlinkCode (short-long-short): 5 - 3 - 8 BlinkCode (short-long-short): 2 - 2 - 3 SPN: 102
SPN: 523568 SPN: 102 possible FMI:
possible FMI: possible FMI: 2: data stream is defective
2: data stream is defective 3: Voltage to high or short circuit to +Ubatt 2: data stream is defective
2: data stream is defective 4: Voltage to low or short circuit to -Ubatt 12. Errormode not identifiable
2: data stream is defective 2: data stream is defective 12. Errormode not identifiable
2: data stream is defective 2: data stream is defective Errordetection
Errordetection Errordetection Errorlamp shows permanent light
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory. oder
Possible reason for error Possible reason for error blinking. Entry in errormemory.
Value outside target range or missing (cylinder 8), magnet valve Cable break or short circuit, sensor defective, onnection cable Possible reason for error
or injection pump defective demaged Outside target range with system reaction, air system demaged,
Take actions for error repair Take actions for error repair sensor defective, onnection cable demaged
Check magnetic valve or injection pump and if Check cabling, if LDF6T sensor not working, check sensor and if Take actions for error repair
necessary change them necessary replace it, check connection cable and if necessary Check air system, inspect air system and if necessary repair it,
BW 220 D-5
other error properties repair or replace it check sensor and if necessary replace it, check connection cable
System reaction: No function at the moment/ Allocation check other error properties and if necessary repair or replace it
cylinder! System reaction: Warning, substitute value other error properties
Behaviour error lamp: permanent light Behaviour error lamp: permanent light System reaction: Advice: BPSCD_stSysReacReq
Selfhealing: yes Selfhealing: yes Behaviour error lamp: permanent light
Signal Priority: 3 Signal Priority: 4 oder
Measurement @ errortime: actual value Measurement @ errortime: default value blinking
Selfhealing: yes
Signal Priority: 4

679
680
DTC-List P490_: 220, 310, 501 P492_: 213
37 / 111 / CLSCDSysReac 38 / 1323 / CmbChbMisfire1 39 / 1324 / CmbChbMisfire2

Error description ENG COOLANT LEVEL Error description MISFIRE CYL. 1 Error description MISFIRE CYL. 2
Coolant level: the coolant level calculated by ECU is underneath Misfire at cylinder 1: the number of the misfire detected by ECU Misfire at cylinder 2: the number of the misfire detected by ECU
the allowed minimum is out of the allowed limit value is out of the allowed limit value
SPN: 111 SPN: 1323 SPN: 1324
1: data valid, but below normal working area 12: Defective component 12: Defective component
1: data valid, but below normal working area 12. Errormode not identifiable 12. Errormode not identifiable
Errorlamp shows permanent light Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory.
oder Possible reason for error Possible reason for error
blinking. Entry in errormemory. Misfire detected (cylinder 1), magnet valve or injection pump Misfire detected (cylinder 2), magnet valve or injection pump
Possible reason for error defective, fuel system defective, motor engineering demaged defective, fuel system defective, motor engineering demaged
Outside target range with system reaction, cooling system Take actions for error repair Take actions for error repair
untight, sensor defective, onnection cable demaged Check magnetic valve or injection pump and if necessary replace Check magnetic valve or injection pump and if necessary replace
Take actions for error repair them, check fuel system and if necessary repair it, check motor them, check fuel system and if necessary repair it, check motor
Check coolant level, check cabling, inspect cooling system and if engineering and if necessary repair it engineering and if necessary repair it
BW 220 D-5
necessary repair it, check sensor and if necessary replace it, other error properties other error properties
check connection cable and if necessary repair or replace it System reaction: System reaction:
other error properties Behaviour error lamp: permanent light Behaviour error lamp: permanent light
System reaction: Advice: CLSCD_stSysReacReq Selfhealing: no Selfhealing: no
Behaviour error lamp: permanent light Signal Priority: 0 Signal Priority: 0
oder Measurement @ errortime: actual value Measurement @ errortime: actual value
blinking
Selfhealing: no
Signal Priority: 3

DTC-List P490_: 220, 310, 501 P492_: 213
40 / 1325 / CmbChbMisfire3 41 / 1326 / CmbChbMisfire4 42 / 1327 / CmbChbMisfire5

Error description MISFIRE CYL. 3 Error description MISFIRE CYL. 4 Error description MISFIRE CYL. 5
Misfire at cylinder 3: the number of the misfire detected by ECU Misfire at cylinder 4: the number of the misfire detected by ECU Misfire at cylinder 5: the number of the misfire detected by ECU
is out of the allowed limit value is out of the allowed limit value is out of the allowed limit value
SPN: 1325 SPN: 1326 SPN: 1327
12: Defective component 12: Defective component 12: Defective component
Misfire detected (cylinder 3), magnet valve or injection pump Misfire detected (cylinder 4), magnet valve or injection pump Misfire detected (cylinder 5), magnet valve or injection pump
defective, fuel system defective, motor engineering demaged defective, fuel system defective, motor engineering demaged defective, fuel system defective, motor engineering demaged
Check magnetic valve or injection pump and if necessary replace Check magnetic valve or injection pump and if necessary replace Check magnetic valve or injection pump and if necessary replace
them, check fuel system and if necessary repair it, check motor them, check fuel system and if necessary repair it, check motor them, check fuel system and if necessary repair it, check motor
engineering and if necessary repair it engineering and if necessary repair it engineering and if necessary repair it
BW 220 D-5
System reaction: System reaction: System reaction:
Selfhealing: no Selfhealing: no Selfhealing: no

681
682
DTC-List P490_: 220, 310, 501 P492_: 213
43 / 1328 / CmbChbMisfire6 44 / 1450 / CmbChbMisfire7 45 / 1451 / CmbChbMisfire8

Error description MISFIRE CYL. 6 Error description MISFIRE CYL. 7 Error description MISFIRE CYL. 8
Misfire at cylinder 6: the number of the misfire detected by ECU Misfire at cylinder 7: the number of the misfire detected by ECU Misfire at cylinder 8: the number of the misfire detected by ECU
is out of the allowed limit value is out of the allowed limit value is out of the allowed limit value
SPN: 1328 SPN: 1450 SPN: 1451
Misfire detected (cylinder 6), magnet valve or injection pump Misfire detected (cylinder 7), magnet valve or injection pump Misfire detected (cylinder 8), magnet valve or injection pump
defective, fuel system defective, motor engineering demaged defective, fuel system defective, motor engineering demaged defective, fuel system defective, motor engineering demaged
Check magnetic valve or injection pump and if necessary replace Check magnetic valve or injection pump and if necessary replace Check magnetic valve or injection pump and if necessary replace
them, check fuel system and if necessary repair it, check motor them, check fuel system and if necessary repair it, check motor them, check fuel system and if necessary repair it, check motor
engineering and if necessary repair it engineering and if necessary repair it engineering and if necessary repair it
BW 220 D-5

DTC-List P490_: 220, 310, 501 P492_: 213
46 / 1322 / CmbChbMisfireMul 47 / 1346 / CmbChbSysReac 48 / 1109 / CoEngShOffDemIgr

Error description MULTIPL. CYL. MISFIRE Error description MISFIRE SYST. REACT Error description SHUT OFF REQUEST
Misfire at more cylinders: the number of the misfire detected by Misfire at more cylinders: the number of the misfire detected by Request of engine off: the operator ignors the engine off request
ECU is out of the allowed limit value ECU is out of the allowed limit value; the ECU activates a system within an allowed period.
Error codes reaction Error codes
12: Defective component possible FMI: 2: data stream is defective
12. Errormode not identifiable 0: data valid, but above normal working area 12. Errormode not identifiable
Errordetection 12. Errormode not identifiable Errordetection
Misfire detected, magnet valve or injection pump defective, fuel Possible reason for error Shut-off request ignored by operator
system defective, motor engineering demaged Misfire detected with system reaction, magnet valve or injection Take actions for error repair
Take actions for error repair pump defective, fuel system defective, motor engineering Warranty relevant
Check magnetic valve or injection pump and if necessary replace demaged other error properties
them, check fuel system and if necessary repair it, check motor Take actions for error repair System reaction: Warning
engineering and if necessary repair it Check magnetic valve or injection pump and if necessary replace Behaviour error lamp: permanent light
BW 220 D-5
other error properties them, check fuel system and if necessary repair it, check motor Selfhealing: no
System reaction: engineering and if necessary repair it Signal Priority: 4
Behaviour error lamp: permanent light other error properties Measurement @ errortime: actual value
Selfhealing: no System reaction:
Signal Priority: 0 Behaviour error lamp: permanent light
Measurement @ errortime: actual value Selfhealing: no
Signal Priority: 0

683
684
DTC-List P490_: 220, 310, 501 P492_: 213
52 / 1072 / CRERCD 53 / 1081 / CSLpCD 54 / 704 / CTLpCD

Error description ENGINE BRAKE INT. Error description PREHEAT LAMP Error description TEMP. LAMP
Engine brake actuator (internal): the current drain measured by Indicator lamp of air heater relay: the current drain measured by Warning lamp for coolant temperature: the current drain
ECU is out of the target range or the maximum permissble ECU is out of the target range or the maximum permissble measured by ECU is out of the target range or the maximum
temperature of the ECU component for power supply of the temperature of the ECU component for power supply of the lamp temperature of the ECU component for power supply of the lamp
actuator is exceeded. is exceeded is exceeded
SPN: 1072 SPN: 1081 SPN: 704
3: Voltage to high or short circuit to +Ubatt 3: Voltage to high or short circuit to +Ubatt 12. Errormode not identifiable
4: Voltage to low or short circuit to -Ubatt 4: Voltage to low or short circuit to -Ubatt 12. Errormode not identifiable
5: current to low or broken wire 5: current to low or broken wire 12. Errormode not identifiable
12. Errormode not identifiable 2: data stream is defective 12. Errormode not identifiable
cable break or short circuit, sensor defective, connection cable Cable break or short circuit, lamp defective, connection cable Cable break or short circuit, lamp defective, connection cable
demaged demaged demaged
Check actuator and if necessary replace it, check connection Check cabling and load, check lamp and if necessary replace it, Check cabling and load, check lamp and if necessary replace it,
BW 220 D-5
cable and if necessary repaire or replace it check connection cable and if necessary repair or replace it check connection cable and if necessary repair or replace it
System reaction: Warning, shutoff output, capacity reduction via System reaction: Warning, shutoff output System reaction: Warning, shutoff output
second topcurve? Behaviour error lamp: permanent light Behaviour error lamp: permanent light
Behaviour error lamp: permanent light Selfhealing: no Selfhealing: no
Selfhealing: no Signal Priority: 1 Signal Priority: 1
Signal Priority: 2 Measurement @ errortime: setpoint for output status Measurement @ errortime: setpoint for output status
Measurement @ errortime: setpoint for output status

DTC-List P490_: 220, 310, 501 P492_: 213
55 / 110 / CTSCD 56 / 110 / CTSCDSysReac 57 / 701 / Dummy1CD_Max

Error description ENG COOLANT TEMP. Error description ENG COOLANT TEMP. Error description RESERVE 2
Coolant temperature sensor: the voltage of the sensor measured Coolant temperature: the coolant temperature calculated by ECU Reserve output 1: the ECU detects a short circuit to battery
by ECU is out of the target range; the coolant temperature is above the target range; the ECU activates a system reaction Error codes
calculated by ECU is implausible compared with the oil Error codes DEUTZ-Errorcode: 57
temperature or the received value via CAN is defective DEUTZ-Errorcode: 56 BlinkCode (short-long-short): 1 - 0 - 0
Error codes BlinkCode (short-long-short): 2 - 3 - 2 SPN: 701
DEUTZ-Errorcode: 55 SPN: 110 possible FMI:
BlinkCode (short-long-short): 2 - 2 - 5 possible FMI: 12. Errormode not identifiable
SPN: 110 0: data valid, but above normal working area 12. Errormode not identifiable
possible FMI: 0: data valid, but above normal working area 12. Errormode not identifiable
3: Voltage to high or short circuit to +Ubatt 12. Errormode not identifiable 12. Errormode not identifiable
4: Voltage to low or short circuit to -Ubatt 12. Errormode not identifiable Errordetection
2: data stream is defective Errordetection Errorlamp shows permanent light. Entry in errormemory.
2: data stream is defective Errorlamp shows permanent light Possible reason for error
Errordetection oder Short circuit to Ubatt (output 1), connection cable demaged
Errorlamp shows permanent light. Entry in errormemory. blinking. Entry in errormemory. Take actions for error repair
Possible reason for error Possible reason for error Check connection cable and if necessary repair or replace it
Cable break or short circuit, lamp defective, connection cable Outside target range with system reaction, cooling system not other error properties
demaged enough to be filled, clogged or demaged, cooling compressor System reaction: Warning, shutoff output
Take actions for error repair dropped out, sensor defective, onnection cable demaged Behaviour error lamp: permanent light
Check cabling, sensor defect, check sensor and if necessary Take actions for error repair Selfhealing: no
BW 220 D-5
replace it, check connection cable and if necessary repair or Check cycle cooling system and compressor, inspect cooling Signal Priority: 1
replace it system and if necessary repair it, check cooling compressor and Measurement @ errortime: shut off value
other error properties if necessary replace it, check sensor and if necessary replace it,
System reaction: Warning, substitute value check connection cable and if necessary repair or replace it
Behaviour error lamp: permanent light other error properties
Selfhealing: yes System reaction: Advice: CTSCD_stSysReacReq
Measurement @ errortime: default value oder
blinking
Selfhealing: yes
Signal Priority: 4

685
686
DTC-List P490_: 220, 310, 501 P492_: 213
58 / 701 / Dummy1CD_Min 59 / 701 / Dummy1CD_SigNpl 60 / 702 / Dummy2CD_Max

Error description RESERVE 2 Error description RESERVE 2 Error description THRUST MODE
Reserve output 1: the ECU detects a short circuit to ground Reserve output 1: the ECU detects no load or excess Reserve output 2: the ECU detects a short circuit to battery
Error codes temperature of the ECU component for power supply of the Error codes
DEUTZ-Errorcode: 58 connected components DEUTZ-Errorcode: 60
BlinkCode (short-long-short): 1 - 0 - 0 Error codes BlinkCode (short-long-short): 1 - 0 - 0
SPN: 701 DEUTZ-Errorcode: 59 SPN: 702
possible FMI: BlinkCode (short-long-short): 1 - 0 - 0 possible FMI:
12. Errormode not identifiable SPN: 701 12. Errormode not identifiable
12. Errormode not identifiable possible FMI: 12. Errormode not identifiable
Errordetection 12. Errormode not identifiable Errordetection
Errorlamp shows permanent light. Entry in errormemory. 12. Errormode not identifiable Errorlamp shows permanent light. Entry in errormemory.
Possible reason for error Errordetection Possible reason for error
Short circuit to ground (output 1), connection cable demaged Errorlamp shows permanent light. Entry in errormemory. Short circuit to Ubatt (output 2), onnection cable demaged
Take actions for error repair Possible reason for error Take actions for error repair
Check connection cable and if necessary repair or replace it Cable break or ECU internal error (output 1), connection cable Check connection cable and if necessary repair or replace it
other error properties demaged, connected components defective, parametering of the other error properties
System reaction: Warning, shutoff output output inaccurate, ECU defective System reaction: Warning, shutoff output
Behaviour error lamp: permanent light Take actions for error repair Behaviour error lamp: permanent light
Selfhealing: no Check connection cable and if necessary repair or replace it, Selfhealing: no
BW 220 D-5
Signal Priority: 1 check parameters and if necessary correct it, replace ECU Signal Priority: 1
Measurement @ errortime: shut off value other error properties Measurement @ errortime: shut off value
System reaction: Warning, shutoff output
Behaviour error lamp: permanent light
Selfhealing: no
Signal Priority: 1
Measurement @ errortime: shut off value

DTC-List P490_: 220, 310, 501 P492_: 213
61 / 702 / Dummy2CD_Min 62 / 702 / Dummy2CD_SigNpl 69 / 2791 / EGRCD_Max

Error description THRUST MODE Error description THRUST MODE Error description EGR ACTUATOR
Reserve output 2: the ECU detects a short circuit to ground Reserve output 2: the ECU detects no load or excess Actuator of the external EGR valve: the ECU detects a short
Error codes temperature of the ECU component for power supply of the circuit to battery
DEUTZ-Errorcode: 61 connected components Error codes
BlinkCode (short-long-short): 1 - 0 - 0 Error codes DEUTZ-Errorcode: 69
SPN: 702 DEUTZ-Errorcode: 62 BlinkCode (short-long-short): 4 - 1 - 4
possible FMI: BlinkCode (short-long-short): 1 - 0 - 0 SPN: 2791
12. Errormode not identifiable SPN: 702 possible FMI:
12. Errormode not identifiable possible FMI: 3: Voltage to high or short circuit to +Ubatt
Errordetection 12. Errormode not identifiable 12. Errormode not identifiable
Errorlamp shows permanent light. Entry in errormemory. 12. Errormode not identifiable Errordetection
Possible reason for error Errordetection Errorlamp shows permanent light. Entry in errormemory.
Short circuit to ground (output 2), connection cable demaged Errorlamp shows permanent light. Entry in errormemory. Possible reason for error
Take actions for error repair Possible reason for error Short circuit to Ubatt, connection cable demaged
Check connection cable and if necessary repair or replace it Cable break or ECU internal error (output 2), connection cable Take actions for error repair
other error properties demaged, connected components defective, parametering of the Check cabling, sensor defect, check sensor and if necessary
System reaction: Warning, shutoff output output inaccurate, ECU defective replace it, check connection cable and if necessary repair or
Behaviour error lamp: permanent light Take actions for error repair replace it
Selfhealing: no Check connection cable and if necessary repair or replace it, other error properties
BW 220 D-5
Signal Priority: 1 check parameters and if necessary correct it, replace ECU System reaction: Warning, shutoff output, power reduction via
Measurement @ errortime: shut off value other error properties second topcurve?
System reaction: Warning, shutoff output Behaviour error lamp: permanent light
Behaviour error lamp: permanent light Selfhealing: no
Selfhealing: no Signal Priority: 3
Signal Priority: 1 Measurement @ errortime: shut off value

687
688
DTC-List P490_: 220, 310, 501 P492_: 213
70 / 2791 / EGRCD_Min 71 / 2791 / EGRCD_SigNpl 72 / 2791 / EGRCDIntEGR

Error description EGR ACTUATOR Error description EGR ACTUATOR Error description EGR ACTUATOR
Actuator of the external EGR valve: the ECU detects a short Actuator of the external EGR valve: the ECU detects no load or Actuator of the internal EGR valve: the ECU detects no load or
circuit to ground excess temperature of the ECU component for power supply of excess temperature of the ECU component for power supply of
Error codes the connected components the actuator
DEUTZ-Errorcode: 70 Error codes Error codes
BlinkCode (short-long-short): 4 - 1 - 4 DEUTZ-Errorcode: 71 DEUTZ-Errorcode: 72
SPN: 2791 BlinkCode (short-long-short): 4 - 1 - 5 BlinkCode (short-long-short): 4 - 1 - 6
possible FMI: SPN: 2791 SPN: 2791
12. Errormode not identifiable possible FMI: possible FMI:
4: Voltage to low or short circuit to -Ubatt 12. Errormode not identifiable 3: Voltage to high or short circuit to +Ubatt
12. Errormode not identifiable 12. Errormode not identifiable 4: Voltage to low or short circuit to -Ubatt
12. Errormode not identifiable 5: current to low or broken wire 5: current to low or broken wire
Errordetection 2: data stream is defective 2: data stream is defective
Errorlamp shows permanent light. Entry in errormemory. Errordetection Errordetection
Possible reason for error Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory.
Short circuit to ground, connection cable demaged Possible reason for error Possible reason for error
Take actions for error repair Cable break or excess temperature, sensor defective, connection Cable break, short circuit or excess temperature, sensor
Check cabling, sensor defect, check sensor and if necessary cable demaged defective, connection cable demaged
replace it, check connection cable and if necessary repair or Take actions for error repair Take actions for error repair
replace it Check cabling, sensor defect, check sensor and if necessary Check cabling, sensor defect, check sensor and if necessary
other error properties replace it, check connection cable and if necessary repair or replace it, check connection cable and if necessary repair or
BW 220 D-5
System reaction: Warning, shutoff output, power reduction via replace it replace it
second topcurve? other error properties other error properties
Behaviour error lamp: permanent light System reaction: Warning, shutoff output, power reduction via System reaction: Warning, shutoff output, power reduction via
Selfhealing: no second topcurve? second topcurve?
Signal Priority: 3 Behaviour error lamp: permanent light Behaviour error lamp: permanent light
Measurement @ errortime: shut off value Selfhealing: no Selfhealing: no

Measurement @ errortime: shut off value Measurement @ errortime: shut off value

DTC-List P490_: 220, 310, 501 P492_: 213
74 / 923 / EngCDTrqCalcOut 75 / 190 / EngMBackUp 76 / 190 / EngMCaS1

Error description ENGINE POWER OUT Error description ENGINE SPEED Error description ENGINE SPEED
Output with PWM signal of the engine power: the current drain Crankschaft speed sensor: the ECU receives no signal and uses Camschaft speed sensor: the ECU receives no signal or the
measured by ECU is out of the target range or the maximum the signal from camschaft speed sensor as alternative to signal is defective
permissible temperature of the ECU component to control the calculate the engine speed Error codes
output is exceeded Error codes DEUTZ-Errorcode: 76
Error codes DEUTZ-Errorcode: 75 BlinkCode (short-long-short): 2 - 1 - 2
DEUTZ-Errorcode: 74 BlinkCode (short-long-short): 2 - 1 - 2 SPN: 190
BlinkCode (short-long-short): 5 - 5 - 5 SPN: 190 possible FMI:
SPN: 923 possible FMI: 12: Defective component
possible FMI: 12. Errormode not identifiable 8: unusual frequency, pulse or period.
3: Voltage to high or short circuit to +Ubatt 12: Defective component 12. Errormode not identifiable
4: Voltage to low or short circuit to -Ubatt 12. Errormode not identifiable 12. Errormode not identifiable
5: current to low or broken wire 12. Errormode not identifiable Errordetection
2: data stream is defective Errordetection Errorlamp shows permanent light. Entry in errormemory.
Errordetection Errorlamp shows permanent light. Entry in errormemory. Possible reason for error
Errorlamp shows permanent light. Entry in errormemory. Possible reason for error Speed signal from cam-shaft defectiveiv or missing, transmitter
Possible reason for error Engine running only with cam-shaft speed signal, transmitter defective, connection cable demaged, parametering of the sensor
Engine Power output: cable break or short circuit, output defective, connection cable demaged wheel inaccurate
defective, connection cable demaged Take actions for error repair Take actions for error repair
Take actions for error repair Check cabling of crankschaft sensor, check crankschaft sensor Check cabling, check camschaft sensor and if necessary replace
Check cabling, sensor defect, check sensor and if necessary and if necessary replace it, check connection cable and if it, check configuration of sensor wheel, check connection cable
BW 220 D-5
replace it, check connection cable and if necessary repair or necessary repair or replace it and if necessary repair or replace it, check parameters and if
replace it other error properties necessary correct them
other error properties System reaction: Warning, calculation of injektion initation point other error properties
System reaction: Warning, shutoff output will be incorrect System reaction: Warning, difficult start
Selfhealing: no Selfhealing: yes Selfhealing: yes
Measurement @ errortime: shut off value Measurement @ errortime: - Measurement @ errortime: 0

689
690
DTC-List P490_: 220, 310, 501 P492_: 213
77 / 190 / EngMCrS1 78 / 190 / EngMOfsCaSCrS 79 / 190 / EngPrtSysReacFOC

Error description ENGINE SPEED Error description ENGINE SPEED Error description ENGINE SPEED
Crankschaft speed sensor: the ECU receives no signal or the Speed sensor of crankschaft and camschaft: the received signals Engine speed: the engine speed calculated by ECU is above the
signal is defective are out of phase target range; the ECU activates a system reaction
SPN: 190 SPN: 190 SPN: 190
12: Defective component 2: data stream is defective 0: data valid, but above normal working area
8: unusual frequency, pulse or period. 12. Errormode not identifiable 12. Errormode not identifiable
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows blinking. Entry in errormemory.
Speed signal from crankshaft defectiveiv or missing, transmitter Speed signals of crank-shaft and cam-shaft are phase-shifted, Engine overspeed detected with system reaction, maximum
defective, connection cable demaged, sensor wheel installed sensor wheel installed in wrong position, sensor wrong wired engine speed exceeded
inaccurately Take actions for error repair Take actions for error repair
Take actions for error repair Check position from crankschaft sensor wheel to camschaft other error properties
Check cabling, check camschaft sensor and if necessary replace sensor wheel, polarisation crankschaft or camschaft sensor, System reaction:
it, check configuration of sensor wheel, check connection cable check position of sensor wheel and if necessary correct it, check Behaviour error lamp: blinking
BW 220 D-5
and if necessary repair or replace it, check the position of sensor cabling and if necessary correct it Selfhealing: no
wheel and if necessary correct it other error properties Signal Priority: 5
other error properties System reaction: Warning, not possible to start engine Measurement @ errortime: actual value
System reaction: Warning, power reduction via second topcurve Behaviour error lamp: permanent light
Behaviour error lamp: permanent light Selfhealing: no
Signal Priority: 4 Measurement @ errortime: -

Measurement @ errortime: 0

DTC-List P490_: 220, 310, 501 P492_: 213
80 / 190 / EngPrtSysReacORC 81 / 703 / ESLpCD 82 / 1074 / ExFlCD

Error description ENGINE SPEED Error description ENG. RUNNING LAMP Error description BRAKE FLAP ACTUATOR
Engine speed: under overrun conditions, the engine speed Indicator lamp for engine running: the current drain measured by Engine brake flap actuator: the current drain measured by ECU is
calculated by ECU is above the target range; the ECU activates a ECU is out of the target range or the maximum permissible out of the target range or the maximum permissible temperature
system reaction temperature of the ECU component for power supply of the lamp of the ECU component for power supply of the actuator is
Error codes is exceeded exceeded
14: Special Instructions possible FMI: possible FMI:
12. Errormode not identifiable 3: Voltage to high or short circuit to +Ubatt 3: Voltage to high or short circuit to +Ubatt
12. Errormode not identifiable 4: Voltage to low or short circuit to -Ubatt 4: Voltage to low or short circuit to -Ubatt
12. Errormode not identifiable 5: current to low or broken wire 5: current to low or broken wire
Errordetection 2: data stream is defective 12. Errormode not identifiable
Overrun conditions detected with system reaction, maximum Possible reason for error Possible reason for error
engine speed exceeded Cable break or internal ECU error, lamp defective, connection Engine brake flap actuator: cable break or short circuit, sensor
Take actions for error repair cable demaged defective, connection cable demaged
other error properties Take actions for error repair Take actions for error repair
System reaction: Check cabling and load, check lamp and if necessary replace it, Check cabling, sensor defect, check sensor and if necessary
BW 220 D-5
Behaviour error lamp: permanent light check connection cable and if necessary repair or replace it replace it, check connection cable and if necessary repair or
Selfhealing: yes other error properties replace it
Signal Priority: 4 System reaction: Warning, shutoff output other error properties
Measurement @ errortime: actual value Behaviour error lamp: permanent light System reaction: Warning, shutoff output
Selfhealing: no Behaviour error lamp: permanent light
Signal Priority: 1 Selfhealing: no
Measurement @ errortime: shut off value Signal Priority: 2

691
692
DTC-List P490_: 220, 310, 501 P492_: 213
83 / 975 / FanCD 85 / 1639 / FanCDEval 86 / 523602 / FanCDSysReac

Error description FAN ACTUATOR Error description Error description FAN SPEED
Fan power stage: the current drain measured by ECU is out of Fan speed sensor: the current drain measured by ECU is out of Fan speed: the fan speed calculated by ECU is above the target
the target range or the maximum permissible temperature of the the target range range; the ECU activates a system reaction
ECU component for power supply of the actuator is exceeded Error codes Error codes
Error codes DEUTZ-Errorcode: 85 DEUTZ-Errorcode: 86
DEUTZ-Errorcode: 83 BlinkCode (short-long-short): 2 - 3 - 8 BlinkCode (short-long-short): 2 - 3 - 8
BlinkCode (short-long-short): 2 - 3 - 8 SPN: 1639 SPN: 523602
SPN: 975 possible FMI: possible FMI:
possible FMI: 3: Voltage to high or short circuit to +Ubatt 2: data stream is defective
3: Voltage to high or short circuit to +Ubatt 4: Voltage to low or short circuit to -Ubatt 2: data stream is defective
4: Voltage to low or short circuit to -Ubatt 12. Errormode not identifiable 12. Errormode not identifiable
5: current to low or broken wire 12. Errormode not identifiable 12. Errormode not identifiable
2: data stream is defective Errordetection Errordetection
Errordetection Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory.
Errorlamp shows permanent light. Entry in errormemory. Possible reason for error Possible reason for error
Possible reason for error Sensor defective, connection cable demaged, fan speed outside Above target range with system reaction
cable break or short circuit, sensor defective, connection cable the target range Take actions for error repair
demaged Take actions for error repair other error properties
Take actions for error repair Check sensor and if necessary replace it, check connectionn System reaction:
Check cabling, sensor defect, check sensor and if necessary cable and if necessary repair or replace it, check fan Behaviour error lamp: permanent light
replace it, check connection cable and if necessary repair or other error properties Selfhealing: yes
BW 220 D-5
replace it System reaction: Signal Priority: 3
other error properties Behaviour error lamp: permanent light Measurement @ errortime: actual value
System reaction: Warning, shutoff output Selfhealing: yes
Behaviour error lamp: permanent light Signal Priority: 2
Selfhealing: no Measurement @ errortime: actual value
Signal Priority: 2
Measurement @ errortime: Sollwert

DTC-List P490_: 220, 310, 501 P492_: 213
87 / 97 / FlFCD 89 / 97 / FlFCD_WtLvl 90 / 94 / FlPSCD

Error description WATER IN FUEL Error description WATER IN FUEL Error description FUEL PRE PRESS.
Fuel filter water level sensor: the voltage of sensor measured by Water in fuel: the water level calculated by ECU is above the Low fuel pressure sensor: the voltage of sensor measured by
ECU is out of the target range allowed limit value ECU is out of the target range
SPN: 97 SPN: 97 SPN: 94
3: Voltage to high or short circuit to +Ubatt 12: Defective component 3: Voltage to high or short circuit to +Ubatt
4: Voltage to low or short circuit to -Ubatt 12. Errormode not identifiable 4: Voltage to low or short circuit to -Ubatt
cable break or short circuit, sensor defective, connection cable Above target range, excess of maximum permissible water level cable break or short circuit, sensor defective, connection cable
demaged in fuel filter demaged
Check cabling, if sensor not working, check sensor and if flush water seperator Check cabling, if sensor not working, check sensor and if
necessary replace it, check connection cable and if necessary other error properties necessary replace it, check connection cable and if necessary
repair or replace it System reaction: Warning repair or replace it
BW 220 D-5
other error properties Behaviour error lamp: permanent light other error properties
System reaction: Warning, substitute value Selfhealing: no System reaction: Warning, substitute value
Behaviour error lamp: permanent light Signal Priority: 3 Behaviour error lamp: permanent light
Selfhealing: yes Measurement @ errortime: actual value Selfhealing: yes
Measurement @ errortime: default value Measurement @ errortime: default value

693
694
DTC-List P490_: 220, 310, 501 P492_: 213
91 / 94 / FlPSCDSysReac 94 / 523239 / FrmMngDecV1 95 / 523240 / FrmMngFunModCtl

Error description FUEL PRE PRESS. Error description CAN ERROR DEC-V1 Error description CAN ERROR FUNMODCTL
Low fuel pressure: the low fuel pressure calculated by ECU is CAN message DecV1 (Pseudo Pedal): the message can not be CAN message FunModCtl (Function Mode Control): the message
underneath the target range; the ECU activates a system received by ECU or the received value is above the target range can not be received by ECU
reaction Error codes Error codes
Error codes DEUTZ-Errorcode: 94 DEUTZ-Errorcode: 95
DEUTZ-Errorcode: 91 BlinkCode (short-long-short): 5 - 2 - 6 BlinkCode (short-long-short): 5 - 2 - 7
BlinkCode (short-long-short): 2 - 1 - 6 SPN: 523239 SPN: 523240
SPN: 94 possible FMI: possible FMI:
possible FMI: 12: Defective component 12: Defective component
2: data stream is defective 12: Defective component 12. Errormode not identifiable
2: data stream is defective 12: Defective component 12. Errormode not identifiable
12. Errormode not identifiable 2: data stream is defective 12. Errormode not identifiable
12. Errormode not identifiable Errordetection Errordetection
Errordetection Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory.
Errorlamp shows permanent light. Entry in errormemory. Possible reason for error Possible reason for error
Possible reason for error Missing or value above target range (message "DecV1" = pseudo Missing message "FunModCtl" = function mode control, CAN bus
Below target range with system reaction, interruption in cycling pedal), CAN bus wrong cabled, wiring is demaged, receiver wrong cabled, wiring is demaged, receiver (sender of the
process of low fuel pressure (for example, fuel pump defective), (sender of the message) work inaccurately, parametering message) work inaccurately, parametering inaccurate
sensor defective, connection cable demaged inaccurate Take actions for error repair
Take actions for error repair Take actions for error repair Check CAN Bus cabling (Bus sheduling, polarity, short circuit,
Check low fuel pressure loop system, Check fuel pump, inspect Check CAN Bus cabling (Bus sheduling, polarity, short circuit, power interrupt), test protocol of receiver, check CAN functional
BW 220 D-5
fuel system and if necessary repair it, check sensor and if power interrupt), test protocol of receiver, check CAN functional range
necessary replace it, check connection cable and if necessary range other error properties
repair or replace it other error properties System reaction: Warning, changing to substitute values
other error properties System reaction: Warning, changing to substitute values according to customers configuration.
System reaction: Advice: FLPSCD_stSysReacReq according to customers configuration. Behaviour error lamp: permanent light

Signal Priority: 3 Signal Priority: 1 Measurement @ errortime: default valuee
Measurement @ errortime: actual value Measurement @ errortime: default value

DTC-List P490_: 220, 310, 501 P492_: 213
106 / 523212 / FrmMngTOEngPrt 110 / 523216 / FrmMngTOPrHtEnCmd 112 / 523218 / FrmMngTORxCCVS

Error description CAN ERROR ENGPRT Error description CAN ERROR PRHTENCMD Error description CAN ERROR RXCCVS
CAN message EngPrt (Engine Protection): the message can not CAN message PrHtEnCmd (Preheat and Engine Command): the CAN message RxCCVS (Cruise Control): the message can not
be received by ECU message received can not be received by ECU be received by ECU
SPN: 523212 SPN: 523216 SPN: 523218
12: Defective component 12. Errormode not identifiable 12. Errormode not identifiable
Missing message "EngPrt" = engine protection, CAN bus wrong Missing message "PrHtEnCmd" = preheat and engine command; Missing message "RxCCVS" = cruise control; CAN bus wrong
cabled, wiring is demaged, receiver (sender of the message) CAN bus wrong cabled, wiring is demaged, receiver (sender of cabled, wiring is demaged, receiver (sender of the message)
work inaccurately, parametering inaccurate the message) work inaccurately, parametering inaccurate work inaccurately, parametering inaccurate
Check CAN Bus cabling (Bus sheduling, polarity, short circuit, Check CAN Bus cabling (Bus sheduling, polarity, short circuit, Check CAN Bus cabling (Bus sheduling, polarity, short circuit,
power interrupt), test protocol of receiver, check CAN functional power interrupt), test protocol of receiver, check CAN functional power interrupt), test protocol of receiver, check CAN functional
BW 220 D-5
range range range
System reaction: Warning. Hold last value. System reaction: Warning, changing to substitute values System reaction:
Behaviour error lamp: permanent light according to customers configuration. Behaviour error lamp: permanent light
Selfhealing: yes Behaviour error lamp: permanent light Selfhealing: yes
Signal Priority: 1 Selfhealing: yes Signal Priority: 1
Measurement @ errortime: default value Signal Priority: 1 Measurement @ errortime: default valuee
Measurement @ errortime: default valuee

695
696
DTC-List P490_: 220, 310, 501 P492_: 213
113 / 523604 / FrmMngTORxEngTemp 117 / 523238 / FrmMngTOSwtOut 118 / 523222 / FrmMngTOTCO1

Error description CAN ERROR RxEngTemp Error description CAN ERROR SWTOUT Error description CAN ERROR TCO1
CAN message RxEngTemp (Engine Temperature): the message CAN message SwtOut (Switching Output): the message can not CAN message "TCO1" (Speedo Signal): the message can not be
can not be received by ECU be received by ECU received by ECU
SPN: 523604 SPN: 523238 SPN: 523222
12: Defective component 12: Defective component 12. Errormode not identifiable
12. Errormode not identifiable 12. Errormode not identifiable 12: Defective component
Missing message "RxEngTemp" = engine temperature, CAN bus Missing message "SwtOut" = switch outputs, CAN bus wrong Missing message "TCO1" = speedo signal, CAN bus wrong
wrong cabled, wiring is demaged, receiver (sender of the cabled, wiring is demaged, receiver (sender of the message) cabled, wiring is demaged, receiver (sender of the message)
message) work inaccurately, parametering inaccurate work inaccurately, parametering inaccurate work inaccurately, parametering inaccurate
BW 220 D-5
range range range
Measurement @ errortime: default value Measurement @ errortime: default valuee Measurement @ errortime: default value

DTC-List P490_: 220, 310, 501 P492_: 213
120 / 523605 / FrmMngTOTSC1AE 121 / 523606 / FrmMngTOTSC1AR 122 / 523607 / FrmMngTOTSC1DE

Error description CAN ERROR TSC1-AE Error description CAN ERROR TSC1-AR Error description CAN ERROR TSC1-DE
CAN message TSC1-AE (Torque/Speed Control #1 from CAN message TSC1-AR (Torque/Speed Control #1 from CAN message TSC1-DE (Torque/Speed Control #1 from
Automatic Traction Control to Engine): the message can not be Automatic Traction Control to Retarder): the message can not be Driveline to Engine): the message can not be received by ECU
received by ECU received by ECU Error codes
possible FMI: possible FMI: 12: Defective component
12. Errormode not identifiable 12. Errormode not identifiable Errordetection
Errordetection Errordetection Errorlamp shows permanent light. Entry in errormemory.
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory. Possible reason for error
Possible reason for error Possible reason for error Missing message "TSC1-DE", CAN bus wrong cabled, wiring is
Missing message "TSC1-AE", CAN bus wrong cabled, wiring is Missing message "TSC1-AR", CAN bus wrong cabled, wiring is demaged, receiver (sender of the message) work inaccurately,
demaged, receiver (sender of the message) work inaccurately, demaged, receiver (sender of the message) work inaccurately, parametering inaccurate
parametering inaccurate parametering inaccurate Take actions for error repair
Take actions for error repair Take actions for error repair Check CAN Bus cabling (Bus sheduling, polarity, short circuit,
Check CAN Bus cabling (Bus sheduling, polarity, short circuit, Check CAN Bus cabling (Bus sheduling, polarity, short circuit, power interrupt), test protocol of receiver, check CAN functional
BW 220 D-5
power interrupt), test protocol of receiver, check CAN functional power interrupt), test protocol of receiver, check CAN functional range
range range other error properties
other error properties other error properties System reaction: Warning, changing to substitute values
System reaction: Warning, changing to substitute values System reaction: Warning, changing to substitute values according to priority chain.
according to priority chain. according to priority chain. Behaviour error lamp: permanent light
Behaviour error lamp: permanent light Behaviour error lamp: permanent light Selfhealing: no
Selfhealing: no Selfhealing: no Signal Priority: 1
Signal Priority: 1 Signal Priority: 1 Measurement @ errortime: default value

697
698
DTC-List P490_: 220, 310, 501 P492_: 213
123 / 523608 / FrmMngTOTSC1DR 124 / 523609 / FrmMngTOTSC1PE 125 / 898 / FrmMngTOTSC1TE

Error description CAN ERROR TSC1-DR Error description CAN ERROR TSC1-PE Error description CAN ERROR TSC1-TE
CAN message TSC1-DR (Torque/Speed Control #1 from CAN message TSC1-PE (Torque/Speed Control #1 from Power CAN message TSC1-TE (Torque/Speed Control #1 from Traction
Driveline to Retarder): the message can not be received by ECU Take Off to Engine): the message can not be received by ECU Control to Engine): the message can not be received by ECU
SPN: 523608 SPN: 523609 SPN: 898
Missing message "TSC1-DR", CAN bus wrong cabled, wiring is Missing message "TSC1-PE", CAN bus wrong cabled, wiring is Missing message "TSC1-TE", CAN bus wrong cabled, wiring is
demaged, receiver (sender of the message) work inaccurately, demaged, receiver (sender of the message) work inaccurately, demaged, receiver (sender of the message) work inaccurately,
parametering inaccurate parametering inaccurate parametering inaccurate
BW 220 D-5
range range range
System reaction: Warning, changing to substitute values System reaction: Warning, changing to substitute values System reaction: Warning, changing to substitute values
according to priority chain. according to priority chain. according to priority chain.

Measurement @ errortime: default value Measurement @ errortime: default value Measurement @ errortime: default value

DTC-List P490_: 220, 310, 501 P492_: 213
126 / 520 / FrmMngTOTSC1TR 127 / 523610 / FrmMngTOTSC1VE 128 / 523611 / FrmMngTOTSC1VR

Error description CAN ERROR TSC1-TR Error description CAN ERROR TSC1-VE Error description CAN ERROR TSC1-VR
CAN message TSC1-TR (Torque/Speed Control #1 from Traction CAN message TSC1-VE (Torque/Speed Control #1 from Vehicle CAN message TSC1-VR (Torque/Speed Control #1 from Vehicle
Control to Retarder): the message can not be received by ECU Control to Engine): the message can not be received by ECU Control to Retarder): the message can not be received by ECU
SPN: 520 SPN: 523610 SPN: 523611
Missing message "TSC1-TR", CAN bus wrong cabled, wiring is Missing message "TSC1-VE", CAN bus wrong cabled, wiring is Missing message "TSC1-VR", CAN bus wrong cabled, wiring is
demaged, receiver (sender of the message) work inaccurately, demaged, receiver (sender of the message) work inaccurately, demaged, receiver (sender of the message) work inaccurately,
parametering inaccurate parametering inaccurate parametering inaccurate
BW 220 D-5
range range range
System reaction: Warning, changing to substitute values System reaction: Warning, changing to substitute values System reaction: Warning, changing to substitute values
according to priority chain. according to priority chain. according to priority chain.

699
700
DTC-List P490_: 220, 310, 501 P492_: 213
131 / 523500 / FrmMngTxTO 133 / 174 / FTSCD 134 / 174 / FTSCDSysReac

Error description CAN MESS. TIMEOUT Error description FUEL TEMP. SENSOR Error description FUEL TEMP. SENSOR
CAN message: the ECU detects a timeout for one or more Fuel temperature sensor: the voltage measured by ECU is out of Fuel temperature: the fuel temperature calculated by ECU is
posted message the target range above the target range; the ECU activates a system reaction
SPN: 523500 SPN: 174 SPN: 174
12. Errormode not identifiable 3: Voltage to high or short circuit to +Ubatt 0: data valid, but above normal working area
12. Errormode not identifiable 4: Voltage to low or short circuit to -Ubatt 0: data valid, but above normal working area
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light
Possible reason for error Possible reason for error oder
Timeout for sent messages Fuel temp. sensor: cable break or short circuit, sendor defective, blinking. Entry in errormemory.
Take actions for error repair connection cable demaged Possible reason for error
other error properties Take actions for error repair Above target range with system reaction, interruption of fuel loop
System reaction: Check cabling, if sensor not working, check sensor and if (for example, rail pressure relief valve defective), sensor
Behaviour error lamp: permanent light necessary replace it, check connection cable and if necessary defective, connection cable demaged
Selfhealing: yes repair or replace it Take actions for error repair
BW 220 D-5
Signal Priority: 1 other error properties Check fuel system and if necessary repair it, check sensor and if
Measurement @ errortime: - System reaction: Warning, substitute value necessary replace it, check connection cable and if necessary
Behaviour error lamp: permanent light repair or replace it
Selfhealing: yes other error properties
Signal Priority: 4 System reaction: Advice: FTSCD_stSysReacReq
Measurement @ errortime: default value Behaviour error lamp: permanent light
oder
blinking
Selfhealing: yes
Signal Priority: 4

DTC-List P490_: 220, 310, 501 P492_: 213
136 / 523618 / GOTSCD 137 / 523619 / GOTSCDSysReac 138 / 29 / HdThrt

Error description CUSTOMER TEMPSENS 1 Error description Error description THROTTLE 2
Customer specific temperature sensor 1: the voltage of sensor Customer specific temperature 1: the temperature calculated by Hand throttle pedal sensor: the voltage measured by ECU is out
measured by ECU is out of the target range or the received value ECU is above the target range; the ECU activates a system of the target range or the calculated pedal position is implausible
of temperature via CAN is defective reaction compared with the position of accelerator pedal 1
SPN: 523618 SPN: 523619 SPN: 29
3: Voltage to high or short circuit to +Ubatt 2: data stream is defective 3: Voltage to high or short circuit to +Ubatt
4: Voltage to low or short circuit to -Ubatt 2: data stream is defective 4: Voltage to low or short circuit to -Ubatt
2: data stream is defective 12. Errormode not identifiable 12. Errormode not identifiable
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light Errorlamp shows permanent light. Entry in errormemory.
Possible reason for error oder Possible reason for error
Cable break or short circuit (sensor 1), sensor defective, blinking. Entry in errormemory. Cable break or short circuit, signal implausible compared to
connection cable demaged, CAN bus wrong cabled, wiring Possible reason for error signal of idle sensor, transmitter defective, connection cable
demaged, receiver (sender of the message) work inaccurately, Outside target range with system reaction (temperature 1), demaged
parametering inaccurate dependant on the application Take actions for error repair
Take actions for error repair Take actions for error repair Check cabling, check sensor and if necessary replace it, check
BW 220 D-5
Customer specific bugfixing, check sensor and if necessary Customer specific bugfixing, denpendant on application connection cable and if necessary repair or replace it
replace it, check connection cable and if necessary repair or other error properties other error properties
replace it, Check CAN Bus cabling (Bus sheduling, polarity, short System reaction: Advice: GOTSCD_stSysReacReq System reaction: Warning, changing to substitute values
circuit, power interrupt), test protocol of receiver, check CAN fun Behaviour error lamp: permanent light according to priority chain or limp home
other error properties oder Behaviour error lamp: permanent light
System reaction: Warning, substitute value (customer specific) blinking Selfhealing: no
Behaviour error lamp: permanent light Selfhealing: yes Signal Priority: 4
Selfhealing: yes Signal Priority: 3 Measurement @ errortime: actual value
Signal Priority: 2 Measurement @ errortime: actual value
Measurement @ errortime: default value

701
702
DTC-List P490_: 220, 310, 501 P492_: 213
139 / 1638 / HOTSCD 140 / 1638 / HOTSCDSysReac 141 / 523617 / HWEMonCom

Error description CUSTOMER TEMPSENS 2 Error description CUSTOMER TEMPSENS 2 Error description INTERNAL COMM. ERROR
Customer specific temperature sensor 2: the voltage of sensor Customer specific temperature 2: the temperature calculated by Internal hardware monitoring: the ECU detects a communication
measured by ECU is out of the target range or the received value ECU is above the target range; the ECU activates a system distrubance
of temperature via CAN is defective reaction Error codes
possible FMI: possible FMI: 12: Defective component
3: Voltage to high or short circuit to +Ubatt 2: data stream is defective 12. Errormode not identifiable
4: Voltage to low or short circuit to -Ubatt 2: data stream is defective 12. Errormode not identifiable
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light Possible reason for error
Possible reason for error oder Communication with chip CJ 940 disturbed, ECU defective
Cable break or short circuit (sensor 2), sensor defective, blinking. Entry in errormemory. Take actions for error repair
connection cable demaged, CAN bus wrong cabled, wiring Possible reason for error If cannot delete the error, change ECU
demaged, receiver (sender of the message) work inaccurately, Outside target range with system reaction (temperature 2), other error properties
parametering inaccurate dependant on the application System reaction: Warning
Take actions for error repair Take actions for error repair Behaviour error lamp: permanent light
BW 220 D-5
Customer specific bugfixing, check sensor and if necessary Customer specific bugfixing, denpendant on application Selfhealing: no
replace it, check connection cable and if necessary repair or other error properties Signal Priority: 4
replace it, Check CAN Bus cabling (Bus sheduling, polarity, short System reaction: Advice: HOTSCD_stSysReacReq Measurement @ errortime: -
circuit, power interrupt), test protocol of receiver, check CAN fun Behaviour error lamp: permanent light
other error properties oder
System reaction: Warning, substitute value (customer specific) blinking
Behaviour error lamp: permanent light Selfhealing: yes


DTC-List P490_: 220, 310, 501 P492_: 213
142 / 630 / HWEMonEEPROM 143 / 523612 / HWEMonRcyLocked 144 / 523612 / HWEMonRcySuppressed

Error description EEPROM MEM. ACCESS Error description INT. RECOVERY Error description INT. RECOVERY
Internal hardware monitoring: the ECU finds an error during the Internal hardware monitoring: the CPU of the ECU is reset and Internal hardware monitoring: the CPU of the ECU is reset and
access to ist EEPROM memory or works with an alternative the cause is logged internally; no item will be created in error the cause is logged internally; no item will be created in error
value memory memory
SPN: 630 SPN: 523612 SPN: 523612
12: Defective component 14: Special Instructions 14: Special Instructions
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows blinking. Entry in errormemory. Errorlamp shows blinking. Entry in errormemory.
Error during EEPROM memory access or EEPROM works with A recovery occurred which is stored as protected A recovery occurred which is not stored
substitute value, programming error, ECU defective Take actions for error repair Take actions for error repair
Take actions for error repair Recoverey occured which is stored as protected Recoverey occured which is stored as protected
If not programmed, EEPROM is defect --> ECU is defect, With parameter HWEMon_numRexxxxxxx the recovery nummer With parameter HWEMon_numRexxxxxxx the recovery nummer
reprogram ECU and if necessary replace it and the subsequent position can be identified. See especially and the subsequent position can be identified. See especially
BW 220 D-5
other error properties SW-Doku _rcy_auto.pdf SW-Doku _rcy_auto.pdf
System reaction: Warning other error properties other error properties
Behaviour error lamp: permanent light System reaction: Recovery of ECU System reaction: Warning, shown at error path
Selfhealing: no Behaviour error lamp: blinking Behaviour error lamp: blinking
Signal Priority: 4 Selfhealing: no Selfhealing: no
Measurement @ errortime: - Signal Priority: 5 Signal Priority: 5
Measurement @ errortime: - Measurement @ errortime: -

703
704
DTC-List P490_: 220, 310, 501 P492_: 213
145 / 523612 / HWEMonRcyVisible 146 / 523612 / HWEMonUMaxSupply 147 / 523612 / HWEMonUMinSupply

Error description INT. RECOVERY Error description INT. RECOVERY Error description INT. RECOVERY
Internal hardware monitoring: the CPU of the ECU is reset and Internal hardware monitoring: the ECU detects an excess of the Internal hardware monitoring: the ECU detects an undershooting
an item will be created in error memory target range for the power supply of ist communication module of the target range for the power supply of ist communication
Error codes Error codes module
12. Errormode not identifiable 3: Voltage to high or short circuit to +Ubatt possible FMI:
14: Special Instructions 12. Errormode not identifiable 12. Errormode not identifiable
Errordetection Errordetection 12. Errormode not identifiable
Errorlamp shows blinking. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory. Errordetection
A recovery occurred which is visible in the error memory Overvoltage at CJ940, power supply voltage too high, ECU Possible reason for error
Take actions for error repair defective Undervoltage at CJ940, power supply voltage too low, ECU
Recoverey occured which is stored as protected Take actions for error repair defective
With parameter HWEMon_numRexxxxxxx the recovery nummer Check working voltage and if necessary correct it, Check ECU Take actions for error repair
and the subsequent position can be identified. See especially and if necessary replace it Check working voltage and if necessary correct it, Check ECU
SW-Doku _rcy_auto.pdf other error properties and if necessary replace it
BW 220 D-5
other error properties System reaction: Power stage shut off other error properties
System reaction: Recovery of ECU Behaviour error lamp: permanent light System reaction: Power stage shut off
Behaviour error lamp: blinking Selfhealing: no Behaviour error lamp: permanent light
Selfhealing: no Signal Priority: 4 Selfhealing: no
Signal Priority: 5 Measurement @ errortime: - Signal Priority: 4
Measurement @ errortime: - Measurement @ errortime: -

DTC-List P490_: 220, 310, 501 P492_: 213
149 / 105 / IATSCD 150 / 105 / IATSCDSysReac 153 / 523350 / InjVlvBnk1A

Error description CHARGE AIR TEMP. Error description CHARGE AIR TEMP. Error description INJECTOR BANK A
Charge air temperature sensor: the voltage of sensor measured Charge air temperature: die charge air temperature calculated by Injector cylinder bank 1: the current drain measured by ECU is
by ECU is out of the target range or the received value of ECU is above the target range; the ECU activates a system above the target range
temperature via CAN is defective reaction Error codes
possible FMI: possible FMI: 3: Voltage to high or short circuit to +Ubatt
3: Voltage to high or short circuit to +Ubatt 0: data valid, but above normal working area 4: Voltage to low or short circuit to -Ubatt
4: Voltage to low or short circuit to -Ubatt 0: data valid, but above normal working area 13: out of calibrated range
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light Possible reason for error
Possible reason for error oder Short circuit (cylinder bank 1), injector defective, connection
Cable break or short circuit, sensor defective, connection cable blinking. Entry in errormemory. cable demaged
demaged, CAN bus wrong cabled, wiring demaged, receiver Possible reason for error Take actions for error repair
(sender of the message) work inaccurately, parametering Above target range with system reaction, air system demaged, Check cabling, check injectors and if necessary replace them,
inaccurate sensor defective, connection cable demaged check connection cable and if necessary repair or replace it
Take actions for error repair Take actions for error repair other error properties
BW 220 D-5
Check cabling, LDF6T-sensor not working, check sensor and if Check construction of LDF6T , check suction parts, check air System reaction: Warning, cylinder shut off
necessary replace it, check connection cable and if necessary system and if necessary repair it, check sensor and if necessary Behaviour error lamp: permanent light
repair or replace it, Check CAN Bus cabling (Bus sheduling, replace it, check connection cable and if necessary repair or Selfhealing: yes
polarity, short circuit, power interrupt), test protocol of receiver, c replace it Signal Priority: 4
other error properties other error properties Measurement @ errortime: actual value
System reaction: Warning, substitute value System reaction: Advice: IATSCD_stSysReacReq
Behaviour error lamp: permanent light Behaviour error lamp: permanent light
Selfhealing: yes oder
Signal Priority: 4 blinking
Measurement @ errortime: default value Selfhealing: yes
Signal Priority: 4

705
706
DTC-List P490_: 220, 310, 501 P492_: 213
154 / 523351 / InjVlvBnk1B 155 / 523352 / InjVlvBnk2A 156 / 523353 / InjVlvBnk2B

Error description INJECTOR BANK A Error description INJECTOR BANK B Error description INJECTOR BANK B
Injector cylinder bank 1: the current drain measured by ECU is Injector cylinder bank 2: the current drain measured by ECU is Injector cylinder bank 2: the current drain measured by ECU is
underneath the target range above the target range underneath the target range
SPN: 523351 SPN: 523352 SPN: 523353
13: out of calibrated range 3: Voltage to high or short circuit to +Ubatt 13: out of calibrated range
13: out of calibrated range 4: Voltage to low or short circuit to -Ubatt 13: out of calibrated range
5: current to low or broken wire 13: out of calibrated range 5: current to low or broken wire
13: out of calibrated range 12. Errormode not identifiable 13: out of calibrated range
Cable break (cylinder bank 1), injector defective, connection Short circuit (cylinder bank 2), injector defective, connection Cable break (cylinder bank 2), injector defective, connection
cable demaged cable demaged cable demaged
Check cabling, check injectors and if necessary replace them, Check cabling, check injectors and if necessary replace them, Check cabling, check injectors and if necessary replace them,
check connection cable and if necessary repair or replace it check connection cable and if necessary repair or replace it check connection cable and if necessary repair or replace it
BW 220 D-5
System reaction: Warning, cylinder shut off System reaction: Warning, cylinder shut off System reaction: Warning, cylinder shut off

DTC-List P490_: 220, 310, 501 P492_: 213
157 / 523354 / InjVlvChipA 158 / 523355 / InjVlvChipB 159 / 651 / InjVlvCyl1A

Error description PWR. INJ. BANK B Error description PWR. INJ. BANK B Error description INJECTOR 1
Internal hardware monitoring: the ECU detects an error of ist Internal hardware monitoring: the ECU detects a disturbance in Injector 1: the current drain measured by ECU is above the target
injector high current output its injector high current output range
SPN: 523354 SPN: 523355 SPN: 651
3: Voltage to high or short circuit to +Ubatt 12: Defective component 3: Voltage to high or short circuit to +Ubatt
2: data stream is defective 12: Defective component 13: out of calibrated range
14: Special Instructions 12: Defective component 4: Voltage to low or short circuit to -Ubatt
Errorlamp shows blinking. Entry in errormemory. Errorlamp shows blinking. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory.
High power stage Injector A, ECU defective High power stage Injector B, ECU defective Short circuit (cylinder 1), injector defective, connection cable
Take actions for error repair Take actions for error repair demaged
If error is not removable, change ECU If error is not removable, change ECU Take actions for error repair
other error properties other error properties Check cabling, check injectors and if necessary replace them,
System reaction: Warninig, outputs shut off System reaction: Warninig, outputs shut off check connection cable and if necessary repair or replace it
Behaviour error lamp: blinking Behaviour error lamp: blinking other error properties
BW 220 D-5
Selfhealing: no Selfhealing: no System reaction: Warning, fuel injection failed, shut off wenn the
Signal Priority: 5 Signal Priority: 5 number of active cylinders below minimum
Measurement @ errortime: actual value Measurement @ errortime: actual value Behaviour error lamp: permanent light
Selfhealing: yes
Signal Priority: 4

707
708
DTC-List P490_: 220, 310, 501 P492_: 213
160 / 651 / InjVlvCyl1B 161 / 652 / InjVlvCyl2A 162 / 652 / InjVlvCyl2B

Error description INJECTOR 1 Error description INJECTOR 2 Error description INJECTOR 2
Injector 1: the current drain measured by ECU is underneath the Injector 2: the current drain measured by ECU is above the target Injector 2: the current drain measured by ECU is underneath the
target range range target range
SPN: 651 SPN: 652 SPN: 652
13: out of calibrated range 13: out of calibrated range 13: out of calibrated range
5: current to low or broken wire 4: Voltage to low or short circuit to -Ubatt 5: current to low or broken wire
Cable break (cylinder 1), injector defective, connection cable Short circuit (cylinder 2), injector defective, connection cable Cable break (cylinder 2), injector defective, connection cable
BW 220 D-5
System reaction: Warning, fuel injection failed, shut off wenn the System reaction: Warning, fuel injection failed, shut off wenn the System reaction: Warning, fuel injection failed, shut off wenn the
number of active cylinders below minimum number of active cylinders below minimum number of active cylinders below minimum

DTC-List P490_: 220, 310, 501 P492_: 213
163 / 653 / InjVlvCyl3A 164 / 653 / InjVlvCyl3B 165 / 654 / InjVlvCyl4A

Injector 3: the current drain measured by ECU is above the target Injector 3: the current drain measured by ECU is underneath the Injector 4: the current drain measured by ECU is above the target
range target range range
SPN: 653 SPN: 653 SPN: 654
3: Voltage to high or short circuit to +Ubatt 13: out of calibrated range 3: Voltage to high or short circuit to +Ubatt
4: Voltage to low or short circuit to -Ubatt 5: current to low or broken wire 4: Voltage to low or short circuit to -Ubatt
12. Errormode not identifiable 13: out of calibrated range 12. Errormode not identifiable
Short circuit (cylinder 3), injector defective, connection cable Cable break (cylinder 3), injector defective, connection cable Short circuit (cylinder 4), injector defective, connection cable
BW 220 D-5

709
710
DTC-List P490_: 220, 310, 501 P492_: 213

SPN: 654 SPN: 655 SPN: 655
BW 220 D-5

DTC-List P490_: 220, 310, 501 P492_: 213
169 / 656 / InjVlvCyl6A 170 / 656 / InjVlvCyl6B 171 / 657 / InjVlvCyl7A

Injector 6: the current drain measured by ECU is above the target Injector 6: the current drain measured by ECU is underneath the Injector 7: the current drain measured by ECU is above the target
range target range range
SPN: 656 SPN: 656 SPN: 657
3: Voltage to high or short circuit to +Ubatt 13: out of calibrated range 3: Voltage to high or short circuit to +Ubatt
4: Voltage to low or short circuit to -Ubatt 5: current to low or broken wire 4: Voltage to low or short circuit to -Ubatt
12. Errormode not identifiable 13: out of calibrated range 12. Errormode not identifiable
Short circuit (cylinder 6), injector defective, connection cable Cable break (cylinder 6), injector defective, connection cable Short circuit (cylinder 7), injector defective, connection cable
BW 220 D-5

711
712
DTC-List P490_: 220, 310, 501 P492_: 213

SPN: 657 SPN: 658 SPN: 658
BW 220 D-5

DTC-List P490_: 220, 310, 501 P492_: 213
175 / 523370 / InjVlvErrDet 176 / 523615 / MeUnCD_ADC 177 / 523615 / MeUnCDNoLoad

Error description RAIL PRESS. MON. DISABLED Error description METERING UNIT Error description METERING UNIT
Rail pressure monitoring: the monitoring of the rail pressure will Fuel volume flow rate: the fuel volume rate calculated by ECU at Valve at outlet of the fuel metering unit: the ECU detects no load
be deactivated by ECU because of the activation of the function outlet of the fuel metering unit is out of the target range or temperature excess of the ECU component for power supply
"compression test" by user Error codes of the valve
Error codes DEUTZ-Errorcode: 176 Error codes
DEUTZ-Errorcode: 175 BlinkCode (short-long-short): 1 - 3 - 5 DEUTZ-Errorcode: 177
BlinkCode (short-long-short): 5 - 5 - 5 SPN: 523615 BlinkCode (short-long-short): 1 - 3 - 5
SPN: 523370 possible FMI: SPN: 523615
possible FMI: 3: Voltage to high or short circuit to +Ubatt possible FMI:
14: Special Instructions 4: Voltage to low or short circuit to -Ubatt 12. Errormode not identifiable
12. Errormode not identifiable 12. Errormode not identifiable 5: current to low or broken wire
12. Errormode not identifiable Errordetection 12: Defective component
Errordetection Errorlamp shows permanent light. Entry in errormemory. Errordetection
Errorlamp shows . Entry in errormemory. Possible reason for error Errorlamp shows permanent light, 15s before shut off. Entry in
Possible reason for error Flow rate outside target range errormemory.
Compression test active: rail-pressure monitoring is going to be Take actions for error repair Possible reason for error
disabled other error properties wiring error or ECU output is switched off because of
Take actions for error repair System reaction: overtemperature, fuel metering unit defective, connection cable
not correct Behaviour error lamp: permanent light demaged
other error properties Selfhealing: no Take actions for error repair
BW 220 D-5
System reaction: Rail pressure monitoring disabled Signal Priority: 4 Check cabling , if necessary check FCU, check fuel metering unit
Behaviour error lamp: Measurement @ errortime: actual value and if necessary replace it, check connection cable and if
Selfhealing: - necessary repair or replace it
Signal Priority: 1 other error properties
Measurement @ errortime: System reaction: Warning, max.extraction of FCU --> open rail
pressure relief valve --> shut the engine off in about 5 minutes
Behaviour error lamp: permanent light, 15s before shut off
Selfhealing: no
Signal Priority: 4

713
714
DTC-List P490_: 220, 310, 501 P492_: 213
178 / 523615 / MeUnCDSCBat 179 / 523615 / MeUnCDSCGnd 182 / 2634 / MnRly1_SCB

Error description METERING UNIT Error description METERING UNIT Error description MAIN RELAY
Valve at outlet of the fuel metering unit: the current drain Valve at outlet of the fuel metering unit: the current drain Main relay 1: the current drains measured by ECU is above the
measured by ECU is above the target range measured by ECU is above the target range target range
SPN: 523615 SPN: 523615 SPN: 2634
12: Defective component 12. Errormode not identifiable 3: Voltage to high or short circuit to +Ubatt
12. Errormode not identifiable 12: Defective component 12. Errormode not identifiable
Errorlamp shows permanent light, 15s before shut off. Entry in Errorlamp shows permanent light, 15s before shut off. Entry in Errorlamp shows permanent light. Entry in errormemory.
errormemory. errormemory. Possible reason for error
Possible reason for error Possible reason for error Short circuit to Ubatt (relay 1), relay defective, connection cable
Short circuit to Ubatt, fuel metering unit defective, connection Short circuit to ground, fuel metering unit defective, connection demaged
cable demaged cable demaged Take actions for error repair
Take actions for error repair Take actions for error repair Check cabling, check ECU, check relay and if necessary replace
Check cabling , if necessary check FCU, check fuel metering unit Check cabling , if necessary check FCU, check fuel metering unit it, check connection cable and if necessary repair or replace it
and if necessary replace it, check connection cable and if and if necessary replace it, check connection cable and if other error properties
BW 220 D-5
necessary repair or replace it necessary repair or replace it System reaction: Warning, shutoff the outputs MPROP
other error properties other error properties Behaviour error lamp: permanent light
System reaction: Warning, rail pressure relief valve will open System reaction: Warning, rail pressure relief valve will open Selfhealing: no
Behaviour error lamp: permanent light, 15s before shut off Behaviour error lamp: permanent light, 15s before shut off Signal Priority: 3
Selfhealing: no Selfhealing: no Measurement @ errortime: actual value

DTC-List P490_: 220, 310, 501 P492_: 213
183 / 2634 / MnRly1_SCG 184 / 523420 / Montr 186 / 2634 / MRlyCD

Error description MAIN RELAY Error description WATCHDOG COUNTER Error description MAIN RELAY
Main relay 1: the current drains measured by ECU is above the Internal hardware monitoring: the ECU detects an disturbance in Main relay: during the switching off, main relay does not switch
target range ist monitoring module (Wachtdog) on within an allowed time
SPN: 2634 SPN: 523420 SPN: 2634
12. Errormode not identifiable 12. Errormode not identifiable 7: Mechanical system not OK
4: Voltage to low or short circuit to -Ubatt 12. Errormode not identifiable 12: Defective component
12. Errormode not identifiable 14: Special Instructions 12. Errormode not identifiable
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows blinking. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory.
Short circuit to ground (relay 1), relay defective, connection cable Watchdog counter exceeds maximum, ECU defective EDC16: main relay not open in allowed time or main relay open
demaged Take actions for error repair too early; EDC7: main relay not open in allowed time or short
Take actions for error repair If error is not removable, change ECU circuit of main relay to ground; EDC16: main relay defective,
Check cabling, check ECU, check relay and if necessary replace other error properties connection cable demaged; generally: rapid shut-off of the ECU
it, check connection cable and if necessary repair or replace it System reaction: Recovery of ECU (witho
other error properties Behaviour error lamp: blinking Take actions for error repair
BW 220 D-5
System reaction: Warning, shutoff the outputs MPROP Selfhealing: no EDC16: check external main relay, check cabling
Behaviour error lamp: permanent light Signal Priority: 5 EDC7: if error is not removable, change ECU, EDC16: Check
Selfhealing: no Measurement @ errortime: - main relay and if necessary replace it, check connection cable
Signal Priority: 3 and if necessary repair or replace it; both: if error is not
Measurement @ errortime: actual value removable, change ECU
other error properties
System reaction: Warning
Selfhealing: no
Signal Priority: 3

715
716
DTC-List P490_: 220, 310, 501 P492_: 213
187 / 563 / MRlyCDMnRly2 188 / 2634 / MRlyCDMnRly3 189 / 523450 / MSSCD1

Error description MAIN RELAY 2 Error description MAIN RELAY Error description MULTISTATE SWITCH 1
Main relay 2 (in ECU): during the switching off, main relay does Main relay 3 (in ECU): during the switching off, main relay does Multi state switch 1: the voltage measured by ECU is out of the
not switch on within an allowed time not switch on within an allowed time target range or the swith setting is not plausible
SPN: 563 SPN: 2634 SPN: 523450
7: Mechanical system not OK 7: Mechanical system not OK 3: Voltage to high or short circuit to +Ubatt
12: Defective component 12: Defective component 4: Voltage to low or short circuit to -Ubatt
rapid shut-off of the ECU (without waiting till the end of the Short circuit to ground or emergency shut-off (relay 3 internal), Cable break or short circuit, input voltage outside target range
afterrun), ECU defective rapid shut-off of the ECU (without waiting till the end of the (switch 1), switch defective, connection cable demaged
Take actions for error repair afterrun), ECU defective Take actions for error repair
If error not removable, change ECU Take actions for error repair Check cabling and sensor, check switch and if necessary replace
other error properties Check cabling, check ECU, if error not removable, change ECU it, check connection cable and if necessary repair or replace it
System reaction: other error properties other error properties
BW 220 D-5
Behaviour error lamp: permanent light System reaction: Warning, shutoff the outputs MPROP (see System reaction: Warning, substitute value
Selfhealing: no BOSCH-Electricity operating plan) Behaviour error lamp: permanent light
Signal Priority: 3 Behaviour error lamp: permanent light Selfhealing: yes
Measurement @ errortime: actual value Selfhealing: no Signal Priority: 2
Signal Priority: 3 Measurement @ errortime: default value

DTC-List P490_: 220, 310, 501 P492_: 213
190 / 523451 / MSSCD2 191 / 523452 / MSSCD3 192 / 639 / NetMngCANAOff

Error description MULTISTATE SWITCH 2 Error description MULTISTATE SWITCH 3 Error description CAN A BUS OFF
Multi state switch 2: the voltage measured by ECU is out of the Multi state switch 3: the voltage measured by ECU is out of the CAN bus A: the ECU is not allowed to send messages, because
target range or the swith setting is not plausible target range or the swith setting is not plausible the status "BusOff" is detected
SPN: 523451 SPN: 523452 SPN: 639
3: Voltage to high or short circuit to +Ubatt 3: Voltage to high or short circuit to +Ubatt 14: Special Instructions
4: Voltage to low or short circuit to -Ubatt 4: Voltage to low or short circuit to -Ubatt 12. Errormode not identifiable
Cable break or short circuit, input voltage outside target range Cable break or short circuit, input voltage outside target range Cable break or short circuit, off-state (CAN bus A), CAN bus
(switch 2), switch defective, connection cable demaged (switch 3), switch defective, connection cable demaged deactivated, connection cable demaged
Check cabling and sensor, check switch and if necessary replace Check cabling and sensor, check switch and if necessary replace Check cabling of CAN bus and if necessary repair it, check
it, check connection cable and if necessary repair or replace it it, check connection cable and if necessary repair or replace it connection cable and if necessary repair or replace it
BW 220 D-5
System reaction: Warning, substitute value System reaction: Warning, substitute value System reaction:
Measurement @ errortime: default value Measurement @ errortime: default value Measurement @ errortime:

717
718
DTC-List P490_: 220, 310, 501 P492_: 213
193 / 1231 / NetMngCANBOff 194 / 1235 / NetMngCANCOff 195 / 705 / OPLpCD

Error description CAN B BUS OFF Error description CAN C BUS OFF Error description OIL PRESS LAMP
CAN bus B: the ECU is not allowed to send messages, because CAN bus C: the ECU is not allowed to send messages, because Warning lamp for oil level: the current drain measured by ECU is
the status "BusOff" is detected the status "BusOff" is detected out of the target range or the maximum temperature of the ECU
Error codes Error codes component for power supply of the lamp is exceeded
14: Special Instructions 14: Special Instructions possible FMI:
12. Errormode not identifiable 12. Errormode not identifiable 3: Voltage to high or short circuit to +Ubatt
12. Errormode not identifiable 12. Errormode not identifiable 5: current to low or broken wire
Errordetection Errordetection 2: data stream is defective
Cable break or short circuit, off-state (CAN bus B), CAN bus Cable break or short circuit, off-state (CAN bus C), CAN bus Possible reason for error
deactivated, connection cable demaged deactivated, connection cable demaged Cable break or short circuit, lamp defective, connection cable
Check cabling of CAN bus and if necessary repair it, check Check cabling of CAN bus and if necessary repair it, check Take actions for error repair
connection cable and if necessary repair or replace it connection cable and if necessary repair or replace it Check cabling and load, check lamp and if necessary replace it,
other error properties other error properties check connection cable and if necessary repair or replace it
BW 220 D-5
System reaction: System reaction: other error properties
Behaviour error lamp: permanent light Behaviour error lamp: permanent light System reaction: Warning, shutoff output
Selfhealing: yes Selfhealing: yes Behaviour error lamp: permanent light
Signal Priority: 2 Signal Priority: 2 Selfhealing: no
Measurement @ errortime: Measurement @ errortime: Signal Priority: 1

DTC-List P490_: 220, 310, 501 P492_: 213
196 / 100 / OPSCD 197 / 100 / OPSCD1 198 / 100 / OPSCDSysReacHi

Error description ENG OIL PRESS. Error description ENG OIL PRESS. Error description ENG OIL PRESS.
Oil pressure sensor: the voltage of sensor measured by ECU is Oil pressure: the oil pressure calculated by ECU is implausibly Oil pressure: the oil pressure calculated by ECU is above the
out of the target range or the received value of oil pressure via low target range; the ECU activates a system reaction
CAN is implausible (Oil pressure is above the target range with Error codes Error codes
higher oil temperature at the same time) DEUTZ-Errorcode: 197 DEUTZ-Errorcode: 198
Error codes BlinkCode (short-long-short): 2 - 3 - 1 BlinkCode (short-long-short): 2 - 3 - 1
DEUTZ-Errorcode: 196 SPN: 100 SPN: 100
BlinkCode (short-long-short): 2 - 2 - 4 possible FMI: possible FMI:
SPN: 100 12. Errormode not identifiable 0: data valid, but above normal working area
possible FMI: 12. Errormode not identifiable 0: data valid, but above normal working area
3: Voltage to high or short circuit to +Ubatt 12. Errormode not identifiable 12. Errormode not identifiable
4: Voltage to low or short circuit to -Ubatt 1: data valid, but below normal working area 12. Errormode not identifiable
2: data stream is defective Errordetection Errordetection
0: data valid, but above normal working area Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light
Errordetection Possible reason for error oder
Errorlamp shows permanent light. Entry in errormemory. Oil pressure implausible low, sensor defective, connection cable blinking. Entry in errormemory.
Possible reason for error demaged Possible reason for error
Cable break or short circuit, sensor defective, connection cable Take actions for error repair Above target range, oil volume too large, sensor defective, oil
demaged, CAN bus wrong cabled, wiring demaged, receiver Check cabling, if sensor not working, check sensor and if pump defective, connection cable demaged
(sender of the message) work inaccurately, parametering necessary replace it, check connection cable and if necessary Take actions for error repair
inaccurate repair or replace it Check oil level and if necessary correct it, check oil pump and if
BW 220 D-5
Take actions for error repair other error properties necessary replace it, check sensor and if necessary replace it,
Check cabling, if sensor not working, check sensor and if System reaction: Warning, substitute value check connection cable and if necessary repair or replace it
necessary replace it, check connection cable and if necessary Behaviour error lamp: permanent light other error properties
repair or replace it, Check CAN Bus cabling (Bus sheduling, Selfhealing: yes System reaction: Advice: OPSCD_stSysReacReqHi
polarity, short circuit, power interrupt), test protocol of receiver, Signal Priority: 2 Behaviour error lamp: permanent light
chec Measurement @ errortime: actual value oder
other error properties blinking
System reaction: Warning, substitute value Selfhealing: yes
Behaviour error lamp: permanent light Signal Priority: 4
Selfhealing: yes Measurement @ errortime: actual value
Signal Priority: 4

719
720
DTC-List P490_: 220, 310, 501 P492_: 213
199 / 100 / OPSCDSysReacLo 200 / 1237 / OSwCD 201 / 175 / OTSCD

Error description ENG OIL PRESS. Error description OVERRIDE SWITCH Error description OIL TEMP. SENSOR
Oil pressure: the oil pressure calculated by ECU is underneath Bridgeover switch: the ECU receives a permanent signal Oil temperature sensor: the voltage of sensor measured by ECU
the target range; the ECU activates a system reaction Error codes is out of the target range; the oil temperature calculated by ECU
Error codes DEUTZ-Errorcode: 200 is implausible compared with coolant temperature or the received
DEUTZ-Errorcode: 199 BlinkCode (short-long-short): 1 - 4 - 5 value via CAN is defective
BlinkCode (short-long-short): 2 - 3 - 1 SPN: 1237 Error codes
SPN: 100 possible FMI: DEUTZ-Errorcode: 201
possible FMI: 12. Errormode not identifiable BlinkCode (short-long-short): 1 - 4 - 4
1: data valid, but below normal working area 12. Errormode not identifiable SPN: 175
1: data valid, but below normal working area 12. Errormode not identifiable possible FMI:
12. Errormode not identifiable 2: data stream is defective 3: Voltage to high or short circuit to +Ubatt
12. Errormode not identifiable Errordetection 4: Voltage to low or short circuit to -Ubatt
Errordetection Errorlamp shows permanent light. Entry in errormemory. 2: data stream is defective
Errorlamp shows permanent light Possible reason for error 2: data stream is defective
oder Switch is blocked, taster locked, connection cable demaged Errordetection
blinking. Entry in errormemory. Take actions for error repair Errorlamp shows permanent light. Entry in errormemory.
Possible reason for error Check cabling, if sensor not working, check switch and if Possible reason for error
Below target range, oil volume too small, sensor defective, oil necessary replace it, check connection cable and if necessary Cable break or short circuit, sensor defective, connection cable
pump defective, connection cable demaged repair or replace it demaged
Take actions for error repair other error properties Take actions for error repair
Check oil level and if necessary correct it, check oil pump and if System reaction: Warning Check cabling, if sensor not working, check switch and if
BW 220 D-5
necessary replace it, check sensor and if necessary replace it, Behaviour error lamp: permanent light necessary replace it, check connection cable and if necessary
check connection cable and if necessary repair or replace it Selfhealing: yes repair or replace it
other error properties Signal Priority: 2 other error properties
System reaction: Advice: OPSCD_stSysReacReqLo Measurement @ errortime: actual value System reaction: Warning, substitute value
Behaviour error lamp: permanent light Behaviour error lamp: permanent light
oder Selfhealing: yes
blinking Signal Priority: 4

Selfhealing: yes Measurement @ errortime: default value
Signal Priority: 4

DTC-List P490_: 220, 310, 501 P492_: 213
203 / 175 / OTSCDSysReac 208 / 523470 / PRVMon 209 / 157 / RailCD

Error description OIL TEMP. SENSOR Error description RAIL PRESS. LIM. VALVE Error description RAIL PRESS. SENSOR
Oil temperature: the oil temperature calculated by ECU is above Rail pressure relief valve: is open, will be forced to open, the Rail pressure sensor: the voltage of sensor measured by ECU is
the target range; the ECU activates a system reaction forced-open failed out of the target range
SPN: 175 SPN: 523470 SPN: 157
0: data valid, but above normal working area 14: Special Instructions 3: Voltage to high or short circuit to +Ubatt
0: data valid, but above normal working area 2: data stream is defective 4: Voltage to low or short circuit to -Ubatt
Errorlamp shows permanent light Errorlamp shows permanent light, 15s before shut off. Entry in Errorlamp shows permanent light, 15s before shut off. Entry in
oder errormemory. errormemory.
blinking. Entry in errormemory. Possible reason for error Possible reason for error
Possible reason for error Rail pressure relief valve open or forced open abortive Cable break or short circuit, sensor defective, connection cable
Above target range with system reaction, oil volume too small, oil (interpretation of the rail pressure gradient), operating voltage too demaged
loop disturbed, sensor defective, connection cable demaged low, rail pressure sensor defective, fuel metering unit defective, Take actions for error repair
Take actions for error repair rail pressure relief valve defective, air in fuel system Check cabling, check rail pressure sensor and if necessary
Check cycle cooling system and compressor, check oil level and Take actions for error repair replace it, check connection cable and if necessary repair or
BW 220 D-5
if necessary correct it, check sensor and if necessary replace it, Check working voltage and if necessary correct it, check rail- replace it
check oil loop and if necessary repair it, check connection cable pressure sensor and if necessary replace it, check FCU and if other error properties
and if necessary repair or replace it necessary replace it, check rail pressure relief valve and if System reaction: Warning, max.extraction of FCU --> open rail
other error properties necessary replace it, bleed the fuel-system pressure relief valve --> shut the engine off in about 5 minutes
System reaction: Advice: OTSCD_stSysReacReq other error properties Behaviour error lamp: permanent light, 15s before shut off
Behaviour error lamp: permanent light System reaction: Warning, shut the engine off in about 5 minutes Selfhealing: no
oder Behaviour error lamp: permanent light, 15s before shut off Signal Priority: 4
blinking Selfhealing: no Measurement @ errortime: default value

721
722
DTC-List P490_: 220, 310, 501 P492_: 213
210 / 157 / RailCDOfsTst 211 / 523613 / RailMeUn0 212 / 523613 / RailMeUn1

Error description RAIL PRESS. SENSOR Error description RAIL PRESSURE Error description RAIL PRESSURE
Rail pressure sensor: the change of the voltage measured by Rail pressure: the fuel pressure in rail calculated by ECU is Rail pressure: the fuel pressure in rail calculated by ECU is
ECU during the engine start or the after-run is out of the target above the target range which is dependant on the engine speed above the target range which is dependant on the volume flow
range Error codes rate
Error codes DEUTZ-Errorcode: 211 Error codes
DEUTZ-Errorcode: 210 BlinkCode (short-long-short): 1 - 3 - 4 DEUTZ-Errorcode: 212
BlinkCode (short-long-short): 1 - 4 - 7 SPN: 523613 BlinkCode (short-long-short): 1 - 3 - 4
SPN: 157 possible FMI: SPN: 523613
possible FMI: 0: data valid, but above normal working area possible FMI:
0: data valid, but above normal working area 12. Errormode not identifiable 0: data valid, but above normal working area
1: data valid, but below normal working area 12. Errormode not identifiable 12. Errormode not identifiable
12. Errormode not identifiable Errordetection 12. Errormode not identifiable
Errordetection Errorlamp shows permanent light Errordetection
Errorlamp shows permanent light. Entry in errormemory. oder Errorlamp shows permanent light
Possible reason for error blinking. Entry in errormemory. oder
Deviation of signal during start or after-run above target range, Possible reason for error blinking. Entry in errormemory.
sensor defective 1) Leakage in high pressure system (external) , Possible reason for error
Take actions for error repair 2) Leakage at rail pressure relief valve (internal), 1) Leakage in high pressure system (external) ,
Replace sensor 3) Needle clampt in open position, 2) Leakage at rail pressure relief valve (internal),
other error properties 4) Abrasion at injector, 3) Needle clampt in open position,
5) Abrasion at high pressure pump, 4) Abrasion at injector,
BW 220 D-5
System reaction: Warning
Behaviour error lamp: permanent light 6) Too low primary pressure on low pressure side, sensor d 5) Abrasion at high pressure pump,
Selfhealing: yes Take actions for error repair 6) Too low primary pressure on low pressure side, sensor d
Signal Priority: 2 (A) Check for leakage Take actions for error repair
Measurement @ errortime: actual value (B) Chek fuel-primary pressure (A) Check for leakage
(C) Change components, check sensor and if necessary replace (B) Chek fuel-primary pressure
it, check fuel system and if necessary repair it (C) Change components, check sensor and if necessary replace
other error properties it, check fuel system and if necessary repair it
System reaction: Warning or Warning and power reduction other error properties
Behaviour error lamp: permanent light System reaction: Warning or Warning and power reduction
oder Behaviour error lamp: permanent light
blinking oder
Selfhealing: yes blinking
Signal Priority: 4 Selfhealing: yes
Measurement @ errortime: actual value Signal Priority: 4

DTC-List P490_: 220, 310, 501 P492_: 213
213 / 523613 / RailMeUn2 214 / 523613 / RailMeUn3 215 / 523613 / RailMeUn4

Error description RAIL PRESSURE Error description RAIL PRESSURE Error description RAIL PRESSURE
Rail pressure: the fuel pressure in rail calculated by ECU is Rail pressure: the fuel pressure in rail calculated by ECU is Rail pressure: the fuel pressure in rail calculated by ECU is
underneath the target range which is dependant on the engine underneath the target range which is dependant on the volume above the absolute target range
speed flow rate Error codes
possible FMI: possible FMI: 0: data valid, but above normal working area
0: data valid, but above normal working area 1: data valid, but below normal working area 12. Errormode not identifiable
Errordetection Errordetection Errorlamp shows permanent light
Errorlamp shows permanent light Errorlamp shows permanent light oder
oder oder blinking. Entry in errormemory.
blinking. Entry in errormemory. blinking. Entry in errormemory. Possible reason for error
Possible reason for error Possible reason for error 1) No power supply in FCU,
1) No power supply in FCU, 1) Leakage in high pressure system (external) , 2) ZME clamped in open position,
2) ZME clamped in open position, 2) Leakage at rail pressure relief valve (internal), 3) Too high pressure nach Nullförderdrossel (FCU),
3) Too high pressure nach Nullförderdrossel (FCU), 3) Needle clampt in open position, 4) Nullförderdrossel clogged,
4) Nullförderdrossel clogged, 4) Abrasion at injector, 5) Too high primary pressure on low pressure side, sensor
BW 220 D-5
5) Too high primary pressure on low pressure side, sensor 5) Abrasion at high pressure pump, defective, fuel system disturbed
defective, fuel system disturbed 6) Too low primary pressure on low pressure side, sensor d Take actions for error repair
Take actions for error repair Take actions for error repair (A) Check return-pressure FCU
(A) Check return-pressure FCU (A) Check for leakage (B) Check flow-pressure
(B) Check flow-pressure (B) Chek fuel-primary pressure (C) Change FCU, check sensor and if necessary replace it, check
(C) Change FCU, check sensor and if necessary replace it, check (C) Change components, check sensor and if necessary replace fuel system and if necessary repair it
fuel system and if necessary repair it it, check fuel system and if necessary repair it other error properties
other error properties other error properties System reaction: Warning or Warning and power reduction
System reaction: Warning or Warning and power reduction System reaction: Warning or Warning and power reduction Behaviour error lamp: permanent light
Behaviour error lamp: permanent light Behaviour error lamp: permanent light oder
oder oder blinking
blinking blinking Selfhealing: yes
Signal Priority: 4 Signal Priority: 4 Measurement @ errortime: actual value

723
724
DTC-List P490_: 220, 310, 501 P492_: 213
216 / 523613 / RailMeUn7 218 / 523490 / SOPTst 219 / 1079 / SSpMon1

Error description RAIL PRESSURE Error description REDUNDANT SHUT OFF DET. Error description 5V SUPPLY 1 FAIL.
Rail pressure: the fuel pressure in rail calculated by ECU is Internal hardware monitoring: the ECU finds an disturbance in the Internal hardware monitoring: the ECU detects a deviation of the
implausible compared with the setpoint setting of the fuel redundant switch off path through a test during the ramp up target range of the power supply voltage of sensor 1
metering unit phase Error codes
possible FMI: possible FMI: 3: Voltage to high or short circuit to +Ubatt
2: data stream is defective 12. Errormode not identifiable 4: Voltage to low or short circuit to -Ubatt
12. Errormode not identifiable 3: Voltage to high or short circuit to +Ubatt 12. Errormode not identifiable
12. Errormode not identifiable 4: Voltage to low or short circuit to -Ubatt Errordetection
Errorlamp shows permanent light Errorlamp shows permanent light. Entry in errormemory. Possible reason for error
oder Possible reason for error 5V sensor supply voltage 1 outside target range, operating
blinking. Entry in errormemory. Test of redundant shut-off paths voltage too high or to low, connection cable demaged, ECU
Possible reason for error Take actions for error repair defective
1) Leakage in high pressure system (external) , Could be triggered by over/undervoltage or external Watchdog Take actions for error repair
2) Leakage at rail pressure relief valve (internal), other error properties If error not removable, change ECU, check cabling of external
3) Needle clampt in open position, System reaction: Test will only be executed with ECU components, check working voltage and if necessary correct it,
4) Abrasion at injector,
BW 220 D-5
Initialisation. Warning, dependent upon application. check connection cable and if necessary repair or replace it
5) Abrasion at high pressure pump, Behaviour error lamp: permanent light other error properties
6) Too low primary pressure on low pressure side, sensor d Selfhealing: no System reaction: Warning
Take actions for error repair Signal Priority: 4 Behaviour error lamp: permanent light
(A) Check for leakage Measurement @ errortime: - Selfhealing: yes
(B) Chek fuel-primary pressure Signal Priority: 3
(C) Change components, check sensor and if necessary replace

it, check fuel system and if necessary repair it
System reaction: Warning or Warning and power reduction
oder
blinking
Selfhealing: yes
Signal Priority: 4

DTC-List P490_: 220, 310, 501 P492_: 213
221 / 1080 / SSpMon2 222 / 523601 / SSpMon3 223 / 677 / StrtCDHS

Error description 5V SUPPLY 2 FAIL. Error description 5V SUPPLY 3 FAIL. Error description START RELAY
Internal hardware monitoring: the ECU detects a deviation of the Internal hardware monitoring: the ECU detects a deviation of the Start relay (high side power stage): the current drain measured
target range of the power supply voltage of sensor 2 target range of the power supply voltage of sensor 3 by ECU is above the target range
SPN: 1080 SPN: 523601 SPN: 677
3: Voltage to high or short circuit to +Ubatt 3: Voltage to high or short circuit to +Ubatt 3: Voltage to high or short circuit to +Ubatt
4: Voltage to low or short circuit to -Ubatt 4: Voltage to low or short circuit to -Ubatt 4: Voltage to low or short circuit to -Ubatt
5V sensor supply voltage 2 outside target range, operating Wrong voltage of internal 5V reference source 3, operating Start relay (high side): short circuit, relay defective, conncection
voltage too high or to low, connection cable demaged, ECU voltage too high or too low, connection cable demaged, ECU cable defective
defective defective Take actions for error repair
Take actions for error repair Take actions for error repair Check cabling and start relay and if necessary replace it, check
If error not removable, change ECU, check cabling of external If error not removable, change ECU, check cabling of external connection cable and if necessary repair or replace it
components, check working voltage and if necessary correct it, components, check working voltage and if necessary correct it, other error properties
BW 220 D-5
check connection cable and if necessary repair or replace it check connection cable and if necessary repair or replace it System reaction: Warning, shutoff output
other error properties other error properties Behaviour error lamp: permanent light
System reaction: Warning System reaction: Warning Selfhealing: no
Behaviour error lamp: permanent light Behaviour error lamp: permanent light Signal Priority: 1
Selfhealing: yes Selfhealing: yes Measurement @ errortime: default value

725
726
DTC-List P490_: 220, 310, 501 P492_: 213
224 / 677 / StrtCDLS 225 / 624 / SysLamp 226 / 158 / T15CD

Error description START RELAY Error description DIAGNOSTIC LAMP Error description TERMINAL 15
start relay (low side power stage): the current drain measured by Error lamp (diagnositic lamp): the current drain measured by Terminal 15: ECU receives no signal
ECU is out of the target range ECU is out of the target range or the maximum permissble Error codes
Error codes temperature of the ECU component for power supply of the lamp DEUTZ-Errorcode: 226
DEUTZ-Errorcode: 224 is exceeded BlinkCode (short-long-short): 5 - 1 - 4
BlinkCode (short-long-short): 5 - 1 - 2 Error codes SPN: 158
SPN: 677 DEUTZ-Errorcode: 225 possible FMI:
possible FMI: BlinkCode (short-long-short): 5 - 1 - 3 12. Errormode not identifiable
3: Voltage to high or short circuit to +Ubatt SPN: 624 12. Errormode not identifiable
4: Voltage to low or short circuit to -Ubatt possible FMI: 12: Defective component
5: current to low or broken wire 3: Voltage to high or short circuit to +Ubatt 12. Errormode not identifiable
12. Errormode not identifiable 4: Voltage to low or short circuit to -Ubatt Errordetection
Errordetection 5: current to low or broken wire Errorlamp shows permanent light. Entry in errormemory.
Errorlamp shows permanent light. Entry in errormemory. 2: data stream is defective Possible reason for error
Possible reason for error Errordetection Ignition ON not detected, ignition switch defective, connection
Start relay (low side): cable break or short circuit, disabled by Errorlamp shows -. Entry in errormemory. cable demaged
ECU, relay defective, connection cable demaged Possible reason for error Take actions for error repair
Take actions for error repair Cable break or short circuit, disabled by ECU, lamp defective, Check cabling, if sensor not working, check ignition switch and if
Check cabling and start relay and if necessary replace it, check connection cable demaged necessary replace it, check connection cable and if necessary
connection cable and if necessary repair or replace it Take actions for error repair repair or replace it
other error properties Check cabling and load, check lamp and if necessary replace it, other error properties
BW 220 D-5
System reaction: Warning, shutoff output check connection cable and if necessary repair or replace it System reaction: Warning, engine can not start
Behaviour error lamp: permanent light other error properties Behaviour error lamp: permanent light
Selfhealing: no System reaction: only error memory item Selfhealing: no
Signal Priority: 1 Behaviour error lamp: - Signal Priority: 2
Measurement @ errortime: default value Selfhealing: no Measurement @ errortime: actual value
Signal Priority: 2
Measurement @ errortime: setpoint Diagnosticlamp

DTC-List P490_: 220, 310, 501 P492_: 213
227 / 523550 / T50CD 228 / 523550 / TPUMon 232 / 84 / VSSCD1

Error description TERMINAL 50 Error description TERMINAL 50 Error description VEHICLE SPEED
Terminal 50: ECU receives a permanent signal Internal hardware monitoring: ECU detects a deviation between Vehicle speed: over the maximum, signal invalid or implausible
Error codes the signal of time module and the system time compared with the injection quantity and the engine speed, offset
DEUTZ-Errorcode: 227 Error codes factors unlearned
BlinkCode (short-long-short): 5 - 1 - 5 DEUTZ-Errorcode: 228 Error codes
SPN: 523550 BlinkCode (short-long-short): 5 - 5 - 5 DEUTZ-Errorcode: 232
possible FMI: SPN: 523550 BlinkCode (short-long-short): 5 - 2 - 1
12: Defective component possible FMI: SPN: 84
12. Errormode not identifiable 12. Errormode not identifiable possible FMI:
12. Errormode not identifiable 12. Errormode not identifiable 0: data valid, but above normal working area
Errordetection 2: data stream is defective 8: unusual frequency, pulse or period.
Errorlamp shows permanent light. Entry in errormemory. Errordetection 14: Special Instructions
Possible reason for error Errorlamp shows blinking. Entry in errormemory. Errordetection
Engine start switch stuck, start switch clamped, connection cable Possible reason for error Errorlamp shows permanent light. Entry in errormemory.
demaged Time processing unit (TPU) defective, ECU defective Possible reason for error
Take actions for error repair Take actions for error repair Speed above target range, signal invalid or implausible compared
Check cabling, if sensor not working, check start switch and if If error not removable, change ECU to injection volume and engine speed, distance factor not
necessary replace it, check connection cable and if necessary other error properties learned, sensor defective, connection cable demaged
repair or replace it System reaction: Recovery of ECU Take actions for error repair
other error properties Behaviour error lamp: blinking Check cabling, if sensor not working, check sensor and if
BW 220 D-5
System reaction: Warning Selfhealing: no necessary replace it, check connection cable and if necessary
Behaviour error lamp: permanent light Signal Priority: 5 repair or replace it
Selfhealing: no Measurement @ errortime: - other error properties
Signal Priority: 1 System reaction: Warning
Measurement @ errortime: actual value Behaviour error lamp: permanent light
Selfhealing: yes
Signal Priority: 3

727
728
DTC-List P490_: 220, 310, 501 P492_: 213
235 / 523600 / WdCom 236 / 523470 / PRVMonSysReac 237 / 523006 / APPCDSwtnSel

Error description SERIAL INTERFACE DEF. Error description RAIL PRESS. LIM. VALVE Error description CONTR. MODE SWITCH
Internal hardware monitoring: the ECU detects a disturbance in Rail pressure relief valve: is open, will be forced to open, the Controller mode switch: the signal received by ECU is defective
internal communication forced-open failed; the ECU activates a system reaction or implausible.
SPN: 523600 SPN: 523470 SPN: 523006
12. Errormode not identifiable 12: Defective component 3: Voltage to high or short circuit to +Ubatt
12. Errormode not identifiable 12: Defective component 4: Voltage to low or short circuit to -Ubatt
Errorlamp shows blinking. Entry in errormemory. Errorlamp shows permanent light, 15s before shut off. Entry in Errorlamp shows permanent light. Entry in errormemory.
Possible reason for error errormemory. Possible reason for error
Communication disturbed, ECU defective Possible reason for error Cable break, signal implausible, switch defective, connection
Take actions for error repair Rail pressure relief valve open or forced open abortive cable demaged
If error not to removable, change ECU (interpretation of the rail pressure gradient), power supply voltage Take actions for error repair
other error properties too low, rail pressure sensor defective, fuel metering unit Check switch and if necessary replace it, check connection cable
System reaction: Recovery of ECU defective, rail pressure relief valve defective, air in fuel system and if necessary repair or replace it
Behaviour error lamp: blinking Take actions for error repair other error properties
BW 220 D-5
Selfhealing: no Check working voltage and if necessary correct it, check rail- System reaction:
Signal Priority: 5 pressure sensor and if necessary replace it, check FCU and if Behaviour error lamp: permanent light
Measurement @ errortime: - necessary replace it, check rail pressure relief valve and if Selfhealing: yes
necessary replace it, bleed the fuel-system Signal Priority: 2
other error properties Measurement @ errortime: actual value
System reaction: Warning, shut the engine off in about 5 minutes
Behaviour error lamp: permanent light, 15s before shut off

Selfhealing: no
Signal Priority: 4

DTC-List P490_: 220, 310, 501 P492_: 213
238 / 523007 / FrmMng_TORxEngPress 239 / 523008 / MplCtl 240 / 98 / OLSCD

Error description CAN ERROR RxEngPress. Error description MANIPULATION CONTROL Error description OIL LEVEL SWITCH
Error codes Data monitoring: the torque curve does not match the Oil level sensor: the voltage of sensor measured by ECU is out of
DEUTZ-Errorcode: 238 specification the target range or the received value of oil level via CAN is
BlinkCode (short-long-short): 2 - 1 - 5 Error codes defective or the signal value is implausible
SPN: 523007 DEUTZ-Errorcode: 239 Error codes
possible FMI: BlinkCode (short-long-short): 4 - 2 - 4 DEUTZ-Errorcode: 240
12: Defective component SPN: 523008 BlinkCode (short-long-short): 2 - 1 - 1
12. Errormode not identifiable possible FMI: SPN: 98
12. Errormode not identifiable 1: data valid, but below normal working area possible FMI:
12. Errormode not identifiable 2: data stream is defective 3: Voltage to high or short circuit to +Ubatt
Errordetection 12. Errormode not identifiable 4: Voltage to low or short circuit to -Ubatt
Errorlamp shows permanent light. Entry in errormemory. 12. Errormode not identifiable 2: data stream is defective
Possible reason for error Errordetection 2: data stream is defective
Take actions for error repair Errorlamp shows . Entry in errormemory. Errordetection
other error properties Possible reason for error Errorlamp shows permanent light. Entry in errormemory.
System reaction: Manipulation of Topcurve detected, data manipulation, too slow Possible reason for error
Behaviour error lamp: permanent light changed curve Voltage outside target range, CAN signal error, signal
Selfhealing: yes Take actions for error repair implausible, sensor defective, connection cable demaged, CAN
Signal Priority: 1 other error properties bus wrong cabled, wiring demaged, receiver (sender of the
Measurement @ errortime: default value System reaction: message) work inaccurately, parametering inaccurate
Behaviour error lamp: Take actions for error repair
BW 220 D-5
Selfhealing: - Check cabling, if sensor not working, check sensor and if
Signal Priority: 3 necessary replace it, check connection cable and if necessary
Measurement @ errortime: repair or replace it, Check CAN Bus cabling (Bus sheduling,
polarity, short circuit, power interrupt), test protocol of receiver,
chec
System reaction: Warning, substitute value
Selfhealing: yes
Signal Priority: 3

729
730
DTC-List P490_: 220, 310, 501 P492_: 213
241 / 98 / OLSCDSysReacHi 242 / 107 / ADPSCDAna 243 / 98 / OLSCDSysReacLo

Error description OIL LEVEL SWITCH Error description AIR FILTER COND. Error description OIL LEVEL SWITCH
Oil level: the oil level calculated by ECU is above the target Air filter differential pressure sensor: the voltage of sensor Oil level: the oil level calculated by ECU is underneath the target
range; the ECU activates a system reaction measured by ECU is out of the target range range; the ECU activates a system reaction
SPN: 98 SPN: 107 SPN: 98
0: data valid, but above normal working area 3: Voltage to high or short circuit to +Ubatt 1: data valid, but below normal working area
12. Errormode not identifiable 4: Voltage to low or short circuit to -Ubatt 12. Errormode not identifiable
Oil level too high with system reaction, oil volume too large, Voltage outside target range, sensor defective, connection cable Oil level too low with system reaction, oil volume too small,
sensor defective, connection cable demaged, CAN data error demaged sensor defective, connection cable demaged, CAN data error
Check oil level and if necessary correct it, check sensor and if Check cable harness, check sensor and if necessary replace it, Check oil level and if necessary correct it, check sensor and if
necessary replace it, check connection cable and if necessary check connection cable and if necessary repair or replace it necessary replace it, check connection cable and if necessary
repair or replace it other error properties repair or replace it
BW 220 D-5
other error properties System reaction: Warning, substitute value other error properties
System reaction: Advice: OLSCD_stSysReacReq Behaviour error lamp: permanent light System reaction: Advice: OLSCD_stSysReacReq
Behaviour error lamp: permanent light Selfhealing: yes Behaviour error lamp: permanent light
Selfhealing: yes Signal Priority: 3 Selfhealing: yes
Signal Priority: 4 Measurement @ errortime: default value Signal Priority: 4

DTC-List P490_: 220, 310, 501 P492_: 213
244 / 523009 / PrvMonWear 245 / 523010 / RailMeUn8 246 / 523650 / FlSys_FLPFMSysReac

Error description REPL. RAIL PRESS. VALVE Error description LEAKAGE DETECTION Error description
Rail pressure relief valve: is open more frequently or for a longer Wenn the engine is in idle running, the metering unit compares its Low fuel pressure Diesel: the low fuel pressure calculated by
time than what the technical specification allows output and rail pressure with the default value (Parameter) and ECU is underneath the target range; the ECU activates a system
Error codes calculates a correction factor-it calibrates itself then reaction
9: Abnormal update rated possible FMI: possible FMI:
10: Abnormal rate of change 0: data valid, but above normal working area 2: data stream is defective
14: Special Instructions 12. Errormode not identifiable 2: data stream is defective
Errordetection 12. Errormode not identifiable 12. Errormode not identifiable
Rail pressure relief valve open more frequently than the technical Possible reason for error Possible reason for error
specification allowed, rail pressure relief valve open longer than Take actions for error repair Diesel fuel pressure below target range with system reaction,
the technical specification allowed, rail pressure relief valve other error properties interruption in cycling process of low fuel pressure (for example,
defective System reaction: fuel pump defective), sensor defective, connection cable
Take actions for error repair Behaviour error lamp: permanent light demaged
Change rail pressure relief valve and remove the error through Selfhealing: no Take actions for error repair
BW 220 D-5
Serdia command Signal Priority: 3 Check Diesel low fuel pressure loop system, Check electrical fuel
other error properties Measurement @ errortime: actual value pump, inspect fuel system and if necessary repair it, check
System reaction: permanent error message, unerasable by sensor and if necessary replace it, check connection cable and if
"Clear EM" necessary repair or replace it
Behaviour error lamp: permanent light other error properties
Selfhealing: no System reaction: Warning
Measurement @ errortime: actual value Selfhealing: yes
Signal Priority: 4

731
732
DTC-List P490_: 220, 310, 501 P492_: 213
247 / 523651 / FlSys_FTSFMSysReac 248 / 523652 / FlSys_FlushStateEngineOff 249 / 523653 / FlSys_RapeOilHeatEx

Error description Error description Error description RAPEOILSYSTEM
Rape Oil Fuel temperature: the fuel temperature calculated by Engine shut off without flushing or flushing was not already Awaited temperatur rise with opened heat exchanger valve did
ECU is above the target range; the ECU activates a system completed. ECU stores every shutoff with uncompleted or not occur. Error in fuel heating system.
reaction missing flushing process Error codes
possible FMI: possible FMI: 2: data stream is defective
Errorlamp shows permanent light. Entry in errormemory. Errorlamp shows permanent light. Entry in errormemory. Possible reason for error
Possible reason for error Possible reason for error Fuel heating system (heat exchanger) not working correctly
Rape oil fuel temperature above target range with system Engine shut off without flushing of the fuel system in Diesel Take actions for error repair
reaction, interruption of rape oil fuel loop (for example, heat operation mode, Shutoff before flushing in Diesel operation mode Check Heat exchanger and heat exchanger valve, check cooling
exchanger not working properly), sensor defective, connection was finished system going to the heat exchanger, check rape oil system going
cable demaged Take actions for error repair to the heat exchanger
Take actions for error repair Awaiting complete flushing of the fuel system everytime before other error properties
BW 220 D-5
Check rape oil fuel system as well as heat exchanger and heat engine shut off System reaction: Warning
exchanger valve, if necessary repair it, check sensor and if other error properties Behaviour error lamp: permanent light
necessary replace it, check connection cable and if necessary System reaction: Warning Selfhealing: yes
repair or replace it Behaviour error lamp: permanent light Signal Priority: 3
other error properties Selfhealing: yes Measurement @ errortime: -
System reaction: Warning and switchover to Diesel operation Signal Priority: 3
mode Measurement @ errortime: -

Selfhealing: yes
Signal Priority: 3

DTC-List P490_: 220, 310, 501 P492_: 213
250 / 523654 / FrmMngDieselLvl 251 / 523655 / FrmMngFuelTemp 252 / 523656 / FrmMngLowPressureDiesel

Error description RAPEOILSYSTEM Error description RAPEOILSYSTEM Error description RAPEOILSYSTEM
Status DieselLvl (Diesel tank level): the voltage of the sensor Status FuelTemp (Fuel Temperature): the voltage of the sensor Status LowPressureDiesel (Low fuel pressure diesel): the voltage
measured by ECU is out of the target range measured by ECU is out of the target range of the sensor measured by ECU is out of the target range
SPN: 523654 SPN: 523655 SPN: 523656
3: Voltage to high or short circuit to +Ubatt 3: Voltage to high or short circuit to +Ubatt 3: Voltage to high or short circuit to +Ubatt
4: Voltage to low or short circuit to -Ubatt 4: Voltage to low or short circuit to -Ubatt 4: Voltage to low or short circuit to -Ubatt
Cable break or short circuit, sensor defective, connection cable Cable break or short circuit, lamp defective, connection cable Cable break or short circuit, lamp defective, connection cable
Check cabling, if sensor not working, check sensor and if Check cabling, if sensor not working, check sensor and if Check cabling, if sensor not working, check sensor and if
necessary replace it, check connection cable and if necessary necessary replace it, check connection cable and if necessary necessary replace it, check connection cable and if necessary
repair or replace it repair or replace it repair or replace it
BW 220 D-5
System reaction: Warning, substitute value System reaction: Warning, substitute value System reaction: Warning, substitute value

733
734
DTC-List P490_: 220, 310, 501 P492_: 213
253 / 523657 / FrmMngRapeOilIn 254 / 523658 / FrmMngRapeOilLvl 255 / 523659 / FrmMngRapeOilVlv1

CAN messageRapeOilln (Rape oil input): the message can not Status RapeOilLvl (Rape oil tank level): the voltage of the sensor Status RapeOilVlv1 (Valve 1): the current drain measured by
be received by ECU measured by ECU is out of the target range ECU is out of the target range or the maximum permissible
Error codes Error codes temperature of the ECU component is exceeded
12: Defective component 3: Voltage to high or short circuit to +Ubatt possible FMI:
12. Errormode not identifiable 4: Voltage to low or short circuit to -Ubatt 12. Errormode not identifiable
Errordetection Errordetection 12. Errormode not identifiable
CAN bus wrong cabled, wiring is demaged, receiver (sender of Cable break or short circuit, lamp defective, connection cable Possible reason for error
the message) work inaccurately, parametering inaccurate demaged Cable break or short circuit, valve defective, connection cable
Check CAN Bus cabling (Bus sheduling, polarity, short circuit, Check cabling, if sensor not working, check sensor and if Take actions for error repair
power interrupt), test protocol of receiver, check CAN functional necessary replace it, check connection cable and if necessary Check cabling, if valve not working, check valve and if necessary
range repair or replace it replace it, check connection cable and if necessary repair or
BW 220 D-5
other error properties other error properties replace it
System reaction: Warning, substitute values System reaction: Warning, substitute value other error properties
Behaviour error lamp: permanent light Behaviour error lamp: permanent light System reaction: Warning and switchover to Diesel operation
Selfhealing: yes Selfhealing: yes mode
Signal Priority: 3 Signal Priority: 3 Behaviour error lamp: permanent light
Measurement @ errortime: default value Measurement @ errortime: default value Selfhealing: yes
Signal Priority: 3

DTC-List P490_: 220, 310, 501 P492_: 213
256 / 523660 / FrmMngRapeOilVlv2 257 / 523661 / FrmMngRapeOilVlv3 258 / 523662 / FrmMngRapeOilVlv4

Status RapeOilVlv2 (Valve 2): the current drain measured by Status RapeOilVlv3 (Valve 3): the current drain measured by Status RapeOilVlv4 (Valve 4): the current drain measured by
ECU is out of the target range or the maximum permissible ECU is out of the target range or the maximum permissible ECU is out of the target range or the maximum permissible
temperature of the ECU component is exceeded temperature of the ECU component is exceeded temperature of the ECU component is exceeded
SPN: 523660 SPN: 523661 SPN: 523662
Cable break or short circuit, valve defective, connection cable Cable break or short circuit, valve defective, connection cable Cable break or short circuit, valve defective, connection cable
Check cabling, if valve not working, check valve and if necessary Check cabling, if valve not working, check valve and if necessary Check cabling, if valve not working, check valve and if necessary
replace it, check connection cable and if necessary repair or replace it, check connection cable and if necessary repair or replace it, check connection cable and if necessary repair or
BW 220 D-5
replace it replace it replace it
System reaction: Warning and switchover to Diesel operation System reaction: Warning and switchover to Diesel operation System reaction: Warning
mode mode Behaviour error lamp: permanent light
Signal Priority: 3 Signal Priority: 3 Measurement @ errortime: default value

735
736
DTC-List P490_: 220, 310, 501 P492_: 213
259 / 523663 / FrmMngRapeOilVlv5 260 / 523664 / FrmMngSTIN1RX

Error description RAPEOILSYSTEM Error description RAPEOILSYSTEM
Status RapeOilVlv5 (Valve 5): the current drain measured by CAN message STIN1 (State Inputs 1): the message can not be
ECU is out of the target range or the maximum permissible received by ECU
temperature of the ECU component is exceeded Error codes
Error codes DEUTZ-Errorcode: 260
DEUTZ-Errorcode: 259 BlinkCode (short-long-short): 5 - 6 - 8
BlinkCode (short-long-short): 5 - 6 - 7 SPN: 523664
SPN: 523663 possible FMI:
possible FMI: 12: Defective component
12. Errormode not identifiable 12. Errormode not identifiable
12. Errormode not identifiable 12: Defective component
12: Defective component 12. Errormode not identifiable
12. Errormode not identifiable Errordetection
Errordetection Errorlamp shows permanent light. Entry in errormemory.
Errorlamp shows permanent light. Entry in errormemory. Possible reason for error
Possible reason for error CAN bus wrong cabled, wiring is demaged, receiver (sender of
Cable break or short circuit, valve defective, connection cable the message) work inaccurately, parametering inaccurate
demaged Take actions for error repair
Take actions for error repair Check CAN Bus cabling (Bus sheduling, polarity, short circuit,
Check cabling, if valve not working, check valve and if necessary power interrupt), test protocol of receiver, check CAN functional
replace it, check connection cable and if necessary repair or range
BW 220 D-5
replace it other error properties
other error properties System reaction: Warning, substitute values
System reaction: Warning Behaviour error lamp: permanent light
Behaviour error lamp: permanent light Selfhealing: yes
Signal Priority: 3 Measurement @ errortime: default value

Troubleshooting – Trouble shooting, hydraulics
7.5 Trouble shooting, hydraulics

7.5.2 Insufficient hydraulic power................................... 738
7.5.3 Troubleshooting axial piston pumps...................... 741
7.5.4 Troubleshooting axial piston motors...................... 743
7.5.5 Troubleshooting table for hydraulic components... 745
7.5.1 Preliminary remarks

service department.
There are many reasons for faults and malfunctions occurring in

hydraulic systems. After years of trouble-free operation, even a
perfectly designed and carefully operated system will eventually
suffer line losses or undesirable side effects that can be described
as natural: They are caused by wear, clogging and material fatigue.
In such cases, it is particularly important to quickly detect sources
of fault or defective parts and replace them as cost-effectively as
possible. The cause of a component failure needs to be deter-
mined.
Preventive maintenance and servicing, especially regular checks of
oil cleanliness, is of course the best method to pre-emptively mini-
mise any faults and malfunctions. Nevertheless, malfunctions and
faults may occur during operation of a hydraulic system or machine
which impair the general functional sequence but also the safety of
the hydraulic system or machine. In addition to impairing product
quality, this may result in hazards that can no longer guarantee
working safely with the machine.
If the control system is not a purely hydraulic system and, in fact,
the hydraulic system is operated as part of an electro-hydraulic
control system, it may be necessary to involve a qualified electri-
cian in troubleshooting. In the case of complex systems operated
with electronic controls, it may also be necessary to call in a spe-
cialist for electronic hardware or software.
At the beginning of troubleshooting, the necessary technical docu-
ments and information should be available, e.g. operating instruc-
tions, and circuit diagrams including measuring points.
Common symptoms and causes Unusual or excessive noise during operation may indicate clogged
filters or foreign matter in the line. However, even a suction line
bent one time too many or too far, stiff valves, incorrectly adjusted
engines/motors, tired pumps and incorrect operating temperatures
can often cause “unhealthy” noises.
BW 220 D-5 737

Too little or no pressure – this is how a hydraulic system may stop

working. There is often incorrect air in the system because there
are one or more leaks. The correct viscosity of the liquid used and
sufficient cooling are also important for the pressure to be correct.
And, of course, the coupling, pump and engine must not be
allowed to grind, overheat or foam.
Fluctuations in pressure and flow make operation difficult and the
system unpredictable. This is usually caused by contamination,
blockages or tension. Many hydraulic systems can already be rem-
edied by cleaning the corresponding components, bleeding the
system and replacing the old liquids.
7.5.2 Insufficient hydraulic power

Trouble shooting charge pressure,
example travel circuit If the charge pressure is not inside the nominal
range, no high pressure can be built up in the
system.
738 BW 220 D-5

Diesel engine running, travel lever

position "0"
Fig. 759: Charge pressure (6S) present

1 Charge pump
2 Variable displacement pump
3 Hydraulic motor
4 Charge pressure relief valve (example 30 bar)
5 Pressure limiting valves (example 300 bar)
6 Pressure gauge, (6S) charge pressure, (6H) high pressure
7 Cooler (optional)
8 Filter
9 Connection for pump control
n If the charge pressure in the system drops, there is an internal

leak in the hydraulic circuit.
n But there may also be an internal leak in an external compo-
nent, which is also controlled by charge pressure. For example:
Brake valve, brake piston, etc.
n However, the steering pump could also be defective, because
the steering pump delivers the the oil that is fed into the closed
hydraulic circuit.
BW 220 D-5 739

Troubleshooting closed circuit

using the example of a travel circuit
Fig. 760
10 Pressure resistance plugs
1. Connect pressure gauges (6) for high pressure and charge
pressure.
2. Disconnect hydraulic motor/s (3) and close the ports with
pressure resistant plugs (10).
ð The variable displacement pump can now be pressure

tested.
NOTICE!
Do not run the test over a longer period of time
(danger of overheating).
3. Start the engine and accelerate to full speed.

4. Shift the travel lever to forward and reverse.
5. Read the pressure gauges (6).Read the pressure gauge.
ð If the pressure gauges show the correct values, the vari-
able displacement pump is OK. The fault is in the
hydraulic motor/s (3).
740 BW 220 D-5

7.5.3 Troubleshooting axial piston pumps

The following table should be of help when performing trouble-
shooting. This table is by no means complete. In practice, other
problems may occur that have not been listed here.
Procedure: 1. Always proceed systematically, even under time pressure.
Indiscriminate, ill-considered disassembly and changing of
settings can lead to a situation in which the original cause of
a fault can no longer be detected.
2. Get an overview of the function of the product in connection
with the overall system.
3. Try to clarify whether the product was able to deliver the
required function within the overall system before the fault
occurred.
4. Develop a clear understanding of the troubleshooting
process. If necessary ask the direct operator or machine
driver.
5. Have conditions or area of application of the product been
changed?
6. Were changes (e.g. changeovers) or repairs made to the
overall system (machine/plant, electrics, control) or to the
product? If yes: What kind?
7. Has the product or the machine been operated as intended?
8. How does the fault manifest itself?
Fault description Cause Remedy

Unusual noises Insufficient suction conditions, e.g. air in the Machine or system manufacturer
suction line, inadequate diameter of the suc- (e.g. optimize feed conditions, use
tion line, excessive viscosity of the pressure suitable pressure fluid).
fluid, extreme suction height, too low suction
Completely purge the axial piston
pressure, foreign bodies in the suction line.
unit, fill the suction line with pres-
sure fluid.
Remove foreign bodies from
inside the suction line.
Inappropriate fastening of the axial piston unit. Check the fastening of the axial
piston unit as specified by the
machine or plant manufacturer.
Observe the tightening torques.
Inappropriate fastening of attachment parts, Fasten attachment parts as speci-
e.g. coupling and hydraulic lines. fied by the coupling or fittings
manufacturer.
Pressure limiting valves of the axial piston unit Purge the axial piston unit, check
(charge pressure, high pressure, pressure the viscosity of the pressure fluid,
override valve). consult the service department.
Consult the service department.
Mechanical damage to the axial piston unit. Replace the axial piston unit, con-
sult the service department.
BW 220 D-5 741


No or insufficient Faulty mechanical drive (e.g. defective cou- Check and repair the drive.
volumetric flow pling).
Drive speed too low. Consult the service department
Insufficient suction conditions, e.g. air in the Completely purge the axial piston
suction line, inadequate diameter of the suc- unit, fill the suction line with pres-
tion line, excessive viscosity of the pressure sure fluid.
Pressure fluid not within the optimal viscosity Use appropriate pressure fluid.
range.
External control and setting facilities defective. Check the external control.
Pilot or control pressure too low. Check pilot and control pressure,
consult the service department.
Functional disturbance in the control facility or Consult the service department.
the regulator on the axial piston unit.
Mechanical damage to the axial piston unit. Replace the axial piston unit.
No or insufficient Faulty mechanical drive (e.g. defective cou- Check and repair the drive.
pressure pling).
Poor drive power. Consult the service department.
Pressure fluid not within the optimal viscosity Use appropriate pressure fluid.
range.
External control and setting facilities defective. Check the external control.
Pilot or control pressure too low. Check pilot and control pressure.
Functional disturbance in the control facility or Consult the service department.
the regulator on the axial piston unit.
Wear of the axial piston unit. Replace the axial piston unit.
Mechanical damage to the axial piston unit. Replace the axial piston unit.
Drive unit defective (e.g. hydraulic motor or Check the drive unit, replace if
cylinder). necessary.
Fluctuations in pres- Axial piston unit not or insufficiently purged. Completely purge the axial piston
sure/volumetric flow unit.
742 BW 220 D-5


Fluctuations in pres- Insufficient suction conditions, e.g. air in the Remove foreign bodies from
sure/volumetric flow suction line, inadequate diameter of the suc- inside the suction line.
tion line, excessive viscosity of the pressure
Pressure fluid too hot Excessive input temperature on axial piston Check the system, e.g. malfunc-
unit. tion of the cooler, pressure fluid
level in tank too low.
Malfunction of the pressure control valves (e.g. Consult the service department.
high pressure limiting valve, pressure override
valve, pressure controller).
Malfunction of the flushing valve (not for nom- Consult the service department.
inal size 18).
Wear of the axial piston unit. Replace the axial piston unit.
7.5.4 Troubleshooting axial piston motors

The following table should be of help when performing trouble-
shooting. This table is by no means complete. In practice, other
Procedure: 1. Always proceed systematically, even under time pressure.
Indiscriminate, ill-considered disassembly and changing of
settings can lead to a situation in which the original cause of
a fault can no longer be detected.
2. Get an overview of the function of the product in connection
with the overall system.
3. Try to clarify whether the product was able to deliver the
required function within the overall system before the fault
occurred.
4. Develop a clear understanding of the troubleshooting
process. If necessary ask the direct operator or machine
driver.
5. Have conditions or area of application of the product been
changed?
6. Were changes (e.g. changeovers) or repairs made to the
overall system (machine/plant, electrics, control) or to the
product? If yes: What kind?
7. Has the product or the machine been operated as intended?
8. How does the fault manifest itself?

Unusual noises Inappropriate fastening of the axial Check the fastening of the axial
piston unit piston unit as specified by the
machine or plant manufacturer.
Observe the tightening torques
BW 220 D-5 743


Unusual noises Inappropriate fastening of attachment Fasten attachment parts as specified
parts, e.g. coupling and hydraulic lines by the coupling or fittings manufac-
turer
Mechanical damage to the axial piston Replace the axial piston unit
unit
Fluctuations in pressure/ Axial piston unit not or insufficiently Completely purge the axial piston
volumetric flow purged unit
Operation data are not Insufficient flow from hydraulic pump Check the function of the hydraulic
reached pump
Minimum displacement incorrectly set Consult the service department
External control and setting facilities Check the external control
defective
Control pressure too low Check control pressure, consult the
service department
Functional disturbance in the control Consult the service department
facility or the regulator on the axial
piston unit
Pressure fluid not within the optimal vis- Use appropriate pressure fluid
cosity range
Wear of the axial piston unit Replace the axial piston unit
Mechanical damage to the axial piston Replace the axial piston unit
unit
Pressure fluid too hot Excessive input temperature on axial Check the system, e.g. malfunction
piston unit of the cooler, pressure fluid level in
tank too low
Malfunction of the pressure control Consult the service department
valves (e.g. high pressure limiting valve,
pressure override valve, pressure con-
troller)
Failure of the flushing valve Consult the service department
Wear of the axial piston unit Replace the axial piston unit
744 BW 220 D-5

7.5.5 Troubleshooting table for hydraulic components

The following table shows possible malfunctions of hydraulic com-
ponents. This table is by no means complete. In practice, other
Drive elements
Fault Possible cause
n Mechanical parts on the drive side are defective (clutch seat, align-
Abnormal noises
ment faults, etc.)
No or insufficient volumetric n Speed transfer or distance transfer defective
flow
No or insufficient pressure n Torque transfer defective
Fluctuation of pressure/volu- n Drive elements defective
metric flow
Hydraulic cylinder/hydraulic motor

n Insufficient rotary speed or velocity
n Overtaking processes (hydraulic motor is driven by machine to the
pump)
Abnormal noises
n Braking noises
n Faulty inner seal
n Drive damage
n Internal losses
No or insufficient volumetric
n Leaking sleeves
flow
n Wear caused by dirt
n Inner or outer leaks
No or insufficient pressure n Wear caused by dirt
n Drive damage
n Not or insufficiently vented
n Defective sleeves
Fluctuation of pressure/volu-
n StickSlip effect
metric flow
n Changing load direction
n Displacement of hydraulic motor incorrect (to low or too high)
n Internal leakage
n Gap losses
Hydraulic fluid too hot
n Wear damage
n Hydro motor and cylinder too small
BW 220 D-5 745

Flow valves
n Trapped air
Abnormal noises n Differential pressure too small
n Vibrations
No or insufficient volumetric n Control orifice blocked
flow n Throttle check valve adjusted
n Trapped air
Fluctuation of pressure/volu- n Differential pressure too small
metric flow n Flow valve contaminated
n Check valve defective
n Wear
n Gap losses
Pressure valves/replenishing valve (secondary)

n Vibrations or noises indicate trapped air or missing attenuation
n Wrong pressure setting
Abnormal noises n Anti-cavitation defective
n Opening pressure of replenishing valves too high
n Cavitation on oil motor
n Setting too low
n Valve seat damaged
flow
n Clogged with dirt
n Setting too low
No or insufficient pressure
n Broken spring
n Foreign body in valve seat
n Changing counter pressure
n Pressure valve set too low
metric flow
Setting too high:
n Increase of gap losses in all components
n Increased leakage
n Excessive load frequency caused by machine
Setting too low:
n Power loss
n Generation of heat
n Valve cone jams in open position
746 BW 220 D-5

Way-valves
n Control defective
Abnormal noises n Design fault (nominal width)
n Restrictions
n Incorrect or inaccurate spool position
n Negative overlap
flow
n Control pressure too low - does not switch
n Incorrect position
n Mechanically jammed
No or insufficient pressure n Return spring broken
n Leaking
n Dummy plug loose
n Flow forces influence the spool action and the opening distances
Fluctuation of pressure/volu- n Positioning fault
metric flow n Unstable position
n Control pressure fluctuations
n Incorrect position
n Throttle losses
Hydraulic fluid too hot n Dimensioning too small
n Cross-section too small
n Wear
Pressure valves (primary)

n Vibrations or noises indicate trapped air or missing attenuation
Abnormal noises
n Wrong pressure setting
n Setting too low
flow
n Clogged with dirt
n Setting too low
n Broken spring
n Foreign body in valve seat
BW 220 D-5 747

Pressure valves (primary)

n Changing counter pressure
n Pressure valves set too low
metric flow
Setting too high:
n Increase of gap losses in all components
n Increased leakage
n Excessive load frequency caused by machine
Setting too low:
n Power loss
n Generation of heat
n Valve cone jams in open position
Pressure accumulator
n Accumulator bladder defective
n Nitrogen filling enters hydraulic circuit
n Defective seals
Abnormal noises
n Inflow and outflow velocity too high
Note: Accumulators in connection with throttle losses can form resonant
systems
No or insufficient volumetric n Nitrogen filling pressure too low
flow
n Nitrogen filling pressure too low or too high _ Stored power is not
enough
Fluctuation of pressure/volu- n Resonant system between hydraulic accumulator, pressure and flow
metric flow valves and pump
Return flow lines

n Line not connected below the pressure fluid level
n Turbulence towards the suction side
Abnormal noises n Lack of partitioning
n Mechanical vibrations
n Insufficient fastening
Hydraulic fluid too hot n Cross-section too small
748 BW 220 D-5

Filter
n Insufficient fastening
Abnormal noises
No or insufficient volumetric n In the case of high pressure filters: Insert contaminated
flow n Bypass vale jammed
n In the case of high pressure filters: Insert contaminated
n Bypass vale jammed
Hydraulic fluid too hot n Opening pressure of bypass valve too high
Radiator
n Air/oil radiator fan noises
Abnormal noises
n Dimensioning too small
n Insufficient cooling effect
n Room or ambient temperature too high
n External ventilation or water supply interrupted
n Surface contaminated
n Bypass valve open
Pressure lines
n Inappropriate fastening
Abnormal noises n Structure-borne noise
n Pipe cross-section too small
n Screw fittings leaking
flow
n Throttle actuator pressure increase
n Line breakage
No or insufficient pressure n Screw fittings leaking
n Display or measuring equipment defective
n Not correctly vented
n Display or measuring equipment defective
metric flow
n Incorrect display
n Necking caused by insufficiently large bending radii
BW 220 D-5 749

Drive motor
n Incorrect rotary direction
n Speed too high
Abnormal noises
n Bearing clearance
n Bearing damage
No or insufficient volumetric n Speed too low
flow
n Incorrect rotary direction
n Output power too low
Fluctuation of pressure/volu- n Inhomogeneity of engine too high
metric flow n Engine idle speed too low
Hydraulic fluid too hot n Speed too high
Clutch
n Clutch seat defective
Abnormal noises n Alignment fault
n Flexible elements defective
No or insufficient volumetric n Rotary speed transfer defective
flow
No or insufficient pressure n Torque transfer defective
Pump
n Speed too high
n Air intake
Abnormal noises
n Cavitation
n Mechanical damage
No or insufficient volumetric n Internal leakage
flow n Wear caused by dirt
n Internal leakage
No or insufficient pressure n Wear caused by dirt
n Drive damage
750 BW 220 D-5

Pump
n Air intake
n Internal leakage
n Wear caused by dirt
Fluctuation of pressure/volu- n Drive damage
metric flow n With engine under load or temporary overloading disturbed control
behaviour caused by contamination
n Engine overload caused by power input on auxiliary drive
n Governor oscillates
n Internal leakage
n Wear damage
Leakage oil line

Abnormal noises n Insufficient fastening
n High temperatures caused by high leakage indicate an expected
failure of a component
Suction conditions
n Insufficient suction cross-section
n Suction head too high
n Redirections
n Cross-section narrowing
Abnormal noises
n Leaking suction line
n Air bubbles
n Tank shut-off valve not opened
n Resistance on filter
n Suction behaviour disturbed
No or insufficient volumetric n Suction head too high
flow n Redirections
BW 220 D-5 751

Suction conditions
No or insufficient pressure n Redirections
n Trapped air
n Redirections
metric flow
n Trapped air
Hydraulic oil tank

n Oil level too low
n Frothing of oil
n Water in oil
Abnormal noises
n Cold hydraulic fluid
n Excessive viscosity
n Tank ventilation ineffective
No or insufficient volumetric n Oil level too low
flow n Tank ventilation ineffective
n Oil level too low
n Insufficient viscosity of hydraulic fluid _ caused by high leakage
losses
n Gap losses
n Air bubbles
n Turbulence from return flow to suction side
metric flow
n No partitioning between return flow and suction space
n Incorrect viscosity
n Oil filling too low
n In the case of extreme local heating up, the lubricity, pressure loading
Hydraulic fluid too hot and ageing resistance of the hydraulic fluid is impaired
n Wear of components
n Gap losses
n Heating up
752 BW 220 D-5

Troubleshooting – Troubleshooting the air conditioning system
7.6 Troubleshooting the air conditioning system

7.6.1 Basic principles...................................................... 753
7.6.3 Leak test................................................................ 773
7.6.4 Checking the magnetic clutch ............................... 774
7.6.1 Basic principles

Requirements For trouble shooting two requirements must be fulfilled:
n Expert knowledge
n technical equipment
BW 220 D-5 753

Overview
Fig. 761: Refrigerant circuit diagram

1 Cold air
2 Evaporator
3 Thermostat
4 Warm air
5 Fan
6 Inspection glass
7 Expansion valve
8 Pressure gauge, high pressure
9 Pressure switch with high and low pressure contacts
10 Dryer
11 Fluid container
12 Hot air
13 Compressor
14 Condenser
15 Cooling air
16 Pressure gauge, low pressure
754 BW 220 D-5

Fig. 762: Refrigerant circuit with t, h- diagram

1 Hot gas line (superheated steam)
2 Desuperheating (superheated steam)
3 Condenser
4 Condensation (wet steam)
5 Fluid line (subcooled fluid)
6 Expansion valve
7 Injection line (wet steam)
8 Evaporation (wet steam)
9 Evaporator
10 Superheating (superheated steam)
11 Suction steam line (superheated steam)
12 Compressor
13 Subcooling (liquid)
14 Compaction
15 Expansion
General procedures n Visual inspection of the complete system for damage.

n Check the compressor mounting bracket on the vehicle engine
for tight fit and damage.
n Check the condition, alignment and tightness of the V-belt.
BW 220 D-5 755

n Check the routing of refrigerant hoses and cables in the area of

the vehicle engine and transmission, as well as on the chassis
for chafing and rectify any detected faults. Ensure sufficient
clearance to hot parts, such as the exhaust; install a protective
shield, if necessary.
n Check the routing of refrigerant hoses and cables in the area of
the vehicle engine and transmission, as well as on the chassis
for chafing and rectify any detected faults. Ensure sufficient
clearance to hot parts, such as the exhaust; install a protective
shield, if necessary.
n Check the routing of hoses and hoses on the attachment box
or in the cabin.
n Check all hose and screw fittings for leaks.
n Check the fastening of the condenser unit.
n Clean the condenser fins, replace the condenser block if dam-
aged fins are found.
n Check the fastening of the evaporator unit.
n Check the function of evaporator and condenser fans.
n Check the electric control panel. If discolourations are found on
conductors, these are to be replaced and possibly also the cor-
responding relays.
n Switch on the cooling system and check the refrigerant level.
n Filter/dryer and filter/dryer/fluid container combinations must
always be replaced after opening the refrigerant circuit. If these
are in service for more than 1 year, there is a risk that they may
be clogged by excessive absorption of moisture! The filter/
dryer should be replaced at regular intervals.
n Measure the temperature on the evaporator: Measure the
intake air temperature - measure the blow out air temperature.
- The temperature difference should be at least 8-10 K.
n Measure the pressure in the refrigerant circuit.
Technical equipment Pressure gauge and thermometer are the most important auxiliary
tools for troubleshooting. The refrigerant states, such as super-
heating and subcooling, provide important information when per-
forming troubleshooting. Never underestimate your own senses
when troubleshooting. Bubbles in the inspection glass, contamina-
tion and white frost are visible indicators. If the compressor draws
in wet steam, this is visible in the suction line and may also be
audibly perceptible. An overloaded compressor can even be
smelled.
The following tools and auxiliary means nedd to be available for
troubleshooting:
n Service station
n Pressure gauge
n Thermometer
n Dry nitrogen
n Refrigerant bottle for new refrigerant
n Container for old oil
n Vacuum pump
n Hoses
n Scales
756 BW 220 D-5

n Suction station
n Leak detector
The measuring equipment must be checked at regular intervals.
Calibration can only be made by an approved testing authority.
Pressure gauge: Most pressure gauges used in practice are (for
cost reasons) overpressure gauges. These pressure gauges
measure the excess pressure in relation to the ambient pressure
(air pressure). In order to achieve the absolute (actual) pressure
the ambient pressure must be added to the pressure gauge
reading. The absolute pressure is needed for the calculation and
determination of material data.
Pabs = Pamb + Pe
Pabs = absolute pressure
Pamb = atmospheric air pressure (ambient pressure)
Pe = excess pressure (pressure gauge reading)
Example:
A totally empty air conditioning system holds an atmospheric pres-
sure of approx. Pamb = 1 bar.
Fig. 763: Pressure gauge
Filling the system with refrigerant causes an overpressure of Pe = 3
bar.
Pabs = Pamb + Pe = 1 bar + 3 bar = 4 bar
Evacuating the system down to Pe = -0.6 bar, creates a "vacuum"
(negative overpressure).
Pabs = Pamb + Pe = 1 bar +(- 0.6) bar = 0.4 bar
Pressure gauge with saturation temperature scale: Tempera-

ture scales on the pressure gauges always refer to the absolute
pressures Pabs. Please note that it is not possible to measure a
temperature directly with a pressure gauge. The indicated temper-
atures are just reference values. Only the saturation temperature is
assigned to the measured pressure.
If the refrigerant is fluid, the temperature is below the saturation
temperature.
If the refrigerant is gaseous, the temperature is above the satura-
tion temperature.
Pressure gauges must indicate 0 bar when not connected to the
system.
Low pressure gauges have a blue border; high pressure gauges a
red one.
Fig. 764: Absolute pressure gauge
Thermometer: The thermometers used are normally digital ther-

mometers with surface or attachment sensors. Good heat insula-
tion of the measuring location must be assured, especially in case
of big temperature differences. An economical use of heat-conduc-
tion paste is recommended. If the measuring location is exces-
BW 220 D-5 757

sively contaminated, it needs to be cleaned and possibly treated

with a fine emery cloth. Only the temperature of the sensor is
measured. Temperature differences between the measured and
the actual values of a few degree Kelvin may be caused by missing
heat insulation and by insulating oxide layers on the cable.
Subcooling It is the task of the thermostatic expansion valve Ä Fig. 765 to

reduce the refrigerant to a lower pressure level (evaporation pres-
sure) after it has been liquefied. For the valve to function perfectly,
pure fluid must be applied to its inlet port.
The refrigerant must "squeeze" (literally speaking) through a
throttle gap inside the expansion valve. When comparing a certain
mass of refrigerant in liquid and vaporous condition (under con-
stant pressure), the vaporous refrigerant requires a much higher
volume. That is why the vaporous refrigerant needs a much longer
time to "squeeze" through the throttle gap.
Vaporous refrigerant upstream of the expansion valve reduces the
flow rate and results in an undersupply of the evaporator with
refrigerant. Evaporation pressure and evaporator power will drop.
If the refrigeration system is operated with the "expansion valve
inlet" state directly on the boiling curve, bubbles may form
upstream of the expansion element if the operating conditions fluc-
tuate slightly.
For this reason, the "expansion valve inlet" state is moved away
from the boiling curve into the liquid area and is referred to as sub-
cooling. This subcooling ensures a fluid supply upstream of the
expansion valve.
Common subcooling values: In systems with fluid container, the
subcooling at the fluid container outlet is approx. zero "0" Kelvin
(assuming that the system is filled with the correct refrigerant quan-
tity). In this case, the fluid container provides the required fluid
supply.
Reasons for very low or no subcooling:

n Insufficient refrigerant (check the refrigeration circuit for leaks)
n Insufficient heat dissipation from the heater at high pressure
downstream of the compressor
n Expansion valve is not properly adjusted or defective.
Reasons for excessive subcooling:
n Too much refrigerant
n Dry cartridge is defective (e.g. clogged)
n Expansion valve is not properly adjusted or defective
n Low flow rate in the heating circuit (check the pump).
Subcooling is calculated as follows:

Delta tc2u = tc - tc2u
Delta tc2u, subcooling at condenser outlet in K
tc2u, temperature at evaporator outlet in °C
758 BW 220 D-5

tc, condensation temperature in °C

“u” stands for “subcooled”
1 2 3
8 7 6
5 4
S-KLI-0004
Fig. 765: Thermostatic expansion valve

1 Diaphragm
2 Capillary tube
3 Pressure compensation line
4 Refrigerant to compressor
5 Temperature sensor
6 Regulator spring
7 Valve pin
8 Refrigerant from compressor
Superheating Due to its design a refrigerant compressor can only deliver gas-
eous or vaporous substances. Fluids are not compressible and
must therefore not enter into the compression chamber of the com-
pressor.
If the suction condition of the compressor is directly on the dew
line, an e.g. incorrect evaporator load can cause "wet suction".
This can lead to two processes, which are destructive for the com-
pressor. The liquid refrigerant washes off the lubricating film
between piston and cylinder wall, and insufficient lubrication will
cause extreme wear. Liquid refrigerant remaining in the cylinder
causes a direct energy transfer from piston to cylinder cover during
compression. The valve plate may then be damaged by so-called
fluid strokes.
Apart from protecting the compressor against fluid, superheating
has further advantages. Since the flow rate of the compressor is
reduced by liquid components in the suction steam, it may be
increased by a certain superheating. Superheating also improves
the oil recirculation.
BW 220 D-5 759

Common superheating values: The optimal superheating value

is approx. 5-8 Kelvin. With this superheating the maximum system
power is reached. However, the thermostatic expansion valve
Ä Fig. 765 is unable to regulate this value precisely. Depending
on design and operating conditions, superheating fluctuates within
a range of 4 to 12 Kelvin. The influence of the ambient air on the
suction line causes an additional superheating effect.
Reasons for low or no superheating:

n Expansion valve is not properly adjusted
n Capillary tube is not properly fitted
n Expansion valve is defective, stays open, and ices up.
Reasons for excessive superheating:
n Expansion valve is defective, won’t open, and ices up
n Expansion valve is not properly adjusted
n Capillary tube is not properly fitted
n Insufficient refrigerant (check the refrigeration circuit for leaks).
Superheating is calculated as follows:

Delta to2h = to2h - to
Delta to2h, superheating at evaporator outlet in K
to2h, temperature at evaporator outlet in °C
to, evaporation temperature in °C
“H”h” stands for “superheated”
7.6.2 Troubleshooting
Troubleshooting air conditioning The most frequent sources of mechanical faults in mobile air condi-
systems tioning systems are leaks and blockages in the refrigerant circuit
and the resulting compressor damage. Especially when replacing a
compressor, it is important to determine the causes of the com-
pressor failure in order to avert another failure. In the process, the
specialist must ask whether the fault is in the automatic air condi-
tioning system or in the refrigerant circuit. The specialist should
also know when and why an air conditioning system is flushed and
how to do this professionally.
Visual inspection With the appropriate experience some faults can be visually
detected or felt. Frequently occurring condenser contamination or
formation of steam bubbles in the inspection glass can be quickly
detected.
In the case of unusual evaporator frost, the frost pattern provides
valuable information. An evaporator that is only frosted on the inlet
side is a clear indication that the refrigerant supply is too low, which
indicates an improperly operating expansion element or lack of
refrigerant. Complete frost covering indicates load problems, i.e. no
or insufficient air flow.
760 BW 220 D-5

Even superheating can sometimes be detected with the naked eye.

At the end of the evaporator there should be an area which is dry
or at least drier at evaporator temperatures above -2 °C.
The fluid line in the refrigeration system is warm. If a local cooling
can be felt or if condensation develops, this is a clear indication of
an extreme pressure drop in the line. Similar phenomena can be
noticed in the case of blocked filters.
Unusually cold pressure lines indicate "wet" intake of the com-
pressor.
The oil level in the compressor sight glass provides information
about the oil quantity and the oil recirculation in the system. How-
ever, the oil level may also be considerably influenced by con-
densing refrigerant. Discolouration can provide an indication of the
state of the oil.
Water in the system can simply be detected through the inspection
glass with moisture indicator.
The dangerous part of common rules is that they

apply in most, but not in all cases. The refrigerant
states in the individual piping sections or compo-
nents must therefore be exactly determined by
means of pressure and temperature measure-
ments.
Test prerequisites n Cooler and condenser are clean, clean if necessary.

n The ribbed belt for compressor and generator is correctly tight-
ened.
n All air ducts, covers and seals are OK and correctly fitted.
Flaps reach their end positions.
n The engine has operating temperature.
n Evaporator and heating (with highest fresh air fan speed) do
not draw leak air.
n The fresh air fan runs when the engine is running and the air
conditioning system is set to max. cooling power.
n Ambient temperature above 15 °C.
n The thermostat is correctly installed and the switching tempera-
tures are correct.
BW 220 D-5 761

Function tests n Rule out operating errors: In order to check the function of an
air conditioning system and also to rule out any possible oper-
ating errors by the vehicle driver, the cooling system needs to
be set to maximum and the engine speed increased. If cold air
then comes out of the air outlet openings, however, it cannot
be assumed one hundred percent that the air conditioning
system is working properly; in fact, the following points are also
to be observed.
n Initial diagnosis: It is quick and easy to determine whether
refrigerant is being pumped by touching the high and low pres-
sure lines by hand. The high-pressure line must be warm (cau-
tion: there is a risk of burns in systems with high pres-
sures). The low pressure line, on the other hand, must be cold.
If this is the case, refrigerant is still present and the compressor
is running.
n Check for leaks: Despite the use of forming gas, it is generally
not possible to detect all leaks in the air conditioning system. If
there is no hissing noise or if the inspection with an electronic
gas analyser does not reveal any leaks in the system, practical
expertise will be required: In this case, the belt wheel of the
compressor is to be shaken back and forth by hand (when the
motor is at a standstill); in this way, a slight hissing noise may
be heard. Refrigerant losses are primarily caused by leaking
compressor shaft seals. The compressor shaft is centred
during operation of the air conditioning system, which means
that the seal ring fits tightly against the compressor shaft. At
standstill, however, the shaft rests against the seal ring on one
side and can be damaged as a result. Leaks are aggravated if
the compressor is not switched on in winter and no oil is sup-
plied to the shaft seal.
n Target pressure diagnostics: To detect further damage, the
system pressures must be checked with an A/C service unit. If
the target pressures (high pressure: 8 to 14 bar; low pressure:
1 to 3 bar) are reached at an ambient temperature of approx.
20 °C, the problem of insufficient cooling is not in the refrig-
erant circuit.
n Temperature discharge diagnostics: In addition, the air
outlet temperature at the air outlet openings should also be
determined with a suitable temperature measuring device. The
appropriate test conditions such as outside temperature,
ambient air pressure or air humidity are to be observed. A
rough indication in this case is an outlet temperature of no
more than approx. 8 °C at an ambient temperature of 20 to 25
°C.
n Check for subcooling: Furthermore, the three temperature
zones of the condenser are to be checked. Subcooling is the
difference between the condensing temperature and the tem-
perature of the refrigerant at the outlet of the air conditioning
condenser. For example, if refrigerant flows into the condenser
at 50 °C, it will have a temperature of approximately 33 °C at
the end of the pre-cooling zone at an assumed cooling air tem-
perature of 25 °C; it will also have the same temperature at the
end of the condensation zone. Only in the subcooling zone
must the temperature have fallen significantly. If the tempera-
ture already drops in the upper third of the condenser, this indi-
cates insufficient subcooling and a lack of refrigerant.
n Check superheating
762 BW 220 D-5

Measuring points and measure-

ments
Fig. 766: Flow diagram with measuring points

n C, condenser measuring points
n E, expansion valve measuring points
n O, evaporator measuring points
n V, compressor measuring points
The flow diagram contains "Minimum Requirements" which must
be fulfilled to be able to check the system or perform trouble
shooting.Temperature and pressure at the evaporator outlet can be
used to derive the overheating of the evaporator. Overheating is a
clear indicator for the evaporator filling level. In case of excessive
overheating the refrigerant quantity fed into the evaporator is too
low, in case of insufficient overheating it is too high. In individual
cases one must then check if this situation is caused by the expan-
sion element or by insufficient filling. A differentiation is only pos-
sible if there is a clear indicator for the refrigerant filling quantity.
Pressure and temperature at the condenser outlet can be used to
derive the supercooling. This can be used to assess the filling
quantity. In systems with fluid container the inspection glass is
most suitable to check the minimum filling quantity. Supercooling is
in this case the between indicator for overfilling.The hot gas tem-
perature can be used to check whether the compressor runs in the
permissible operating range.
Example: Measurement of over- n a) Which measuring equipment is required?

heating n b) Where to measure with which size?
BW 220 D-5 763

n c) A pressure gauge connected to the evaporator indicates

"Peo2 = 1.7 bar". How high is the evaporator pressure "Po" ?
n d) How high is the evaporator temperature "to" ?
n e) A thermal sensor attached to the evaporator outlet meas-
ures the temperature "to2h = +3 °C". How high is the over-
heating „Δto2h“ ?
n f) Evaluation of the measured overheating.
Example: Measuring supercooling n a) Which measuring equipment is required?

n b) Where to measure with which size?
n c) A pressure gauge connected to the condenser indicates
"Pec2 = 15 bar". How high is the condensing pressure "Pc" ?
n d) How high is the condensing temperature "tc" ?
n e) A thermal sensor attached to the condenser outlet measures
the temperature "tc2u = 58 °C". How high is the supercooling
"Δtc2u" ?
n f) Evaluation of the measured supercooling.
Solution: n a) Pressure gauge, thermometer, steam table

n b) Condensing pressure "Pec2" and temperature "tc2u" are
measured at the same point on the condenser.
n c) Pc = Pec2 + Pamb, "Evaporation pressure = pressure on evap-
orator + atmospheric pressure" = 15 bar + 1 bar = 16 bar.
n d) "Pcc = 16 bar can then be used to derive an condensing
temperature "tc" of 57.9 °C from the steam table for R134a.
n e) Δtc2u = tc - tc2u, "Supercooling at condenser outlet = con-
densing temperature - condenser outlet temperature" = 57.9°C
- 58 °C) = -0.1 Kelvin.
n f) The determined overheating is within the usual range of
approx. "0" Zero Kelvin.
Typical faults and possible causes Most of the faults in the refrigerant side can be assigned with the
help of the checklist. In many cases faults have a quite similar
appearance, but totally different causes. White frost on an evapo-
rator, for instance, may be quite normal. However, in this case the
expansion valve may be defective or there may be oil return prob-
lems.
The following list contains pressure values in a system, that can be
expected at various ambient temperatures (measured at medium
speeds).
Suction pressure (low pressure gauge)

Ambient temperature in °C Excess pressure in bar
25 approx. 2.0
30 approx. 2.5
35 approx. 3
764 BW 220 D-5

High pressure (high pressure gauge)

Ambient temperature in °C Excess pressure in bar
25 approx. 8.0
35 approx. 13
40 approx. 16
45 approx. 18
Values effecting the operating pres- Since the pressures occurring in a refrigeration system are highly
sures dependent on environmental conditions, it is mandatory to know
these dependencies. The following table contains some of these
dependencies.
Measured variable Suction pressure High pressure

increase drops increase drops
s s
Com- increase X X
pressor s
speed
drops X X
Vehicle increase X X
interior s
temper-
ature
drops X X
Ambient increase X X
temper- s
ature
drops X X
Humidit increase X X
y s
drops X X
BW 220 D-5 765

Suction pressure too low (1), high

pressure too low to normal (2)
Fig. 767
Cause Possible effect Remedy

Lack of refrigerant no supercooling, bubbles in inspection glass, high Check for leaks,
overheating, hoarfrost on evaporator refill
Evaporator fins or air filter Cooling power too low clean
soiled
Evaporator fan failed Low pressure shut off Repair the fan
Expansion valve defective Suction pressure gauge shows vacuum, because the Replace the valve
valve has closed
Screen or nozzle in expan- high overheating clean
sion valve clogged
Filter dryer clogged Bubbles in inspection glass, high overheating, filter Change filter dryer
dryer cold
Heat power too low Frequent low pressure shut off, thawing thermostat / Check the control
rotary thermostat switching too frequently
766 BW 220 D-5

Suction pressure normal (1), high

pressure too high (2)
Fig. 768

Condenser dirty high hot gas temperature, low cooling power clean
Condenser fan failed high hot gas temperature, high pressure shut down repair
overfilled high hot gas temperature, low supercooling, low cooling Correct the filling
power capacity
Leak gas (air) high hot gas temperature, low measured supercooling, renew filling
low cooling power
Restriction between com- high hot gas temperature, low cooling power Check lines and
pressor and condenser valves
BW 220 D-5 767

Suction pressure too high (1), high

pressure too low to normal (2)
Fig. 769

Compressor defective Cooling power too low Replace the compressor
Suction pressure too high (1), high

pressure too high (2)
Fig. 770
768 BW 220 D-5


Expansion valve defective overheating too low, wet operation of compressor Replace the valve
Condenser The following symptoms may indicate a defective condenser:

n Poor cooling power
n Air conditioning failure
n Condenser fan is constantly on.
Causes of the faults may be:
n Leaky connections or damage
n A lack of heat exchange due to contamination.
Test steps for troubleshooting:
n Check the condenser for contamination
n Leak test
n Pressure test on the high and low pressure side.
Filter/dryer The following symptoms may indicate a filter/dryer failure:

n Air conditioning failure.
Causes of the filter/dryer failure may be:
n Obsolescence
n Defective filter pad inside
n Leaky connections or damage.
The following steps are to be observed during troubleshooting:
n Check the maintenance intervals (every 2 years)
n Leak test/proper fit of connections and check for damage
n Pressure test on the high and low pressure side.
Expansion/throttle valve A defective expansion valve may be indicated as follows:

n Air conditioning failure.
Reasons for failure may have multiple causes:
n Temperature problems due to superheating or icing up
n Contamination in the system
n Leaks in the component or connecting lines.
In the event of a malfunction, the following test steps are to be per-
formed:
n Visual inspection
n Acoustic inspection
n Check the connecting lines are tight and secure
n Check the component and connections for leaks
n Temperature measurement of the pipeline system
n Pressure measurement with the compressor on and the motor
running.
BW 220 D-5 769

Evaporator A defective evaporator shows the following symptoms:

n Air conditioning failure
n Poor fan output.
Causes of the evaporator failure may be:
n Pipelines in the evaporator are clogged
n Evaporator is leaking (at connections; due to damage)
n Evaporator is contaminated (air flow is disrupted).
The following test steps are to be observed during troubleshooting:
n Check the evaporator for contamination
n Check the evaporator for damage
n Check the connecting lines are secure
n Leak test
running
n Temperature measurement of the input and output line.
Pressure switch A defective or failed pressure switch may be indicated as follows:

n Air conditioning not functioning
n Compressor coupling is frequently switched on and off.
Reasons for failure may have multiple causes:
n Contact failure at electrical connections
n Contamination in the system
n Damage to housing caused by vibration or accidents.
Test steps for troubleshooting:
n Visual inspection
n Check the connector plugs are properly fitted
n Check the component for damage
running
n Component check when dismantled with nitrogen bottle, pres-
sure-reducer and multimeter.
770 BW 220 D-5

Other faults
Symptom Cause Possible effect Remedy

Hot gas temperature Lack of refrigeration oil increased com- Refill refrigeration oil
too high, the hot gas pressor wear
line becomes so hot
that it cannot be
touched long with a
hand
Compressor does not Pressure switch or any other System stopped Check the control units,
start safety feature has triggered, check cause for switching
electrical fault, cylinder filled and rectify
with liquid refrigerant
Compressor switches Switching difference too small, Cycling of com- Check the control units,
continuously triggering of a switching ele- pressor, increased check cause for switching
ment (overpressure switch, low wear, too low and rectify
pressure switch), lack of refrig- cooling power
erant, fan defective, overfilled
Excessive overheating Expansion valve deadjusted or low cooling power, Replace the expansion
screen blocked, lack of refrig- hot gas tempera- valve, clean the screen,
erant tures too high fill in refrigerant, leak test
Hoarfrost on inlet side incorrectly working expansion too low infeed of Check the expansion
of evaporator valve, lack of refrigerant refrigerant into the valve, check the refrig-
evaporator erant filling
Evaporator fully cov- Load problem, too low air flow low cooling power of Clean the evaporator,
ered with hoarfrost volume system check the evaporator fan
Fluid line is warm and Pressure drop in fluid line, filter low cooling power Eliminate the pressure
shows condensation dryer clogged drop, replace the filter
dryer
Exceptionally cold pres- "Wet intake" of the compressor low cooling power, Clean the compressor,
sure lines due to insufficient overheating excessive wear of replace if necessary,
of evaporator compressor replace the expansion
valve if necessary
Noise in system
Faults Possible cause Remedy

V-belt loose or excessively worn V-belt slips and generates Retention or renew the V-belt
noise
Magnetic clutch loud Magnetic clutch runs until high Repair or replace the mag-
pressure builds up, then the netic clutch
clutch starts to slip
Refrigerant compressor is loud Mounting bracket is loose, Repair the mounting bracket,
internal parts worn, low oil replace the compressor,
level in compressor renew the refrigeration oil
Fan is loud, fan motor excessively worn Replace the fan motor
BW 220 D-5 771


Whistling and rattling noise in operation, V-belt pulley and bearing worn Replace the bearing, check
noticeable unevenness when turning by V-belt pulley for wear
hand
Rattling noise or vibration of high pressure System overfilled Draw out refrigerant
line, knocking noise in compressor, ball in
inspection glass floating at the top
Expansion valve loud excessive moisture in system Replace the dryer
Hissing noise in evaporator housing, on refrigerant level in system too Perform a leak test, fill up the
expansion valve, turbidity in inspection low system
glass or ball does not float
Inspection glass

Steam bubbles in inspection No supercooling before expansion valve, Fill up the system, replace the
glass lack of refrigerant in system, pressure loss in filter dryer, perform a leak test
system, supercooling caused by excessively
soiled filter dryer
Discolouration of inspection Lubricant destroyed by excessive operating Replace the refrigeration oil,
glass (black from inside) temperatures examine the temperature
increase
Moisture indicator changes Moisture level of drying agent too high Replace the filter dryer
to pink
Ball floats at bottom lack of refrigerant Fill the system
Monitoring devices

The high pressure contact System pressure exceeded, condenser Clean the condenser, replace
has switched off the mag- excessively soiled, condenser fan defective, the expansion valve, check the
netic clutch expansion valve defective condenser fan
The low pressure contact System pressure fallen short of, refrigerant Clean the evaporator, replace
has switched off the mag- level too low, expansion valve defective, the expansion valve, check the
netic clutch evaporator fan defective, heat load too low, evaporator fan
ambient temperature below 1.5 °C
The thermostat has Ambient temperature below 1°C, expansion Check the thermostat switching
switched off the magnetic valve defective, thermostat defective, air flow point, replace the expansion
clutch volume too low valve, clean the evaporator,
check the evaporator fan
772 BW 220 D-5

7.6.3 Leak test
NOTICE!
The use of leak detection colouring matter is not
permitted, because its chemical composition is
unknown and its effect on compressor oil and
rubber elements is not predictable. The use of leak
detection colouring matter makes any warranty
claims null and void.
Before starting the evacuation process, the refrigerant circuit is

filled with nitrogen through a pressure reducer valve (approx. 22
bar). After this all connections in the air conditioning system are
checked with the help of a suitable leak detection spray. A leak is
thereby indicated by means of foam bubbles.
A leak test is required if a pressure drop is noticed.
The leak test must be repeated after filling the air conditioning
system with refrigerant.
Leak test with electronic leak tester
Small leaks with only very low amounts of refrigerant escaping can
be detected, e.g. with an electronic leak tester. Such equipment is
able to detect leaks of less than 5 gr. per year.
The leak tester used must be specially designed for the refrigerant
composition in the air conditioning system. For example, leak
detectors for refrigerant R12 are not suitable for R134a, because
the refrigerant R134a is free of chlorine atoms, meaning that this
leak detector will not respond.
Fig. 771
Leak test with soap bubbles

Points susceptible for leakage are sprayed with a soapy solution.
Bubbles indicate the leak. The detection limit for R 134a is 250 g/
year.
Fig. 772: Soap bubble test
BW 220 D-5 773

7.6.4 Checking the magnetic clutch

Cross-section of non-operated
magnetic clutch
If the coil (7) is not supplied with operating voltage, there is no con-
tact between the front plate of the clutch (1) and the V-belt pulley
(2). A spring presses the front plate away from the belt pulley. The
V-belt pulley rotates with the bearing (3) in idle speed, the com-
pressor does not work. When the coil is supplied with operating
voltage (12 or 24 V), a magnetic field is generated and pulls the
front plate of the clutch. Both front plate and compressor shaft (8)
are then driven by the V-belt pulley, the compressor works.
In case of excessive flatness faults or deviations

the magnetic clutch needs to be replaced.
Fig. 773
Checking the magnetic clutch

1. Take off the drive V-belt and rotate the V-belt pulley by hand
while the magnetic clutch is disengaged.
2. Measure the air gap on the magnetic clutch between V-belt
pulley (2) and thrust plate (1). The gap should be 0.4 to 0.8
mm.
3. Measure the voltage (nominal value: vehicle voltage)
4. Check the current consumption.
at 12 Volt vehicle voltage approx. 3.5 Amp.

Fig. 774: Measuring the air gap
at 24 Volt vehicle voltage approx. 1.75 Amp.
Overcurrent indicates a short circuit inside the
magnetic coil.
No current indicates an interrupted electric circuit.
774 BW 220 D-5

Troubleshooting – Troubleshooting the auxiliary heating
7.7 Troubleshooting the auxiliary heating

7.7.1 Fuse assignment................................................... 775
7.7.2 Components.......................................................... 776
7.7.3 Control and safety elements.................................. 777
7.7.5 Diagnostics............................................................ 779
7.7.6 Check the fuel supply............................................ 782
7.7.7 Circuit diagram, AIRTRONIC D2/D4...................... 784
B-586-0424
Fig. 775

BW 220 D-5 775

7.7.2 Components
9
11
8
7
10
6 5
4
12
2
13
S-586-0262
Fig. 776
1 Combustion air fan
2 Seal – combustion air fan / heat exchanger
3 Combustion chamber
4 Seal – combustion chamber / heat exchanger
5 Heat exchanger
6 Control unit
7 Combined sensor (overheating/flame sensor) with assembly tool Assembly tool only required for AIRTRONIC D2
8 Bow
9 Glow pin, with special tool (SW 12)
776 BW 220 D-5

10 Lining – plug socket, with assembly tool

11 Cover
12 Outer shell (bottom part)
13 Flange gasket
7.7.3 Control and safety elements

n If the AIRTRONIC does not ignite within approx. 90 seconds
after the start of fuel delivery, the start will be repeated.
Should the AIRTRONIC still not ignite after another approx. 90
seconds, a fault related shut-down will occur, i.e. fuel delivery
off and fan overrun for another 4 minutes.
n If the flame goes out by itself during operation, the system will
first be started again. If the AIRTRONIC does not ignite within
approx. 90 seconds after the fuel supply has been reopened,
or it ignites, but goes out again within 15 minutes, a fault
related shut-down will occur, i.e. fuel supply off and fan overrun
of approx. 4 minutes.
This fault related shut-down can be eliminated by switching the
system off and on again. This switching off and on should not
be repeated more than 2 times!
n In case of overheating, the combined sensor will respond, the
fuel supply will be shut off and a fault related shut-down will
occur.
Once this overheating has been eliminated, the AIRTRONIC
can be restarted by switching it off and on again.
n When the lower or upper voltage limit is reached, a fault related
shut-down will occur after 20 seconds.
n With a defective glow pin, fan motor or an interrupted electric
line to the dosing pump the AIRTRONIC will not start.
n With a defective combined sensor or an interrupted electric line
the AIRTRONIC will not start and a fault related shut-down will
occur.
n The rotary speed of the fan motor is continuously monitored.
If the fan motor does not run or if its rotary speed deviated by
more than 10 %, a fault related shut-down will take place after
30 seconds.
n When switching the AIRTRONIC off, the glow pin is switched
on again during the overrun of the fan (post glowing) to clean it
from combustion residues.
7.7.4 Troubleshooting
WARNING!
BW 220 D-5 777

NOTICE!
During the maintenance process the AIRTRONIC
should be de-energized. Disconnect the plug-in
connection to the AIRTRONIC.
If the AIRTRONIC does not start after being switched on:

n Switch the AIRTRONIC off and on again, but not more than 2
times in succession.
If the AIRTRONIC still does not start, please check if:
n Fuel in tank?
n Fuses ok?
n Electric cables, connections, terminals ok?
n Hot air duct, combustion air duct or exhaust duct congested?
n If the AIRTRONIC remains in “Ventilation” condition after
switching on, check the control element for short circuits.
In this case no fault code will be submitted.
778 BW 220 D-5

7.7.5 Diagnostics
1 4
2
3 17:30 21°C
6 5
B-DIS-0523
Fig. 777

1 [◀] button Navigating in the menu levels
2 Menu bar Display of available menus
3 Status section Time
Cabin temperature
Information on active functions
Fault indicator
4 [▶] button Navigating in the menu levels
5 [ ] button Selecting menu levels and functions
Switching functions on
6 [ ] button Switching functions on and off
Returning to the main menu
Optional equipment
BW 220 D-5 779

If a fault occurs, the following dis-

plays are possible:
Display Description Remedy

Automatic detection is active. Wait until the automatic recogni-
tion has been completed, then set
EasyStart Timer was discon- up the time and weekday.
nected from the power supply and
then reconnected.
INIT
S-586-0470
No communication. Check the fuse for heater unit,

replace if necessary.
Visit workshop.
NO SIGNAL
S-586-0471
Fault 1. Heater unit Visit workshop.
Error
S-586-0472
Fault 2. Heater unit Visit workshop.
Error
S-586-0473
Undervoltage is applied. Load battery; if necessary, visit

workshop.
S-586-0474
780 BW 220 D-5

Display Description Remedy

Temperature sensor defective. Visit workshop.
18:30 °C
S-586-0475
BW 220 D-5 781

7.7.6 Check the fuel supply

Before measuring the fuel quantity, check the following points in
the fuel supply:
n Check the screen in the dosing pump.
n Check the routing of the fuel lines.
n Check the fuel lines for leaks.
n Check and retighten the hose connections.
Preparation
Fuel measurement
For an accurate fuel measurement, at least 11/22
Volt or maximum 13/26 Volt should be applied to
the control unit.
Hold the measuring glass at height of the glow pin
during the measurement.
1. Pull the fuel line off the AIRTRONIC and hold it into the
4 measuring glass (size 25 ml) Ä Fig. 778.
1
2. Switch on the AIRTRONIC.
ð Once fuel is evenly delivered (starts approx. 60 sec. after
3 2
S-586-0263
switching on), the fuel line is filled and bled.
3. Switch off the AIRTONIC and empty the measuring glass.
Fig. 778
1 AIRTRONIC
2 Measuring glass (size 25 cm3)
3 Dosing pump
4 Fuel line
Measurement 1. Switch on the AIRTRONIC.

ð The delivery of fuel starts approx. 60 seconds after
switching on.
AITRONIC D2: After 90 seconds fuel

delivery, it will be automatically switched
off.
AITRONIC D4: After 110 seconds fuel
delivery, it will be automatically switched
off.
2. Switch off the heater unit.

ð
Important
Otherwise the delivery of fuel will be
resumed after approx. 120 seconds!
3. Read the fuel quantity in the measuring glass.

ð Nominal value Airtronic D2: min. 3.7 ml max. 4.3 ml.
Nominal value Airtronic D4: min. 5.4 ml max. 6.3 ml.
782 BW 220 D-5

If the measured fuel quantity is outside the values listed

above, the dosing pump needs to be replaced.
BW 220 D-5 783

7.7.7 Circuit diagram, AIRTRONIC D2/D4
Fig. 779
1 Overheating and flame sensor
2 Fan motor
3 Glow pin
784 BW 220 D-5

4 Control unit
5 Control element, module clock
6 Fuel dosing pump
7 Fuses
8 Ignition switch
bk Black
wt White
rd red
ye yellow
gn green
vi violet
br brown
gr grey
bl blue
li lilac
Resistance values
Component AIRTRONOC D2 AIRTRONOC D2 AIRTRONOC D4 AIRTRONOC D4
12 Volt 24 Volt 12 Volt 12 Volt
Fan motor 0.6 W ± 0.1 W 2 W ± 0.4 W 0.4 W ± 0.1 W 1.5 W ± 0.3 W
When applying a When applying a When applying a When applying a
voltage of 8 V ± 0.1 voltage of 18 V ± voltage of 8 V ± 0.1 voltage of 18 V ±
V, a current of £ 6.5 0.1 V, a current of £ V, a current of £ 6.5 0.1 V, a current of £
A will be present 6.5 A will be A will be present 6.5 A will be
after 40 seconds. present after 40 after 40 seconds. present after 40
seconds. seconds.
Glow pins 0.5 W ± 0.05 W 2 W ± 0.2 W 0.5 W ± 0.05 W 2 W ± 0.2 W
Applying a voltage Applying a voltage Applying a voltage Applying a voltage
of 8 V results in a of 18 V results in a of 8 V results in a of 18 V results in a
current flow of 9 A current flow of 4 A current flow of 9 A current flow of 4 A
+ 1.5 A / - 1.2 A. ± 0.5 A + 1.5 A / - 1.2 A. ± 0.5 A
Dosing pump 10 W ± 0.5 W 36 W ± 1.8 W 10 W ± 0.5 W 36 W ± 1.8 W
Control facility nom- 1740 - 2180 W ± 80 W
inal value potenti-
ometer Resistance value at short circuit < 486 W
Resistance value in case of interruption > 7175 W
Flame sensor
Temperature °C Resistance min. Resistance max.
- 40 825.90 W 859.60 W
0 980.00 W 1020.00 W
40 1132.30 W 1278.50 W
80 1282.80 W 1335.10 W
120 1431.50 W 1489.90 W
160 1578.30 W 1642.80 W
BW 220 D-5 785


200 1723.40 W 1793.70 W
240 1866.60 W 1942.80 W
280 2008.10 W 2090.00 W
320 2147.70 W 2235.40 W
360 2285.50 W 2378.80 W
400 2421.50 W 2520.30 W
Resistance value in case of interruption > 7175 W
Resistance value at short circuit < 486 W
Check the flame sensor with a digital multimeter, if the resistance value is outside the value table replace
the combined sensor.
Overheating sensor
- 40 1597.00 W 1913.00 W
- 20 458.80 W 533.40 W
0 154.70 W 175.50 W
20 59.30 W 65.84 W
40 25.02 W 28.04 W
60 11.56 W 13.16 W
80 5.782 W 6.678 W
100 3.095 W 3.623 W
120 1.757 W 2.081 W
140 1.050 W 1.256 W
160 0.6554 W 0.792 W
180 0.4253 W 0.5187 W
200 0.2857 W 0.3513 W
Resistance value in case of interruption > 223W
Resistance value at short circuit < 183 W
Check the overheating sensor with a digital multimeter, if the resistance value is outside the value table,
replace the combined sensor.
Engine speeds
Control stage AIRTRONOC D2 AIRTRONOC D4
Power 4800 U/min ± 140 U/min 4400 U/min ± 130 U/min
High 4000 U/min ± 120 U/min 3600 U/min ± 100 U/min
786 BW 220 D-5

Control stage AIRTRONOC D2 AIRTRONOC D4

Medium 2800 U/min ± 80 U/min 2800 U/min ± 80 U/min
Low 2000 U/min ± 60 U/min 1600 U/min ± 50 U/min
Ventilation 4800 U/min ± 140 U/min 3600 U/min ± 100 U/min
BW 220 D-5 787

788 BW 220 D-5

Special tools
8 Special tools
BW 220 D-5 789

Special tools – Special tools, electrics
8.1 Special tools, electrics........................................... 790

8.2 Special tools for hydraulic system....................... 791
8.2.1 Special tools, tests and adjustments..................... 791
8.2.2 Special tools for flushing........................................ 793
8.3 Special tools for oscillating articulated joint....... 794
8.4 Special tools, drum................................................. 796
8.5 List of special tools................................................ 798
8.1 Special tools, electrics
Special pliers tool kit

The contacts are not included in the kit. Depending
on the contact to be crimped, the matching tool
head must be attached to the handle.

n Comprising:
– Different tool heads
– Unlocking tools
Fig. 780: Special pliers – Manual
– Operating manual and plastic boxes for storing different
contacts
Equipment kit for special pliers tool kit
Fig. 781: Equipment kit (1)
Measuring set

n Comprising:
– Clamp multimeter
– Measuring adapter
– Measurement lines
– Screwdriver
Fig. 782: Measuring set
– Other accessories
790 BW 220 D-5

Special tools – Special tools for hydraulic system
8.2 Special tools for hydraulic system

8.2.1 Special tools, tests and adjustments
n Hydraulic test case, large
n BOMAG part no.: 007 610 03
– 4 x 60 bar pressure gauges

– 8 pressure test hoses
Fig. 783
n Hydraulic test case, small


– 4 pressure test hoses
Fig. 784
n Measurement lines
n 1000 mm BOMAG part no.: 079 930 02
n 2500 mm BOMAG part no.: 079 930 03
Fig. 785
BW 220 D-5 791

n Pressure gauge
n 60 bar BOMAG part no.: 059 721 07
n 600 bar BOMAG part no.: 059 721 04
Fig. 786
n Adapter for pressure test hose

Fig. 787
n Gear pump testing device

Fig. 788
792 BW 220 D-5

n Vacuum pump for hydraulic oil tank

n BOMAG part no.: 007 610 04 (12 Volt)
n BOMAG part no.: 007 610 24 (24 Volt)
Fig. 789
8.2.2 Special tools for flushing
The following list informs about special tools for

flushing. You should choose the corresponding tool
for the work to be carried out.
n Filling and filtering unit

Fig. 790
n Flushing filter (S connection)

n Filter element 1μ
n Flushing hose 20S - 25S (2 pieces)
n Screw socket R1“ - 25S (2 pieces)
Fig. 791
n Flushing filter (L connection)

n Filter element
n Flushing hose 15L (2 pieces)
n Screw socket R3/4“ -- 15L (2 pieces)
Fig. 792
BW 220 D-5 793

Special tools – Special tools for oscillating articulated joint
8.3 Special tools for oscillating articulated joint

n Pressing in the rocker bearing
Fig. 793
n Pressing bushing for outer rocker bearing race
Fig. 794
n Pressing bushing for inner rocker bearing race
Fig. 795
n Guide pin
Fig. 796
794 BW 220 D-5

Special tools – Special tools for oscillating articulated joint
n Clamping device
Fig. 797
n Disassembly device
Fig. 798
BW 220 D-5 795

Special tools – Special tools, drum
8.4 Special tools, drum

n Disassembly device for side plate
n BOMAG part-no.: 007 211 55
Fig. 799
n Assembly device for side plate

Fig. 800
n Assembly device for coupling hub and flanged hub
Fig. 801
n Pressing plate for cylinder roller bearing
Fig. 802
796 BW 220 D-5

Special tools – Special tools, drum
n Pressing plate for travel bearing
Fig. 803
n Pressing bushing for radial seal
Fig. 804
n Lifting device for exciter unit

Fig. 805
BW 220 D-5 797

Special tools – List of special tools
8.5 List of special tools

Belt tension tester
BOMAG No. 079 947 09
Fig.
Rotation angle disc

BOMAG 057 250 72
Fig.
798 BW 220 D-5

Index
9 Index
BW 220 D-5 799

Index
D
Description
Electric components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Hydraulic units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
E
Electrics
Circuit diagram for auxiliary heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 784
Electrics training
Machine control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
L
List of equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
List of error codes
Deutz DTC error code list, EMR3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 670
List of fault codes
Machine control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
M
Maintenance intervals
Additional heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 590
Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
Drive axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 555
Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 522
Electric systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377
ROPS / FOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 622
O
Operating equipment
A01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
A02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
A12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95, 129, 141, 152
A15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95, 129, 132, 133, 150, 152, 408
A16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
A34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95, 129, 131, 150, 152, 166, 178, 387, 407, 408
A48 . . . . . . . . . . . . . . . . . . . . . . . . . . 95, 98, 129, 131, 138, 150, 152, 166, 179, 386, 387, 406, 407, 408
A67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95, 129, 150, 152, 408
A83 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95, 129, 131, 146, 150, 152, 166, 178, 387, 407, 408
A87 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150, 152, 408
A93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88, 152
800 BW 220 D-5

Index
A103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147, 150, 152, 408

A108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
A124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95, 129, 131, 150, 152, 166, 387, 407, 408
A138 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
A161 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131, 150, 152, 166, 180, 387, 407, 408
A162 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131, 148, 150, 152, 166, 180, 387, 407, 408
A175 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150, 152, 408
A177 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150, 152, 408
A178 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95, 129, 150, 408
B03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95, 129, 134, 152, 175
B11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95, 129, 133
B11.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135, 152
B11.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135, 152
B11.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
B11.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
B21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95, 129, 135, 153, 174, 339
B30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
B51.L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
B51.R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
B51L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
B51R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
B55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95, 129, 134, 153
B57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95, 129, 131, 153, 166, 387, 407
B59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139, 153
B60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
B62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146, 153
B84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147, 153
B88 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153, 432
B93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
B97 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
B104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153, 579
B105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100, 564
B113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153, 435
B114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
B124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98, 134, 153, 176, 386, 406
B130 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
B133 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
B145 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
B171 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146, 153
B218 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95, 129, 134
B234 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95, 129, 153
BW 220 D-5 801

Index
B235 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95, 129, 153

B236 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95, 129, 153
B237 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95, 129, 153
B312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
B313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
D2.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153, 182
D2.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153, 182
D2.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153, 182
D2.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153, 182
D05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153, 169
D6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
D09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153, 169
D11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153, 169
D13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154, 169
D16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154, 169
D22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154, 169
D38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154, 169
D41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154, 169
D43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154, 169
D48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154, 169
D61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154, 169
D118 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
D145 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154, 169
D209 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154, 169
DX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154, 169, 172
E08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
E09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
E10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
E11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
E12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
E13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
E14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
E15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
E16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
E17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
E23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95, 129, 140, 154
E25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95, 129, 140, 154
E27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95, 129, 140, 154
E28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95, 129, 140, 154
E29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
E30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101, 154, 598
802 BW 220 D-5

Index
E32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140, 154

E72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
E159 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
E243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
F00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136, 154, 163, 439, 653
F05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154, 162, 171, 651
F07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155, 162, 171, 651
F08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155, 162, 171, 651
F09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155, 162, 171, 652
F10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155, 162, 171, 652
F11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155, 162, 171, 652
F13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155, 162, 171, 652
F17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
F19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155, 162, 171, 652
F22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155, 162, 171, 652
F23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155, 162, 171, 652
F24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155, 162, 171, 652
F25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
F27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
F28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
F29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155, 162, 171, 652
F39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155, 162, 171, 652
F40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155, 162, 171, 652
F41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
F48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136, 155, 163, 439, 653
F67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155, 162, 171, 652
F68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155, 162, 171, 652
F84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155, 162, 171, 652
F91 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155, 162, 171, 652
F95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136, 155, 163, 439, 653
F103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155, 162, 171, 652
F122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155, 162, 171, 652
F124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155, 162, 171, 652
F129 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155, 162, 652
F143 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
F146 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155, 162, 171, 652
F148 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155, 162, 171, 652
F150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
F157 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155, 162, 171, 652
F164 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136, 155, 163, 439, 653
F169 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155, 163, 171, 652
BW 220 D-5 803

Index
F243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163, 171, 652

F244 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156, 163, 171, 652
F264 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
F266 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
F268 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156, 163, 171, 652
F271 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
F272 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
F279 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
F320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101, 144, 156, 163, 165, 598, 599, 602, 652, 655, 775
F321 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101, 144, 156, 163, 165, 598, 599, 602, 652, 655, 775
FM1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156, 163, 171, 652
FM2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156, 163, 171, 652
FX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
G01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95, 129, 137, 156
G02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134, 136, 156
G03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137, 156
H06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
H07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133, 156
H14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95, 129, 135, 156
K05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156, 170
K06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156, 170
K09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156, 170
K11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156, 170
K13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156, 170
K14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156, 438
K16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156, 170
K20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156, 182
K21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156, 182
K22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156, 170
K32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156, 182
K38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156, 170
K41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156, 170
K43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156, 170
K48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157, 170
K61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157, 170
K78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
K141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157, 182
K145 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157, 170
K189 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
K209 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
M01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136, 157
804 BW 220 D-5

Index
M04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95, 129, 157

M05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95, 129, 157
M06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95, 129, 133, 157
M07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95, 129, 133, 157
M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
M25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
M57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101, 144, 598
P09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95, 129, 141, 157
P11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95, 129, 157
P15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150, 157, 408
P32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95, 129, 157
P42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95, 129, 157
P43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
R03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95, 129, 157
R10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157, 169
R19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
R20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
R21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
R22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
R23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
R24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
R25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
R26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
R27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
R28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
R29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
R33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
R34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
R40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
R79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149, 158
R80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
R80.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
R80.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
S00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132, 133, 158
S01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132, 133, 158
S06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
S09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132, 133, 158
S14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
S15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132, 158
S25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
S26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132, 158
BW 220 D-5 805

Index
S28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101, 158, 598, 599

S29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
S30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95, 129, 136, 137, 158
S35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133, 158
S36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133, 158
S37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132, 158
S42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132, 133, 158
S55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95, 129, 132, 133, 150, 158, 408
S64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
S107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133, 158
S109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
S127 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132, 133, 158
S139 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
S154 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
S299 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132, 133
S439 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
T14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
T21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
U100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95, 129
V01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
V02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
V03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
V04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
V05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
V06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
V07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
V08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
V09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
V10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Y04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95, 129, 135, 159, 339, 341
Y07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135, 159, 347
Y08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135, 159, 347
Y14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101, 598, 599
Y15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100, 134, 159, 564
Y16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135, 159, 342
Y17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135, 159, 342
Y30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135, 139, 159
Y31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135, 159, 341
Y60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Y72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Y73 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
806 BW 220 D-5

Index
Y98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Y102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Y122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Y123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Y137 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Y140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Y141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Y142 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Y143 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Y144 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Y145 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Y147 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Y148 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Y149 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Y166 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Y169 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Y170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Y378 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Y379 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Y380 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Operating means
A48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413, 415
A67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
A87 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
A124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
A138 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
B55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
B62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
B88 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
B93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413, 415, 427
B104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
B105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 566, 574
B113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
B114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415, 424
B124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413, 439
B130 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415, 425
B133 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415, 433
B145 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415, 429
B171 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
B234 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
B235 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
BW 220 D-5 807

Index
B236 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
B237 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
F17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164, 654
F27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164, 654
F28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164, 654
F143 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164, 654
F150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164, 654
F264 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164, 654
F266 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164, 654
F271 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164, 654
F272 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164, 654
F279 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164, 654
G01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
H04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
M09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
R03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
R79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439
R81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
R82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
R83 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
R84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
S00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
S44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
S118 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
Y04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97, 325
Y07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
Y08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
Y15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181, 566
Y16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
Y17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
Y30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97, 325
Y31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97, 325
Y72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
Y73 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
Y137 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413, 415, 431
Y147 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413, 431
Y148 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413, 431
Y149 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413, 431
Y166 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413, 431
Overview
Additional heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101, 598
808 BW 220 D-5

Index
Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100, 564, 566

Auxiliary heating, AIRTRONIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 599
Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98, 386, 406
Diesel engine, cooling circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393
Diesel engine, lubrication oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99, 343, 351, 465, 466
Electrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95, 129
Electrics, cabin control console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Electrics, CAN bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150, 408
Electrics, diesel engine with sensors and actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
Electrics, fuse assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Electrics, power board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Electrics, wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97, 325
Hydraulic system, charge circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
Hydraulic system, flushing diagram for vibration circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
Hydraulic system, pump overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
Hydraulic system, steering circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
Hydraulic system, travel circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
Hydraulic system, travel circuit flushing diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359, 361
Hydraulic system, vibration circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
Hydraulics, closed circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
Hydraulics, open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
P
Plug
X0A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
X0B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
X0C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
X1A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
X1B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
X2A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
X2B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
X4A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
X4B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
X4D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
X4E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140, 169
X5.E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
X5E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
X5E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
X6B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
BW 220 D-5 809

Index
X6C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
X7.C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
X7.C2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
X7A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
X8A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140, 169
X8B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140, 169
X10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
X11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
X12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
X14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133, 140
X15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
X20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
X21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
X23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
X24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
X25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
X26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
X30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
X31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
X32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95, 129, 131, 138, 150, 166, 386, 387, 406, 407, 408
X33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
X34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95, 129, 131, 150, 166, 387, 407, 408
X39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
X41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
X45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131, 138, 166, 387, 407
X48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
X50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
X65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
X66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
X67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134, 149
X68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
X69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
X72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
X73 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
X76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
X78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
X79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
X80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
X81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
X82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
X83 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
810 BW 220 D-5

Index
X85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
X87 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
X88 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
X94 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
X99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
X100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
X100 - X109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95, 129, 131, 166, 387, 407
X101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134, 167
X102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133, 167
X103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135, 167
X104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139, 167
X105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
X106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
X107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146, 167
X108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134, 138, 167
X109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
X109f . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
X109m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
X110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
X200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140, 182
X201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140, 182
X202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140, 182
X203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140, 182
X204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
X205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141, 182
X206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
X207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
X400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148, 150, 408
XA103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
XA161 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
XR79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
XS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
XS28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Plugs
X0A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
X0B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
X0C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
X1A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
X1B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
X2A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
X2B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
BW 220 D-5 811

Index
X4A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
X4B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
X4D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
X5A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
X5B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
X5E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
X6B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
X6C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
X6D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142, 169
X7A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
X7B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143, 169
X7C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
X7D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
X16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
X32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98, 417
X38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
X85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
X90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
X91 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
X93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
X95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
X96 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
X204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
X205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
X210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
X211 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
T
Trouble shooting
Additional heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 775
Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 753
Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 666
Electric systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 646
Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 737
Troubleshooting
Hydraulics - axial piston motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 743
Hydraulics - axial piston pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 741
Hydraulics - insufficient hydraulic power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 738
Hydraulics - troubleshooting table for hydraulic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745
812 BW 220 D-5

Appendix
Appendix
BW 220 D-5 813

Appendix
Appendix
A Circuit diagrams.......................................................... 815
814 BW 220 D-5

Circuit diagrams
A Circuit diagrams
A.1 Circuit diagram 643................................................ 815
A.2 Hydraulic diagram.................................................. 917
A.1 Circuit diagram 643
BW 220 D-5 815

Circuit diagrams
816 BW 220 D-5

Table of contents
Inhaltsverzeichnis BO_F06_001
Page Higher-level function Function

Blatt Anlage Funktion Description Beschreibung
1 Cover sheet Deckblatt
2 Table of contents Inhaltsverzeichnis
5 Structure identifier overview Strukturkennzeichenübersicht
6 Structure identifier overview Strukturkennzeichenübersicht
7 Layout mounting locations Anordnung Einbauorte
8 =SUPL Supply, Starting unit Versorgung, Starten
9 =SUPL Fuse protection potential 30 Absicherung Potential 30
10 =SUPL Fuse protection potential 15 Absicherung Potential 15
11 =SUPL Supply Driving Controller Versorgung Fahrsteuerung
12 =SUPL Supply Measurement controller Versorgung Messtechniksteuerung
13 =SUPL Supply 8,5V sensors Versorgung 8,5V Sensoren
14 =SUPL Supply Monitoring module, Travel lever Versorgung Überwachungsmodul, Fahrhebel
15 =COM Communication, Diagnosis Kommunikation, Diagnose
16 =COM Communication Kommunikation
17 =COM Communication Kommunikation
18 =ENGI Pre-heating, Fuel lift pump, Fuel-pre-heating Vorglühen, Kraftstoffförderpumpe, Kraftstoffvorwärmung
19 =ENGI Engine speed, Regeneration mode Motordrehzahl, Regenerationsmodus
BW 220 D-5
20 =ENGI Engine - Machine-part Motor - Fahrzeugseite
21 =ENGI3 Deutz TCD 2012 Tier 3 Deutz TCD 2012 Tier 3
24 =MON Monitoring, Failure indicators Überwachung, Störmeldungen
25 =DRIV Slope sensor, Speed sensors Neigungssensor, Geschwindigkeitsaufnehmer
26 =DRIV Travel lever Fahrhebel
27 =DRIV Pressure sensors Drucksensoren
28 =DRIV Travel pumps Fahrpumpen
29 =DRIV Brake, Speed ranges Bremse, Fahrstufen
30 =DRIV Warning horns, Back up alarm, Warnhörner, Rückfahralarm,
31 =VIB Vibration Vibration
32 =EXC Variocontrol Variocontrol
33 =EXC Variocontrol Variocontrol
34 =DBL Dozer blade Planierschild
35 =VPL Vibratory plate compactor Anbauplatten
36 =VPL Vibratory plate compactor Anbauplatten
37 =MEAS Measurement equipment Messtechnik
38 =MEAS Economizer Economizer
39 =MEAS Economizer Economizer
0 1 2 3 4 5 6 7 8 9
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Created M. Vogt Blatt2 von
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Table of contents Kind of Document
Dokumentenart &AAB
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Inhaltsverzeichnis
817
643 EPE /00
818
Table of contents

40 =MEAS Interface measurement Schnittstelle Messtechnik
Circuit diagrams
41 =OPT Rops - Lighting, Socket Rops - Beleuchtung, Steckdose

42 =OPT StVZO illumination StVZO Beleuchtung
43 =OPT Electronical Burglary protection Elektronische Diebstahlsicherung
44 =OPT BOMAG Telematics BOMAG Telematik
45 =OPT Morey Telematics, ZTR Telematics Morey Telematic, ZTR Telematic
46 =OPT Cabin - Additional heater Kabine - Zusatzheizung
47 =OPT Cabin - Heating, Air conditioning, Washer pumps Kabine - Heizung, Klimaanlage, Wascherpumpen
48 =OPT Cabin - Supply Kabine - Versorgung
49 =OPT Cabin - Fuse protection Kabine - Absicherung
50 =OPT Cabin - Lighting Kabine - Beleuchtung
51 =OPT Cabin - Cabin equipment Kabine - Kabinenausrüstung
52 =OPT Cabin - Cabin equipment Kabine - Kabinenausrüstung
53 =OPT Cabin - Radio, Tachograph, Printer measurement Kabine - Radio, Tachograph, Drucker Messtechnik
54 =OPT BOMAG Compaction Management BCM, GPS BOMAG Verdichtungsmanagement BCM, GPS
55 =OPT Back up monitoring Rückraumüberwachung
56 Device tag list Betriebsmittelliste
BW 220 D-5
63 Plug overview Steckerübersicht
0 1 2 3 4 5 6 7 8 9
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101
Dokumentenart &AAB
Checked K. Brand
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Table of contents

84 Cable diagram W1, W2, W3 Kabelplan W1, W2, W3
85 Cable diagram W4, W6, W7, W8 Kabelplan W4, W6, W7, W8
86 Cable diagram W8, W9, W10, W17 Kabelplan W8, W9, W10, W17
87 Cable diagram W18 Kabelplan W18
88 Pin overview A15 Pin Übersicht A15
96 Pin overview S55 Pin Übersicht S55
97 Overview CAN communication Übersicht CAN Kommunikation
BW 220 D-5
98 Overview central electric Übersicht Zentralelektrik
99 Overview plugs X100 - X110 Übersicht Stecker X100 - X110
100 Overview Powerboard Übersicht Powerboard
101 Overview Powerboard Übersicht Powerboard
0 1 2 3 4 5 6 7 8 9
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101
Dokumentenart &AAB
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Inhaltsverzeichnis
819
643 EPE /00
820
Structure identifier overview
Strukturkennzeichenübersicht BO_F24_001
Higher-level function Range

Anlage Bereich
Description Beschreibung
=COM Communication Kommunikation
=DBL Dozer blade Planierschild
Circuit diagrams
=DRIV Drive functions Antriebsfunktionen

=ENGI Engine Antriebsmaschine
=ENGI3 Engine Deutz TCD 2012 Tier 3 Motor Deutz TCD 2012 Tier 3
=EXC Exciter displacement Erregerverstellung
=MEAS Measurement equipment Messtechnik
=MON Monitoring, Failure indicators Überwachung, Störmeldungen
=OPT Optional functions Optionale Funktionen
=SUPL Supply Versorgung
=VIB Vibration and compaction Vibration und Verdichtung
=VPL Vibratory plate Vibrationsplatte
Mounting location Range
Einbauort Bereich
+ARC Armature carrier Armaturenträger
+BAT Battery-box Batteriekasten
+CAB Cabin Kabine
+DPL Drivers platform Fahrerstand
+DRUM Drum Bandage
BW 220 D-5
+EBOX Central electric Zentralelektrik
+FRFR Front frame Vorderrahmen
+MOT Engine and attachment parts Motor und Anbauteile
+PLA Vibratory plate compactor Anbauplatten
+PUMP Pump mounting Pumpenanbau
+REFR Rear frame Hinterrahmen
+ROPS Roll-Over Protection System Überrollschutz System
+SEAT Seat console Sitzkonsole
Kind of Document Range
Dokumentenart Bereich
&AAA Title page / cover sheet Titel- / Deckblatt
&AAB Table of contents Inhaltsverzeichnis
&ADB Structure identifier overview Strukturkennzeichenübersicht
&ALU Layout mounting locations Anordnung Einbauorte
&EFA1 Pin overview ECU Pin Übersichten Steuerungen
&EFA2 Overview CAN communication Übersicht CAN Kommunikation
&EFS Circuit diagram Schaltpläne
0 1 2 3 4 5 6 7 8 9
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101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Structure identifier overview Kind of Document
Dokumentenart &ADB
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Strukturkennzeichenübersicht 643 EPE /00
Structure identifier overview
Strukturkennzeichenübersicht BO_F24_001
Kind of Document Range

Dokumentenart Bereich
&EMA3 Plug overview Steckerübersicht
&EMB2 Cable diagram Kabelplan
&EPB Device tag list electrical engineering Betriebsmittelliste Elektrotechnik
&ETL1 Overview central electric Übersicht Zentralelektrik
BW 220 D-5
0 1 2 3 4 5 6 7 8 9
Page from
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Structure identifier overview Kind of Document
Dokumentenart &ADB
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Strukturkennzeichenübersicht
821
643 EPE /00
822
Circuit diagrams
+FRFR
+DRUM +REFR
+PLA
+CAB
+ROPS
+DPL
+SEAT
+MOT
+ARC +PUMP
BW 220 D-5
+BAT
+EBOX
0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage = Blatt7 von
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Layout mounting locations Mounting location Kind of Document
Einbauort + Dokumentenart &ALU
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Anordnung Einbauorte 643 EPE /00
F13:2 / 9.0
+REFR X4.A 9
RD
4 mm² F95:2 / 10.0
X0.A
RD 1 +ARC RD
25 mm² 30_PB / 9.0 1,5 mm²
RADSOK® 8mm RD
1,5 mm² S15:11 / =OPT/42.0
RD F48:2
25 mm²
=ENGI/18.3 30
P 0 IIIIII
RD
50 mm² S00 P,0,I
1 switch ignition 58 15/54 19 17 50a

Schalter Motorstart
WH
F39 1,5 mm²
80A
MAXI Fuse
2
Fuse, main cabin WH
MAXI Sicherung
1,5 mm² S15:23 / =OPT/42.0
Hauptsicherung WH WH WH
1,5 mm² 1,5 mm² 1,5 mm²
RD Kabine
70 mm²
X8.A
Fuse, engine controller

Sicherung Motorsteuerung
Fuse, main battery
Hauptsicherung Batterie
Sicherung Glühanlage
Fuse, B+ charge
Sicherung B+ Ladeleitung
=OPT+CAB/48.1
X4.A 13 3 20
XF48.2 Fuse, glow plug system

1 S00:50a / 10.0
2 2 2
F95 4 F00 3 F48 2 F164 1 S00:19 / =ENGI/20.1

30A 125A 125A 150A 1
1 1 1 1
V01 15_CAB
=OPT+CAB/48.1
S5G-E3 2
+MOT 30
86 1 1
K61
RD
70 mm² K61 R10 /8.6 87 87a
D61
green
/8.7 2 82Ω / 22W Relay, charge control
85 2 Relais Ladekontrolle
12V/20A
!!! Auch bei ausgeschaltetem Batterietrennschalter unter Spannung

9.2
D+ / =MON/24.0
M01:50
!!! There is still power supply even if the battery disconnector switch is turned off
4
BW 220 D-5
S30 X1.A 7 X7.C 5
250A =MEAS/40.0
3
Disconnect switch, battery WH X1.A_f 7X7.C-2 5 X7.C:4
6 mm²
RD Batterietrennschalter
4 mm²
=OPT+DPL/46.1
X7.C-2
5 31_AH
XM01.50
1 1
RD
XG02.D+
+BAT 70 mm² 30 50 B+ D+
86 1 86 1
X7.C 4
RD G
70 mm²
M01 G02 K09 K11
D09
D11
green
green
M1 14V / 70A X7.C-2 4 12V/20A 2 12V 2

85 85
Starter - Generator B- W BN
1,5 mm²
Starter Generator
G03 + G01 + -U300
Ground engine
12V / 88Ah Battery
1Masse Motor 2 Ground engine 3 X7.C-2 4
Battery - Batterie -
at BW 219-226
-U300 = Masse Motor
Batterie 12V / 88Ah
bei BW 219-226 X7.C 4
at BW 211-216
Only at BW 219-226
Nur bei BW 219-226
12V / 110Ah
X0.B
bei BW 211-216 BN 1
16 mm² Gnd_PB / 9.0
BK XU600.3 RADSOK® 6mm
70 mm² 31_Eng / =ENGI/18.0
BK
3 XU600.4
70 mm²
XU600.2
4 31_EMR / =ENGI3/21.0 X8.B / =OPT+CAB/48.1
BK
70 mm² -U600 31_DCtrl / 11.0
Ground central electric 2 5
Ground rear frame 1Masse Zentralelektrik 87 30 87 /10.0
-U500 = Masse Hinterrahmen 6 31_MCtrl / 12.0 87a 30 =OPT+CAB/47.1
1Ground rear frame 2 3 -U600

Masse Hinterrahmen
Ground central electric 7 31_RFr / =DRIV+REFR/28.1
-U500 Relay, air conditioning Relay, potential 30 on 15
Masse Zentralelektrik -XU600.8 Relais Klimaanlage Relais Potential 30 auf 15
8 1 31_Ar / 14.6
9 31_Db / 14.1
XU600.10
10 1 31_Econ / =MEAS/38.1
0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage =SUPL Blatt 8 von
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Supply, Starting unit Mounting location Kind of Document
Einbauort +EBOX Dokumentenart &EFS
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Versorgung, Starten
823
643 EPE /00
824
8.6 / 30_PB 30_PB / 10.0
30
K06
=OPT/41.5 87 87a
Relay, headlights rear
Relais Scheinwerfer hinten
F13 F157 F68 F22 F19 F84 F23 F67 F146 F11 F07 F268
15A 30A 15A 15A 15A 10A 15A 15A 15A 15A 10A 20A
Circuit diagrams
Fuse, fuel pump
Fuse, hazard light
Fuse, potential 30
Fuse, signal horns
Fuse, headlight left
Fuse, ignition switch

Sicherung Potential 30
Sicherung Warnblinker
Sicherung Startschalter
Sicherung Signalhörner
Fuse, controller (Pin 54)
Fuse, working lights rear

Sicherung Kraftstoffpumpe
Fuse, solenoid switch starter

Sicherung Scheinwerfer links
Fuse, controller (potential 30)

Fuse, working headlight front left

Sicherung Steuerung (Kontakt 54)
Sicherung Magnetschalter Anlasser

Sicherung Steuerung (Potential 30)
Sicherung Arbeisscheinwerfer hinten

X4.A 19 F268:2
Sicherung Arbeitsscheinwerfer vorne links

=ENGI/18.0
8.9 / F13:2 30 F07:2

+ARC WH =OPT/42.0
K145 1,5 mm²
=ENGI/20.8 87a 87 X7.C 1

Relay, solenoid starter F11:2
1
XS01.11
Relais Hubmagnet Starter X7.C-2 1 =OPT/42.0
11 21 A1
-S01 F146:2
switch emergency off 12.0
30 12 22 A2
RD Schalter Not Aus
K38 1,5 mm² 1
F67:2
/10.2
=ENGI/20.6 87a 87
BW 220 D-5
Relay, starter control 11.0
X7.C-2 1
XS01.12
Relais Anlassteuerung
X7.C 1 F23:2
WH =DRIV+REFR/30.2
=DRIV+REFR/29.5
1,5 mm²
X1.A 1 2 F84:2
1 =COM/15.0
Fx X1.A_f 1 2
X4.A 10
Fuseholder, fuse test S01:12
2 11.0
Sicherungshalter Sicherungstest WH WH
2,5 mm² 2,5 mm²
Splice F19:2
Spleiss 11
=OPT/41.0
1 F22:2
=OPT/41.0
Dx
green 2
Indicator light, fuse test X7.C:1
Meldeleuchte Sicherungstest =MEAS/40.0
F68:2
8.4 / M01:50
=OPT+DPL/46.1
8.9 / Gnd_PB Gnd_PB / =COM/15.0
0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage =SUPL Blatt9 von
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Fuse protection potential 30 Mounting location Kind of Document
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Absicherung Potential 30 643 EPE /00
825 BW 220 D-5
Erstellt
Geprüft
Created
Checked
0
9.9 / 30_PB
8.9 / S00:50a
8.6 / F95:2
M. Vogt
K. Brand
16.07.2019
16.07.2019
Relais Potential 30 auf 15
Relay, potential 30 on 15
/8.8
K11
87
30
X7.C-2
X7.C-2
X7.C
X7.C
2
2
2
2
WH
1,5 mm²
15A
F103
Fuse, potential 15
1
+ARC
Sicherung Potential 15
BW11RH - F41
3
3
3
Schalter Not Aus
switch emergency off
/9.4
-S01
10A
F122
X4.A
X4.A
XS01.22 XS01.21 Fuse, engine controller

1
1
1
22
21
Sicherung Motorsteuerung
WH
WH
12
1,5 mm²
1,5 mm²
2
10A
F148

BW11RH - F25
Deutz TCD 2012/13 Tier 3
BW 211-226 D, DH, BVC-5
10A
F24
Fuse, monitoring module

Sicherung Überwachungsmodul
3
5A
F91
Fuse, sensors
Sicherung Sensoren
20A
F05
Fuse, socket
Sicherung Steckdose
4
10A
F08
Fuse, indicators
Sicherung Blinker
Absicherung Potential 15
25A
F124
Fuse, fuel-pre-heating
Fuse protection potential 15

Sicherung Kraftstoffvorheizung
5A
F244
Fuse, Bomag telematics (potential 15)

Sicherung Bomag Telematik (Potential 15)
6
30A
F40
Fuse, heating unit cabin

Sicherung Kabinenheizung
15A
F29
Fuse, compressor suspension seat

Sicherung Kompressor Luftfedersitz
7
5A
F169
Fuse, starting current

Sicherung Startstrom
Anlage
Einbauort
Mounting location
8
7,5A
F243
X0.C
Fuse, Bomag telematics (potential 30)

Sicherung Bomag Telematik (Potential 30)
30
30
=SUPL
+EBOX
Blatt
Page
RADSOK® 3,6mm
14.0
11.0
14.0
F24:2
F91:2
F05:2
F08:2
F40:2
F29:2
10
X7.C:2
F103:2
F148:2
F124:2
F244:2
F169:2
F243:2
S01:22
643
Dokumentenart
=OPT/41.0
=OPT/42.0
=OPT/44.1
=OPT/44.1
Kind of Document
=DRIV/25.0
=ENGI/18.0
=ENGI/20.1
=MEAS/40.0
X0.C / =ENGI/20.1
9
=OPT+DPL/46.1
=OPT+CAB/47.1
=OPT+CAB/47.1
von
from
!!! There is still power supply even if the battery disconnector switch is turned off
!!! Auch bei ausgeschaltetem Batterietrennschalter unter Spannung
&EFS
101
EPE /00
Circuit diagrams
826
9.9 / S01:12 S01:12 / 12.0
10.9 / F148:2 F148:2 / 12.0
9.9 / F67:2
Ground Electronic Ground Electronic Ground Electronic Ground Electronic Ground Electronic
Masse Elektronik Masse Elektronik Masse Elektronik Masse Elektronik Masse Elektronik
GND GND GND GND GND
Circuit diagrams
Driving Controller
Fahrsteuerung A34 A34 A34 A34 A34
GND GND GND GND GND
X35 55 X35 65 X35 66 X35 67 X35 68
X35 55 X35 65 X35 66 X35 67 X35 68
A34
X5.A 19 18 3
X35
Plug, ECU propulsion
Stecker ECU Fahrantrieb
WH
2,5 mm²
Splice
Spleiss 38
B57:2 / =DRIV/25.0
Splice
Spleiss 39
BW 220 D-5
X35 28 X35 54 X35 56 X35 57 X35 58 X35 59 X35 60
X35 28 X35 54 X35 56 X35 57 X35 58 X35 59 X35 60

+Ignition / 0..32V +UE / 0..32V +UB / 0..32V +UB / 0..32V +UB / 0..32V +UB / 0..32V +UB / 0..32V
A34 A34 A34 A34 A34 A34 A34
+ Ignition +UE +UB +UB +UB +UB +UB

Ignition Power Supply (Electronic) Power Supply (Outputs) Power Supply (Outputs) Power Supply (Outputs) Power Supply (Outputs) Power Supply (Outputs)
Zündung Spannungsvers. (Elektronik) Spannungsvers. (Ausgänge) Spannungsvers. (Ausgänge) Spannungsvers. (Ausgänge) Spannungsvers. (Ausgänge) Spannungsvers. (Ausgänge)
8.5 / 31_DCtrl 31_DCtrl / =DRIV/25.0
0 1 2 3 4 5 6 7 8 9
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Supply Driving Controller Mounting location Kind of Document
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Versorgung Fahrsteuerung 643 EPE /00
11.9 / F148:2 F148:2 / =COM/15.0
9.9 / F146:2
11.9 / S01:12
Ground Electronic Ground Electronic Ground Electronic Ground Electronic Ground Electronic
Masse Elektronik Masse Elektronik Masse Elektronik Masse Elektronik Masse Elektronik
Measurement controller GND GND GND GND GND

Messtechnik Steuerung A83 A83 A83 A83 A83
GND GND GND GND GND
X5.E 4 13 6
X88 55 X88 65 X88 66 X88 67 X88 68
X5.E2 4 13 6
X88 55 X88 65 X88 66 X88 67 X88 68
A83
X5.E2 4 13 6
X5.E 13 6 X88
Plug, measurement controller
Stecker Messtechniksteuerung
X5.E 4 X5.E3 4 WH
2,5 mm²
Splice
Spleiss 43
BW 220 D-5
=MEAS/38.1 / X5.E:4
X88 28 X88 54 X88 56 X88 57 X88 58 X88 59 X88 60
X88 28 X88 54 X88 56 X88 57 X88 58 X88 59 X88 60

+Ignition / 0..32V +UE / 0..32V +UB / 0..32V +UB / 0..32V +UB / 0..32V +UB / 0..32V +UB / 0..32V
A83 A83 A83 A83 A83 A83 A83
+ Ignition +UE +UB +UB +UB +UB +UB
Ignition Power Supply (Electronic) Power Supply (Outputs) Power Supply (Outputs) Power Supply (Outputs) Power Supply (Outputs) Power Supply (Outputs)
Zündung Spannungsvers. (Elektronik) Spannungsvers. (Ausgänge) Spannungsvers. (Ausgänge) Spannungsvers. (Ausgänge) Spannungsvers. (Ausgänge) Spannungsvers. (Ausgänge)
8.5 / 31_MCtrl 31_MCtrl / =EXC/33.1
0 1 2 3 4 5 6 7 8 9
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Supply Measurement controller Mounting location Kind of Document
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Versorgung Messtechniksteuerung
827
643 EPE /00
828
FM1 / =DRIV/25.0
AGND_DC / =COM/15.0
FM2 / =EXC/33.1
Circuit diagrams
2 2
FM1 FM2
ATO Fuse
ATO Fuse
1A 1A
ATO Sicherung
ATO Sicherung
1 1
Fuse, sensors Fuse, sensors
Sicherung Sensoren Sicherung Sensoren
X5.A 4 13 X5.E 9
X5.E2 9
X5.E2 9
X5.E 9
BW 220 D-5
AGND / =DRIV/25.0 AGND_MC / =MEAS/37.1
Splice
Spleiss 42
X35 23 X35 1 X88 23 X88 1
X35 23 X35 1 X88 23 X88 1

8.5VEXT AGND 8.5VEXT AGND
A34 A34 A83 A83
8.5VEXT AGND
8.5VEXT AGND
8,5V Sensor Power AGND 8,5V Sensor Power AGND
8,5V Sensor Spannung Analogmasse 8,5V Sensor Spannung Analogmasse
0 1 2 3 4 5 6 7 8 9
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Supply 8,5V sensors Mounting location Kind of Document
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Versorgung 8,5V Sensoren 643 EPE /00
10.9 / S01:22 S01:22 / =ENGI/20.1
10.9 / F24:2
X4.A 18 X4.B 7
+ARC +SEAT Splice

Spleiss 51
=DRIV+SEAT/26.0
15_Ar / =EXC/32.1
Splice
Spleiss 48
15_Db / =ENGI/19.1 X23 1
X23.B 1
A15
module monitoring K189:30 / =DRIV+SEAT/26.8
Modul Überwachung
X33 26 1
X23.A
X33 26 X23 1
Power supply (8...32V) Power supply (8...32V)
A15 S55
+UB +Ub
switch control lever travel

Schalter Steuerhebel Fahren
Power supply Power supply
Stromversorgung Stromversorgung
-S55
Ground Ground Ground Ground

Masse Masse Masse Masse
Ground housing
GND
GND Gnd 0V ADR 1 ADR 2
A15 S55 -S55 -S55 -XGnd 1
BW 220 D-5
Ground Ground Digital IN 7 Digital IN 8
X33 25 X23 2 X23 9 X23 10
X33 25 X23.A 2 X23.A 9 X23.A 10
X33 K189:85
Splice =DRIV+SEAT/26.8
Plug, module monitoring Spleiss #1
Stecker Modul Überwachung
31_Db_2 / =MON/24.0
Splice
Spleiss 67 X23.B 2 X23.B 9 X23.B 10
X23 2 X23 9 X23 10 -XS55.Gnd 1
BN Splice
2,5 mm² Spleiss 83
8.5 / 31_Db 31_Db / =DRIV+REFR/30.1

8.5 / 31_Ar 31_Ar / =DRIV/25.0
0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage =SUPL Blatt 14 von
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Supply Monitoring module, Travel lever Mounting location Kind of Document
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Versorgung Überwachungsmodul, Fahrhebel
829
643 EPE /00
830
=SUPL/9.9 / F84:2 F84:2 / =OPT/43.1
=SUPL/12.9 / F148:2 F148:2 / 17.0
=SUPL/13.9 / AGND_DC AGND_DC / =DRIV/25.0
CAN1+ / 16.0
CAN1- / 16.0
Circuit diagrams
CAN2+ / 16.0
X7.D 15 13 5
CAN2- / 16.0
M_CAN1+ / 17.0
M_CAN1- / 17.0
X34 Diagnosis interface BOMAG
Pot. 30 - 12V
Pot. 15 - 12V
Gnd 1
N A B C D E F X34 = Diagnosesteckdose BOMAG
P R J
Gnd
CAN 1 low
CAN 2 low
CAN 3 low
CAN 1 high
CAN 2 high
CAN 3 high
bestückt
Widerstände nicht
Resistors not equiped
X7.D 2 10 R20 7 6 R22 3 11 R24 8

1 2 1 2 1 2
120 Ω 120 Ω 120 Ω

=SUPL/9.1 / Gnd_PB Gnd_PB / 17.0
R21
1 2 R25
BW 220 D-5
1 2
120 Ω
X7.C 13 X7.C 14 120 Ω
X7.C-2 13 X7.C-2 14
X5.A 12 15 6 9 X5.E 15 12
X5.E2 15 12
X7.C-2 13 X7.C-2 14 X5.E2 15 12
X5.E 15 X5.E3 15 X5.E 12 X5.E3 12
X5.E:12 / =MEAS/38.1
X5.E:15 / =MEAS/38.1
X35 27 X35 26 X35 53 X35 33 X88 27 X88 26
X35 27 X35 26 X35 53 X35 33 X88 27 X88 26

CAN1_H CAN1_L CAN2_H CAN2_L CAN1_H CAN1_L
A34 A34 A34 A34 A83 A83
CAN1_H CAN1_L CAN2_H CAN2_L CAN1_H CAN1_L
CAN 1 high CAN 1 low CAN 2 high CAN 2 low CAN 1 high CAN 1 low
CAN 1 high CAN 1 low CAN 2 high CAN 2 low CAN 1 high CAN 1 low
0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage =COM Blatt15 von
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Communication, Diagnosis Mounting location Kind of Document
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Kommunikation, Diagnose 643 EPE /00
15.9 / CAN1+ CAN1+ / 17.0
15.9 / CAN1- CAN1- / 17.0
15.9 / CAN2+ CAN2+ / 17.0
15.9 / CAN2- CAN2- / 17.0
CAN3+ / =OPT+CAB/48.1
CAN3- / =OPT+CAB/48.1
R26
1 2
120 Ω
R27
1 2
120 Ω
X5.E 1 2
X5.E2 1 2
X5.E:2_2 / =MEAS/40.0
X4.A 14 17 X4.B 1 4
X5.E:1_2 / =MEAS/40.0
X5.E2 1 2
X5.E 1 X5.E3 1 X5.E 2 X5.E3 2

+ARC +SEAT X5.E:2 / =MEAS/39.1
X23 6 X23 7
X5.E:1 / =MEAS/39.1
BW 220 D-5
X23.B 6 X23.B 7
X33 21 X33 22 6 7 X88 53 X88 33

X23.A X23.A
X33 21 X33 22 X23 6 X23 7 X88 53 X88 33
CAN high CAN low CAN bus high CAN bus low CAN2_H CAN2_L
A15 A15 S55 A83 A83
CANH CANL CAN + CAN - CAN2_H CAN2_L
CAN high CAN low CAN high CAN low CAN 3 high CAN 3 low
CAN high CAN low CAN high CAN low CAN 3 high CAN 3 low
0 1 2 3 4 5 6 7 8 9
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Communication Mounting location Kind of Document
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Kommunikation
831
643 EPE /00
832
16.9 / CAN2+ CAN2+ / =ENGI/20.1
16.9 / CAN2- CAN2- / =ENGI/20.1
16.9 / CAN1+ CAN1+ / =OPT/43.1
16.9 / CAN1- CAN1- / =OPT/43.1
15.1 / Gnd_PB Gnd_PB / =ENGI/20.1

Circuit diagrams
15.9 / F148:2 F148:2 / =OPT/43.1
15.9 / M_CAN1+ CAN2+_TM / =OPT/44.1
15.9 / M_CAN1- CAN2-_TM / =OPT/44.1
R28
1 2
120 Ω
Resistors not equiped

Widerstände nicht bestückt
R29
1 2
BW 220 D-5
120 Ω
X7.A 1 2 6 5 3 4 8 7 9 10
0 1 2 3 4 5 6 7 8 9
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Communication Mounting location Kind of Document
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Kommunikation 643 EPE /00
=SUPL/10.9 / F124:2
=SUPL/9.9 / F268:2
+MOT
=SUPL/8.6 / F48:2
30
K209
/20.4 87a 87
Relay, fuel pump
Relais Kraftstoffpumpe
K14:2
=ENGI3/22.8
K14:1
=ENGI3/22.8
X1.A 3 6 X1.A 8 9
XK14.5
1
XK14
1
WH WH
5 1,5 mm² 1,5 mm²
K14
12V 3 XK14.3_1
K2 2 1 Splice
K14:3 / =ENGI3/22.8 Spleiss 84
XK14
1
WH
2,5 mm²
relay glow plug system
XK14.3_2
Relais Vorglühen X67.f 1
RD
25 mm²
BW 220 D-5
1
XR19
1
WH
R19 2,5 mm²
167A 1
R4 XR79
Heating flange 2
1
Heizflansch 4 1
-U300
Ground engine R79
Masse Motor 200W 2
heating prefilter fuel
Heizung Vorfilter Kraftstoff
2
XR79 2
BN
2,5 mm²
X67.f 2
BN
2,5 mm²
BN Splice
=SUPL/8.5 / 31_Eng 6 mm² Spleiss 31_Eng / =MON/24.0
74
0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage =ENGI Blatt18 von
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Pre-heating, Fuel lift pump, Fuel-pre-heating Mounting location Kind of Document
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Vorglühen, Kraftstoffförderpumpe, Kraftstoffvorwärmung
833
643 EPE /00
834
+ARC
=SUPL/14.2 / 15_Db VIB_TM / =OPT/44.1
XS127.13
XS127.23
-XS299.13
-XS299.23
1 1 1 1
Circuit diagrams
13 23
low
eco
high
-S127 X4.A 16
switch engine speed 14 24
Schalter Motordrehzahl 1 1 1 1
XS127.14
XS127.24
-XS299.14
-XS299.24
BW 220 D-5
X33 9 X33 10 X33 11 X33 12 X33 4
X33 9 X33 10 X33 11 X33 12 X33 4

active high active high active high active high +UB, max 1,5A
A15 A15 A15 A15 A15
DIN3 DIN4 DIN5 DIN6 DOUT2
+ARC-S127:14 +ARC-S127:24 +ARC-XS299.14:1 +ARC-XS299.24:1 -A124:11

Switch, engine speed Sx. 1 Switch, engine speed Sx. 2 Switch, regeneration Sy. 1 Switch, regeneration Sy. 2 Vibration Telematics
Schalter Motordrehzahl Sx. 1 Schalter Motordrehzahl Sx. 2 Schalter Regeneration Sy. 1 Schalter Regeneration Sy. 2 Vibration Telematik
0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage =ENGI Blatt19 von
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Engine speed, Regeneration mode Mounting location Kind of Document
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Motordrehzahl, Regenerationsmodus 643 EPE /00
X1.B:3 / =ENGI3/21.0
X1.B:5 / =ENGI3/21.0
X1.B:8 / =ENGI3/21.1
X1.B:6 / =ENGI3/21.1
X1.B:12 / =ENGI3/21.2
X1.B:11 / =ENGI3/21.4
X1.B:10 / =ENGI3/21.2
X1.B:13 / =ENGI3/21.3
X1.B_f 3 5 8 6 16 X1.B_f 12 11 10 13 15 18 7
X1.B 1 2 3 5 8 6 X1.B 14 9 17 16 X1.B 12 11 10 13 4 15 18 7
BW 220 D-5
85 1
K38
D38
green
87 87a 85 86 1 12V/40A 86 87 87a 86 1

2 2
CN403
D41
green
green
green
87a 87
D209
D145
K41 K05
12V/25A 30 86 1 2 Relay, starter control =DRIV+REFR/29.2 30 2
K209 85 K145 85
CN413 Relais Anlassteuerung
12V/30A 30 12V/40A
=SUPL/9.2
Relay, separation K3
Trennrelais
=SUPL/10.8 / X0.C Relay, fuel pump X1.A 4 Relay, starting current Relay, solenoid starter
Relais Kraftstoffpumpe Relais Startstrom Relais Hubmagnet Starter
87 87
!!! There is still power supply even if the battery disconnector switch is turned off 87a 30 /18.6 87a 30 =SUPL/9.2
!!! Auch bei ausgeschaltetem Batterietrennschalter unter Spannung 87 87a
K22
=DRIV+REFR/30.9
Relay, shut off solenoid engine 30
Relais Hubmagnet Abschaltung Motor
=SUPL/8.9 / S00:19
=SUPL/10.9 / F169:2
=SUPL/14.9 / S01:22
=COM/17.8 / CAN2+
=COM/17.8 / CAN2- StU_TM / =OPT/44.1
=COM/17.8 / Gnd_PB Gnd_PB / =DRIV/25.0
0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage =ENGI Blatt 20 von
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Engine - Machine-part Mounting location Kind of Document
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Motor - Fahrzeugseite
835
643 EPE /00
836
Harness EMR - Engine interface
Kabelbaum EMR - Motorschnittstelle
Circuit diagrams
A48
D2
Engine-controller EMR3 (EDC 16) Harness Engine interface - Engine internal
Motorsteuergerät EMR3 (EDC 16) Kabelbaum Motorschnittstelle - Motorintern
D2.1 (A) D2.2 (K)

Plug, engine-controller motor-part Plug, engine-controller machine-part
Stecker Motorsteuergerät Motorseite = X44 X45 = Stecker Motorsteuergerät Maschinenseite
WIF
D2.2 D2.2 D2.2 D2.2 D2.2 D2.2 D2.2 D2.2 D2.2 D2.2 D2.2 D2.2 D2.2 D2.2 D2.2
-A48 1 3 5 72 28 62 61 82 60 25 2 4 6 63 64
-X45 1 3 5 72 28 62 61 82 60 25 2 4 6 63 64
WH WH WH BN BN BN
2,5 mm² 2,5 mm² 2,5 mm² 2,5 mm² 2,5 mm² 2,5 mm²
X108.m 1 2
X108.f 1 2
=ENGI/20.6 / X1.B:11
BW 220 D-5
+MOT
1
R23 2
121Ω/0,6W
1 2
Splice X73
Spleiss 10
X73 1 2
1
B124 2
BN
6 mm²
=ENGI/20.2 / X1.B:3
=ENGI/20.2 / X1.B:5
=ENGI/20.3 / X1.B:8
=ENGI/20.3 / X1.B:6
=ENGI/20.6 / X1.B:12
=ENGI/20.7 / X1.B:10
=ENGI/20.7 / X1.B:13
!!! There is still power supply
even if the battery
disconnector switch is turned
Ubat
CAN 2 high
CAN 2 low
CAN 1 high
CAN 1 low
31-GND
off Sensor, water separator fuel
!!! Auch bei ausgeschaltetem Sensor Wasserabscheider Kraftstoff
A M F H G K B
Batterietrennschalter unter
Spannung
X32
X22
CAN 1 = Diagnosis CAN
CAN 2 = Customer CAN
Diagnosis interface EMR

Diagnoseschnittstelle EMR
=SUPL/8.5 / 31_EMR
0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage =ENGI3 Blatt21 von
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Deutz TCD 2012 Tier 3 Mounting location Kind of Document
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Deutz TCD 2012 Tier 3 643 EPE /00
-A48
D2
Engine-controller EMR3 (EDC 16) Harness Engine interface - Engine internal
D2.1 (A) D2.2 (K)

D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1
-A48 16 47 31 48 32 33 46 1 -A48 16 47 31 48 32 1 24 34 21
X44 16 47 31 48 32 33 46 1 X44 3 6 4 9 5 2 24 34 21
D2.1 D2.1
X41 2 3 5
X41 2 3 5 -X41 = Plug, access pre-heating relay

+MOT Male pin Stecker Anschluß Vorglührelais
X17 X17 X23
-X46 34 35 40 37 41 36 39 42 -X46 34 35 40 37 41 42
BW 220 D-5
X108.m 8 7 6
X108.f 8 7 6
-Y147 1 -Y149 1 -Y148 1 Y147 2 Y166 2
K14:2 K14:1 K14:3

X46 = Plug, engine EMR Y15.1 2 Y15.3 2 Y15.5 2 Y15.1 1 Y15.3 1 =ENGI/18.3
=ENGI/18.3
=ENGI/18.4
Male pin Stecker Motor EMR
X17
-Y170 1 -Y169 1 -Y166 1 Y149 2 Y148 2
Y15.2 2 Y15.4 2 Y15.6 2 Y15.2 1 Y15.4 1
Injector A1 Injector A3 Injector A2 Injector A1 Injector A4

Injektor A1 Injektor A3 Injektor A2 Injektor A1 Injektor A4
Cylinder 1 Cylinder 3 Cylinder 2 Cylinder 1 Cylinder 4
Zylinder 1 Zylinder 3 Zylinder 2 Zylinder 1
Injector A5 Injector A6 Injector A4 Injector A3 Zylinder 4 Injector A2
Injektor A5 Injektor A6 Injektor A4 Injektor A3 Injektor A2
Cylinder 5 Cylinder 6 Cylinder 4 Cylinder 3 Cylinder 2
Zylinder 5 Zylinder 6 Zylinder 4 Zylinder 3 Zylinder 2
at Deutz TCD 2012 L 06 at Deutz TCD 2012 L 04

bei Deutz TCD 2012 L 06 bei Deutz TCD 2012 L 04
0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage =ENGI3 Blatt22 von
101
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Deutz TCD 2012 Tier 3
837
643 EPE /00
838
Circuit diagrams
-A48
D2 Harness Engine interface - Engine internal
Engine-controller EMR3 (EDC 16)
D2.1 (A) D2.2 (K)

-A48
D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1
-A48 56 13 51 43 8 26 10 50 20 27 12 7 58 41 11 57 54 23 53 14 40 19 49
X44 56 13 51 43 8 26 10 50 20 27 12 7 58 41 11 57 54 23 53 14 40 19 49
D2.1
+MOT X17
X46 26 33 27 25 31 32 14 13 9 15 21 1 30 24 10 17 16 28 29 22 23 19 20
BW 220 D-5
1 1 1 1 1
1 1
2 2 2 2 2 -Y137
-B133
n n 3 B48 Y19
-B88 -B93 -B114 -B130 2
4 3 3 3 2 -B113
B6 B49 B40.1 B40.2 4 -B145
B43 B51
sensor engine oil pressure sensor fuel pressure rail sensor engine speed sensor engine speed temperature sensor coolant pressure sensor fuel sensor charge air pressure and temperature solenoid valve adjustment EMR
Sensor Motoröldruck Sensor Raildruck Kraftstoff Sensor Motordrehzahl Sensor Motordrehzahl Temperatursensor Kühlmittel Drucksensor Kraftstoff Sensor Ladeluftdruck und Temperatur Magnetventil Arretierung EMR
Camshaft Crankshaft
Nockenwelle Kurbelwelle
0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage =ENGI3 Blatt 23 von
101
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Deutz TCD 2012 Tier 3 643 EPE /00
+ARC
D+ Alternator Coolant level Water in Fuel Maintenance switch, air cleaner Hydraulic oil filter Warning buzzer, breakdown Fuel level
D+ Generator Kühlmittelfüllstand Wasserabscheider Wartungsschalter Luftfilter Hydraulikölfilter Warnsummer Betriebsstörung Tankfüllstand
AIN_7 DIN_11 DIN_5 DIN_7 +ARC-H07:+
DOUT1 AIN 2
DIN_9
A34 A34 A34 A34 A34 A15 A15
AIN7 / 10V 25mA DIN11 / 0..32V DIN5 / 0..32V DIN9 / 0..32V DIN7 / 0..32V +UB, max 1,5A 0...140Ω
X35 9 X35 39 X35 36 X35 38 X35 37 X33 3 2
X35 9 X35 39 X35 36 X35 38 X35 37 X33 3 X33 2
X4.A 5
X4.A 5
X5.A 10
X101.m 1 2 3 X103 11
X5.A 10 X2.A 15
X101.f 1 3 X103 11
X2.A 15
=SUPL/8.6 / D+ D+ / =OPT/44.1
+REFR
X11 1
1
+MOT +REFR
BW 220 D-5
X72.f 1
X69 2
X72.m 1 XB03
1 1
1 3 (1) +
3
B55 B03 P B21 P H07 R03
4
2 4 (2) 70mA - BW 211-216 = 66 Ω 2
2 2 BW 219-226 = 64,2 Ω
X72.m XB03
X69 3
X72.f 2
X11 2
=ENGI/18.8 / 31_Eng 31_Eng / =OPT+CAB/47.1
=SUPL/14.2 / 31_Db_2 31_Db_2 / =DRIV+SEAT/26.0
=DRIV+REFR/28.2 / 31_RFr.2
Floating switch, coolant expansion tank Maintenance switch, air cleaner Warning buzzer, breakdown Sender, level gauge
Schwimmerschalter Kühlmittelausgleichsbehälter Wartungsschalter Luftfilter Warnsummer Betriebsstörung Geber Tankanzeige
Differential pressure switch, hydraulic oil filter
Differenzdruckschalter Hydraulikölfilter
0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage =MON Blatt24 von
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Monitoring, Failure indicators Mounting location Kind of Document
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Überwachung, Störmeldungen
839
643 EPE /00
840
=SUPL/13.9 / FM1
=SUPL/10.9 / F91:2 F91:2 / +REFR/27.1
=ENGI/20.8 / Gnd_PB Gnd_PB / +REFR/29.2
=SUPL/14.7 / 31_Ar 31_Ar / =EXC/32.1
=SUPL/11.9 / 31_DCtrl 31_DCtrl / +REFR/28.1

Circuit diagrams
=SUPL/13.3 / AGND AGND / =VIB/31.1

1 1
=COM/15.9 / AGND_DC V07 V09
Only at DH-Version S1M 2 S1M 2
=SUPL/11.1 / B57:2 Nur bei DH-Version
1 1
V08 V10
S1M 2 S1M 2
X2.A 12 14 9 13 X5.A 2 16 1
B57
0,5-4,5V
sensor slope speed range selection 1 2 3
X106:1 / =VIB/31.1
Splice
Neigungssensor Stufenumschaltung Spleiss 41
- + S
X14 A X106:5 / =VIB/31.1
X14 A +REFR X104 1 2 3 4 X105:11 / =VPL/35.1

BK -
+SEAT 1 5
4+
S06 B60 3 speed
Switch, seat contact 4 2 Speed sensor, axle +DRUM
Sitzkontaktschalter Drehzahlsensor 2
BU BN
Achsgeschwindigkeit dir Only at DH-Version
X14 B C
Nur bei DH-Version
X14 B
W3 3 4
7x1
-
BW 220 D-5
5
+4
B59
speed 3
X2.A 1 X2.A 4 Speed sensor, drum
2 Drehzahlsensor
dir Bandagengeschwindigkeit
X7.C 11 X7.C 10
5 6 W3
X7.C-2 11 X7.C-2 10 7x1
X4.B 2
X7.C-2 11 X7.C-2 10
X5.B 10 X5.B 6 X5.B 5
X100 1 X104 5 6
X35 32 X35 15 X35 16 X35 13 X35 12 X35 35 X35 17
X35 32 X35 15 X35 16 X35 13 X35 12 X35 35 X35 17

AIN8 / 10V 25mA DIN8 / 0..32V DIN10 / 0..32V, DRZ DIN4 / 0..32V DIN2 / 0..32V, DRZ DIN3 / 0..32V, DRZ DIN12 / 0..32V
A34 A34 A34 A34 A34 A34 A34
AIN_8 DIN_8 DIN_10 DIN_4 DIN_2 DIN_3 DIN_12
Slope sensor Seat contact Proximity switch, arm rest right Direction axle Speed axle Speed drum Direction drum
Neigungssensor Sitzkontakt Näherungsinitiator Armlehne rechts Drehrichtung Achse Geschwindigkeit Achse Geschwindigkeit Bandage Drehrichtung Bandage
0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage =DRIV Blatt25 von
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Slope sensor, Speed sensors Mounting location Kind of Document
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Neigungssensor, Geschwindigkeitsaufnehmer 643 EPE /00
+ARC
+ARC
at DH Version at D Version
bei DH Version bei D Version
BTS_Brake
+REFR/29.1
switch vibration front switch vibration low high
-XS09.13
-XS35.13
-XS35.23
Schalter Vibration vorne 1 Schalter Vibration klein gross 1 1
13 13 23
low
0
high
S09 -S35
14 14 24 3
Switch, speed range selector X23
S42 Schalter Fahrstufen 1 1 1
X23.B 3
-XS09.14
-XS35.14
-XS35.24
12 Steps at DH, 5 Steps at D
12 Stufen bei DH, 5 Stufen bei D Only at BVC Not at BVC
4..20mA / 0-5V Nur bei BVC Nicht bei BVC
87
0V 9-30V 0-20mA 0,5-4,5V 0V +5V
1 2 3 6 4 5 -K189
/26.9 30
X23:5 / =EXC+EBOX/32.1 +EBOX
XS42 1 2 3 6 4 5
X26 3
X102 6 7
31_Db_2 31_Db_2 3 =SUPL+EBOX/14.6 / K189:30
=MON+EBOX/24.8 =OPT+EBOX/42.0
-XS36.13
S139 1
Potentiometer, + 13
+EBOX X102 1 2 3 4 X102 5 frequency plates -S36 =SUPL+EBOX/14.6 / K189:85
Potentiometer Splice
switch vibration 14 Spleiss 50
Frequenzverstellung - S
Schalter Vibration
Anbauplatten 1
15_Ar 1 2 85
=SUPL+EBOX/14.7 Splice
87 30
Spleiss 49 -K189
-XS36.14
X26 1 2 12V/10A 86 /26.9
relay brake
Splice Relais Bremse
Spleiss 47 5
X23
11 8 12
BW 220 D-5
X23 X23 5
X23
X23.B
4 11 8 2 12
X23.B X23.B X23.B X23.B
-R40 resistor
18,2Ω/0,6W Widerstand
1
X23.A 4 X23.A 11 X23.A 8 X23.A 5 X23.A 12 X24 4 X24 1 X24 2 X23.A 3
X23 11 X23 8 X23 5 X23 12 X24 4 X24 1 X24 2 X23 3
Analog IN 1 Ground / 0V / reference to PIN 5 Output voltage supply "+5V" Analog IN 2 Digital IN 4 Digital IN 1 Digital IN 2 Signal "Brake"
S55
AK Ext 1 AGND 1 Uext 1 AK Ext 2 DK Ext 4 DK Ext 1 DK Ext 2 Brake
+ARC-S42:6 -S55:X23:5 -S36:14 +ARC-S35:14 +ARC-S35:24 -K189:86

Switch, speed range selector 2 Ground analog selectors Supply analog selectors Frequency adjustment plates Vibration plates Switch, vibration low/off (on/off) Switch, vibration off/high relay brake
Schalter Fahrstufen 2 Masse Analoge Wahlschalter Versorgung Analoge Wahlschalter Frequenzverstellung Anbauplatten Vibration Anbauplatten Schalter Vibration klein/aus (an/aus) Schalter Vibration aus/groß Relais Bremse
At dozer blade At vibratory plate

Bei Planierschild Bei Vibrationsplatte
0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage =DRIV Blatt 26 von
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Travel lever Mounting location Kind of Document
Einbauort +SEAT Dokumentenart &EFS
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Fahrhebel
841
643 EPE /00
842
+EBOX
+EBOX/25.9 / F91:2 F91:2 / =MEAS+EBOX/37.1
X2.A 10 at D Version
bei D Version
+REFR-X25 5
Circuit diagrams
+PUMP
Only at DH-Version Y16
Nur bei DH-Version Splice
Spleiss 73
Y07
X55 1 X56 1 X57 1 X58 1
A 1 B 1 C 1 D 1
B234 P B235 P B236 P B237 P

Pressure sensor, travel Pressure sensor, travel Pressure sensor, travel Pressure sensor, travel
pump axle MA 2 pump axle MB 2 pump drum MA 2 pump drum MB 2
Drucksensor Fahrpumpe Drucksensor Fahrpumpe Drucksensor Fahrpumpe Drucksensor Fahrpumpe
Achse MA Achse MB Bandage MA Bandage MB
right - front left - front right - back left - back
Y17
rechts - vorne links - vorne rechts - hinten links - hinten
Y08
X55 2 X56 2 X57 2 X58 2
at DH Version
BW 220 D-5
-X25 1 2 3 4 bei DH Version
B234
B236 (X55)
+EBOX (X57)
X103 1 2 3 4
Y16
X35 6 X35 7 X35 29 X35 30 Y73

X35 6 X35 7 X35 29 X35 30
AIN1 / 10V 25mA AIN3 / 10V 25mA AIN2 / 10V 25mA AIN4 / 10V 25mA
A34 A34 A34 A34 Y07
AIN_1 AIN_3 AIN_2 AIN_4
Pressure sensor, travel pump axle MA Pressure sensor, travel pump axle MB Pressure sensor, travel pump drum MA Pressure sensor, travel pump drum MB
Y17
Drucksensor Fahrpumpe Achse MA Drucksensor Fahrpumpe Achse MB Drucksensor Fahrpumpe Bandage MA Drucksensor Fahrpumpe Bandage MB
B235
(X56)
Y72
B237
(X58)
Y08
0 1 2 3 4 5 6 7 8 9
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Pressure sensors Mounting location Kind of Document
Einbauort +REFR Dokumentenart &EFS
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Drucksensoren 643 EPE /00
+EBOX
Travel pump axle forward Travel pump axle backward Travel pump drum forward Travel pump drum backward
Fahrpumpe Achse vorwärts Fahrpumpe Achse rückwärts Fahrpumpe Bandage vorwärts Fahrpumpe Bandage rückwarts
PWM_1 PWM_2 PWM_7 PWM_9
A34 A34 A34 A34

OUT1 / 4A curr.-measur. OUT2 / 4A curr.-measur. OUT14 / 4A curr.-measur. OUT16 / 4A curr.-measur.
X35 46 X35 47 X35 20 X35 21
X35 46 X35 47 X35 20 X35 21
X103 5 6 7 8
BW 220 D-5
-X25 7 8
7 8
+PUMP
1 1 1 1
Y16 Y17 Y72 Y73
Travel pump axle 2 Travel pump axle 2 Travel pump drum 2 Travel pump drum 2
Fahrpumpe Achse C1 Fahrpumpe Achse C2 Fahrpumpe Bandage C2 Fahrpumpe Bandage C1
640...1580mA 640...1580mA 640...1580mA 640...1580mA
Splice
Spleiss 75
Only at DH-Version
Nur bei DH-Version
6
31_RFr.2
=MON+EBOX/24.0 -X25 6
BN Splice
=SUPL+EBOX/8.5 / 31_RFr 10 mm² Spleiss 31_RFr / 29.0
72
+EBOX/25.9 / 31_DCtrl 31_DCtrl / 29.0

Solenoid valve, travel direction forward Solenoid valve, travel direction forward
Magnetventil Fahrtrichtung vorwärts Magnetventil Fahrtrichtung vorwärts
Solenoid valve, travel direction backward Solenoid valve, travel direction backward
Magnetventil Fahrtrichtung rückwärts Magnetventil Fahrtrichtung rückwärts
0 1 2 3 4 5 6 7 8 9
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Travel pumps Mounting location Kind of Document
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Fahrpumpen
843
643 EPE /00
844
+EBOX
BTS brake Travel motor axle Valve brake Travel motor drum
BTS Bremse Fahrmotor Achse Ventil Bremse Fahrmotor Bandage
DO_2 PWM_5 DO_4
DIN_6
A34 A34 A34 A34
DIN6 / 0..32V OUT10 / 2,5A curr.-feedb. OUT5 / 4A curr.-measur. OUT12 / 2,5A curr.-feedb.
X35 14 X35 2 X35 64 X35 3
X35 14 X35 2 X35 64 X35 3

Circuit diagrams
X5.A 21
Relay, travel lever 0-position

Relay, starting current Relais, Fahrhebel 0-Stellung K48
X5.A 14 30
Relais Startstrom 87 /29.3
87 87a 30 /29.5 Relay, travel lever 0-position
87a 30 =ENGI+EBOX/20.8 Relais, Fahrhebel 0-Stellung 87 87a
X4.A 21
X4.B 9
86 1 86 1
K05 K48
D05
D48
green
green
12V/20A 85 2 12V/20A 85 2
+ARC WH
1,5 mm²
Splice
Spleiss 61
XS01.A1
+SEAT/26.9 / BTS_Brake 1
A1
Gnd_PB Gnd_PB -S01
+EBOX/25.9 30.7
=SUPL+EBOX/9.4 A2
X103 9 switch emergency off X103 10 X104 7
1
Schalter Not Aus
WH
1,5 mm²
XS01.A2
X4.A 7
BW 220 D-5
X7.C 12 X2.A 7
+DRUM
X7.C-2 12 1 W3
7x1
Splice Splice
X7.C-2 12 Spleiss 71 Spleiss 70
at DH Version a.
BW 216-219 D
bei DH Version u.
X11 3 4 BW 216-219 D
1
1 1 1 Y30
Y31 Y04 Y30 1,05A
2
1,05A 2,41A 2,41A
2 2 2
at D Version
bei D Version 2 W3
7x1
X11 5 +EBOX-X104 8
BN
1,5 mm²
31_RFr 31_RFr
28.8 30.1
31_DCtrl 31_DCtrl
28.8 =VIB+EBOX/31.1
Solenoid valve, speed range selection axle Solenoid valve, brake Solenoid valve, speed range selection drum Solenoid valve, speed range selection drum
Magnetventil Fahrstufe Achse Magnetventil Bremse Magnetventil Fahrstufe Bandage Magnetventil Fahrstufe Bandage
0 1 2 3 4 5 6 7 8 9
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Brake, Speed ranges Mounting location Kind of Document
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Bremse, Fahrstufen 643 EPE /00
+EBOX
=SUPL+EBOX/9.9 / F23:2
Back-up alarm buzzer Warning horn Relay, shut off solenoid engine
Warnsummer Rückwärtsfahrt Signalhorn Relais Hubmagnet Abschaltung Motor
30
DO_5 DO_3 DO_1
K13 A34 A34 A34
/30.8 87a 87
Relay, warning horn OUT6 / 4A OUT11 / 2,5A curr.-feedb. OUT9 / 2,5A curr.-feedb.
Relais Signalhorn X35 61 X35 25 X35 24
X35 61 X35 25 X35 24
X4.A 2
WH
2,5 mm² X5.A 5 20 17
Splice
Spleiss 26
WH WH
1,5 mm² 1,5 mm²
Rev
=OPT+CAB/48.1
X2.A 2
BW 220 D-5
Only at WH WH Only at
1,5 mm² 1,5 mm²
BW 219-226 -5 BW 219-226 -5
X30 1
Nur bei Nur bei
BW 219-226 -5 BW 219-226 -5
1 1 2 2 1 1 + 86 1 86 1
B11.3 B11.1 V02 V03 B11.2 B11.4 H14 K13 K22
D13
D22
green
green
max. 3,5A 2 max. 3,5A 2 SF 64 1 1 SF 64 2 max. 3,5A 2 max. 3,5A 300mA - 12V/20A 85 2 12V/20A 85 2
BN BN
1,5 mm² 1,5 mm²
X30 2
BN BN
1,5 mm² 1,5 mm²
=SUPL+EBOX/14.2 / 31_Db 31_Db / =OPT+EBOX/41.0
29.9 / 31_RFr 31_RFr

=VIB+EBOX/31.1
Gnd_PB Gnd_PB
29.2 =VIB+EBOX/31.1
87 87
87a 30 /30.3 87a 30 =ENGI+EBOX/20.6
Warning horn Warning horn Warning horn Warning horn Back-up alarm buzzer Relay, warning horn Relay, shut off solenoid engine
Signalhorn Signalhorn Signalhorn Signalhorn Warnsummer Rückwärtsfahrt Relais Signalhorn Relais Hubmagnet Abschaltung Motor
0 1 2 3 4 5 6 7 8 9
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Warning horns, Back up alarm, Mounting location Kind of Document
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Warnhörner, Rückfahralarm,
845
643 EPE /00
846
=DRIV/25.9 / X106:5
=DRIV/25.9 / X106:1
=DRIV/25.9 / AGND
Speed vibration drum Vibration pump low/high Vibration pump PWM

Circuit diagrams
Drehzahl Vibration Bandage Vibrationspumpe klein/groß Vibrationspumpe PWM
DIN_1 PWM_3 PWM_4

A34 A34 A34
DIN1 / 0..32V, DRZ OUT3 / 4A curr.-measur. OUT4 / 4A curr.-measur.
X35 34 X35 48 X35 49
X35 34 X35 48 X35 49
X106 2 1 5 3
X5.B 8 X5.B 1
BW11RH - K78 30
K43
/31.4 87 87a
Relay, vibration
Relais Vibration
X5.B 9 3
not used today
BW 220 D-5
wird zur Zeit nicht genutzt
X103 12 13
86 1 +PUMP 1 1
BW11RH - K78
K43 Y07 Y08
D43
green
12V/20A 2 640...1580mA 2 640...1580mA 2
85
C1 C2
X106 6
=DRIV+REFR/29.9 / 31_DCtrl 31_DCtrl / =DBL/34.1
=DRIV+REFR/30.6 / 31_RFr 31_RFr / =OPT/42.0
=DRIV+REFR/30.9 / Gnd_PB Gnd_PB / =OPT/41.0
87
87a 30 /31.5
Relay, vibration Solenoid valve, vibration front high Solenoid valve, vibration front low
Relais Vibration Magnetventil Vibration vorne gross Magnetventil Vibration vorne klein
0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage =VIB Blatt31 von
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Vibration Mounting location Kind of Document
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Vibration 643 EPE /00
+SEAT
=DRIV+SEAT/26.5 / X23:5
=DRIV/25.9 / 31_Ar 31_Ar / =OPT+CAB/47.1
=SUPL/14.7 / 15_Ar
-XS107
2
-XS439.13
XS439.A1
1 1
2+ -
123 13 A1
1 -XS107
S107 1 S439
switch amplitude adjustment 14 A2
3S
Schalter Amplitudenverstellung switch amplitude limiting
1 1
12 steps 3 Schalter Amplitudenbegrenzung
12 Stufen
4..20mA
-XS107
XS439.A2
-XS439.14
X4.B 8
X5.E 14
BW 220 D-5
X5.E2 14
X5.E2 14
X5.E 14
X88 32 5 6
X24
X88 32 X24 5 X24 6
AIN8 / 10V 25mA Digital IN 5 Digital IN 6
A83 S55 S55
AIN_8 DK Ext 5 DK Ext 6
+SEAT-S107:3 +SEAT-S439:14 +SEAT-S439:A2

switch amplitude adjustment switch amplitude limiting switch amplitude limiting
Schalter Amplitudenverstellung Schalter Amplitudenbegrenzung Schalter Amplitudenbegrenzung
Only at BVC
Nur bei BVC
0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage =EXC Blatt32 von
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Variocontrol Mounting location Kind of Document
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Variocontrol
847
643 EPE /00
848
=SUPL/13.9 / FM2
X5.E 11
X5.E2 11
X5.E2 11
X5.E 11
Circuit diagrams
X107 7
+DRUM Exciter up Exciter down Exciter priority

X86:2 Erreger auf Erreger ab Erreger Priorität
=MEAS/37.1
W1
12x0,75 9 10 PWM_2 PWM_1 DO_5
A83 A83 A83
OUT2 / 4A curr.-measur. OUT1 / 4A curr.-measur. OUT6 / 4A
X86 1 X88 47 X88 46 X88 61
RD 47 46 61
B97 + X86 X88 X88
Sensor, - 2
BK
adjustable
motor
Sensor S
WH
Verstellmotor
X86 3
X107 9 10 11
W1
12x0,75 11
+DRUM
BW 220 D-5
W2
X107 8
7x1 1 3
1 1
Y140 Y141
400-1200mA 2 400-1200mA 2
X88 9 b1 (v.r.) a1 (v.l.)
X88 9 -W2 2 4
AIN7 / 10V 25mA 7x1
A83
AIN_7 Splice
Y140
Spleiss 8 Y141
+DRUM-B97:S BN
1,5 mm²
Sensor, adjustable motor
Sensor Verstellmotor
X107 12
BN
=SUPL/12.9 / 31_MCtrl 1,5 mm²
Solenoid valve, exciter up Solenoid valve, exciter down

Magnetventil Erreger auf Magnetventil Erreger ab
Only at BVC
Nur bei BVC
0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage =EXC Blatt33 von
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Variocontrol Mounting location Kind of Document
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Variocontrol 643 EPE /00
Dozer blade priority Floating position dozer blade Dozer blade up Dozer blade down Adjustment left plates Adjustment right plates
Planierschild Priorität Schwimmstellung Planierschild Planierschild anheben Planierschild absenken Verschiebung links Platten Verschiebung rechts Platten
DO_6 DO_9 PWM_6 PWM_8 DO_10 DO_11

A34 A34 A34 A34 A34 A34
OUT7 / 2,5A curr.-feedb. OUT20 / 2,5A curr.-feedb. OUT13 / 4A curr.-measur. OUT15 / 4A curr.-measur. OUT21 / 5A curr.-feedb. OUT22 / 5A curr.-feedb.
X35 62 X35 11 X35 42 X35 43 X35 50 X35 51
X35 62 X35 11 X35 42 X35 43 X35 50 X35 51
X5.E 10
X105 1 2 3 4 5 6
X105:1 / =VPL+REFR/36.0
X5.A 7 X105:2 / =VPL+REFR/36.0
X105:3 / =VPL+REFR/36.0
Y379
X105:4 / =VPL+REFR/36.0
Y378 +DRUM X105:5 / =VPL+REFR/36.0
W4
X105:6 / =VPL+REFR/36.0
12x0,75 1 3 5 7
BW 220 D-5
Y380
1 1 1 1
Y102 Y378 Y102 Y379 Y380
2 2 2 2
W4
12x0,75 2 4 6 8
Splice
Spleiss 2
BN
1,5 mm²
X105:7 / =VPL+REFR/36.0
X105:10 / =VPL/35.1
X105:12 / =VPL/35.1
X105 7 10 12
BN BN BN
1,5 mm² 1,5 mm² 1,5 mm²
=VIB/31.8 / 31_DCtrl
Solenoid valve, dozer blade priority Solenoid valve, lift dozer blade
Magnetventil Planierschild Priorität Magnetventil Planierschild heben
Solenoid valve, floating position Solenoid valve, lower dozer blade
Magnetventil Schwimmstellung Magnetventil Planierschild senken
0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage =DBL Blatt34 von
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Dozer blade Mounting location Kind of Document
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Planierschild
849
643 EPE /00
850
X105 11 Splice 22
=DRIV/25.9 / X105:11 Spleiss
Splice 23
=DBL/34.8 / X105:12 Spleiss
+REFR
W8 X28 2 1 W7 X29 2 1
BINDER Sensorcable M12 90° BINDER Sensorcable M12 90°
2 1 2 1
4x0,5 BU BN 4x0,5 BU BN
Circuit diagrams
- (bu) - (bu)
3 3
1 1
B312 + (bn) B313 + (bn)
Sensor, height adjustment plates Sensor, lateral adjustment plates
Sensor Höhenverstellung Platten 4 Sensor Seitenverstellung Platten 4
4...20mA S (bk) 4...20mA S (bk)
W8 BK W7 BK
4x0,5 3
4x0,5 3
X28 3 X29 3
13 14
X105 13 X105 14
Hour meter plates Plate pump enable Vibration pump plates

Stundenzähler Platten Freigabe Plattenpumpe Vibrationspumpe Platten
8 X35 31
+PLA DO_7 X35 DIN_18 PWM_11
X35 8 X35 31
View from plate side AIN5 / 10V 25mA AIN6 / 10V 25mA
Ansicht von Plattenseite A34 A34 A34 A34 A34
OUT8 / 2,5A curr.-feedb. AIN_5 DIN18 / 0..32V AIN_6 OUT18 / 4A curr.-measur.
X35 63 X35 10 X35 22
X35 63 X35 10 X35 22

Sensor, height adjustment plates Sensor, lateral adjustment plates
Sensor Höhenverstellung Platten Sensor Seitenverstellung Platten
BW 220 D-5
X105 9 X105 15 X105 8
+REFR
X29 4 X29 5
X27 4 5
W6
1 3x0,75 BK GY
3
2
-X27 3 X27 +MOT
2
1
1
Plug, quick connect coupling plates W9
X27 = Stecker Schnellverschlußkupplung Platten Y98
2X0,75 2 1
400-1200mA 2
Solenoid valve, vibration pump plates
W6 Magnetventil Vibrationspumpe Platten
+
3x0,75 BN
P43
Operating hour meter 6
h plates
Betriebsstundenzähler X29
- 6
Platten
BN Splice
=DBL/34.8 / X105:10 1,5 mm² Spleiss
24
0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage =VPL Blatt35 von
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Vibratory plate compactor Mounting location Kind of Document
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Anbauplatten 643 EPE /00
+EBOX
Floating position plates

Schwimmstellung Anbauplatten
DO_8
A34
OUT19 / 2,5A curr.-feedb.
X35 45
X35 45
X105 16
=DBL+EBOX/34.8 / X105:2
=DBL+EBOX/34.8 / X105:1
=DBL+EBOX/34.8 / X105:6
Y145
=DBL+EBOX/34.8 / X105:5
Y143
=DBL+EBOX/34.8 / X105:4
BW 220 D-5
=DBL+EBOX/34.8 / X105:3 Y142
Y122
Y123
1 1 1 1
Y122 Y142 Y145 Y144
b1 a2 a c2
2 2 2 2
1 1 1
Y123 Y143 Y60
a1 b2 c1
2 2 2
Y144
Y60
BN Splice
=DBL+EBOX/34.8 / X105:7 2,5 mm² Spleiss
25
Solenoid valve, lift plates Solenoid valve, plate displace left Solenoid valve, plate (priority) Solenoid valve, plate floating position
Magnetventil Platten heben Magnetventil Plattenverschieben links Magnetventil Platten (Priorität) Magnetventil Platten Schwimmstellung
Solenoid valve, let down plates Solenoid valve, plate displace right Solenoid valve, floating position
Magnetventil Platten senken Magnetventil Plattenverschieben rechts Magnetventil Schwimmstellung
0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage =VPL Blatt36 von
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Vibratory plate compactor Mounting location Kind of Document
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Anbauplatten
851
643 EPE /00
852
=SUPL/13.6 / AGND_MC
=DRIV+REFR/27.4 / F91:2
X5.E 7
X5.E2 7
X5.E2 7
Circuit diagrams
X5.E 7
RxD Printer TxD Printer Power supply GPS

RxD Drucker TxD Drucker Spannungsversorgung GPS
X107 1 2
RxD TxD DO_3
A83 A83 A83
RxD_1 TxD_1 OUT11 / 2,5A curr.-feedb.
+DRUM WH WH X88 4 X88 5 X88 25
1,5 mm² 1,5 mm²
Splice
Spleiss 7 X88 4 X88 5 X88 25
=EXC/33.6 / X86:2
Splice
Spleiss 6
W1
LÜTZE SUPERFLEX® N PUR
12x0,75 1 2 5 6
X5.E 5 3 8
X5.E2 5
X20 1 2 X21 1 2
BK GNYE BK GNYE
+ +
- - X5.E2 5 3 8
B62 B171
BW 220 D-5
15g 15g
X5.E 5 3 8
front 20g rear 20g
vorne hinten
BN BU BN BU
Transducer, acceleration
Transducer, acceleration
Aufnehmer Beschleunigung
Aufnehmer Beschleunigung
X20 4 3 X21 4 3
15_GPS / =OPT+CAB/48.1
TxD / =OPT+CAB/48.1
W1
RxD / =OPT+CAB/48.1
12x0,75 4 3 8 7
X107 3 4 5 6
X88 31 X88 29 X88 7 X88 30
X88 31 X88 29 X88 7 X88 30

AIN6 / 10V 25mA AIN2 / 10V 25mA AIN3 / 10V 25mA AIN4 / 10V 25mA
A83 A83 A83 A83
AIN_6 AIN_2 AIN_3 AIN_4
Transducer Acceleration front 20g Transducer Acceleration front 15g Transducer Acceleration rear 20g Transducer Acceleration rear 15g
Beschleunigungsaufn. vorne 20g Beschleunigungsaufn. vorne 15g Beschleunigungsaufn. hinten 20g Beschleunigungsaufn. hinten 15g
0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage =MEAS Blatt37 von
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Measurement equipment Mounting location Kind of Document
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Messtechnik 643 EPE /00
Splice 17
=COM/15.8 / X5.E:12 Spleiss X5.E:12 / 39.1
Splice 18
=COM/15.8 / X5.E:15 Spleiss X5.E:15 / 39.1
Splice 1
=SUPL/12.1 / X5.E:4 Spleiss X5.E:4 / 39.1
+REFR
XA103 1 XA103 2
XA103 1 XA103 2
CAN low CAN high
A103
A103 CANL CANH
module ECONOMIZER
Modul ECONOMIZER
XA103 13 CAN low CAN high
XA103 13 CAN low CAN high
Power supply (8...32V) Supply 5V sensors Transducer acceleration Ground Ground
A103 Versorgung 5V Sensoren Beschleunigungsaufnehmer Masse Masse
UE
5Vana_REF Analog_IN0 GND GND

Power supply A103 A103 A103 A103
Stromversorgung +5V supply Sensors 0...5V Ground Ground
Ground XA103 6 XA103 5 XA103 24 XA103 25
Masse XA103 6 XA103 5 XA103 24 XA103 25
Shielding
Schirm 9
GND
A103
Ground W18
XA103 26 3x0,75 1 2 3 SH
XA103 26
-XA103 Shielding
Plug, monitoring module Schirm 10
Stecker Überwachungsmodul
BW 220 D-5
+EBOX X109.m 1 2 3 4
X109.f 1 2 3 4
Shielding
Schirm 7
W17
3x0,75 1 2 3 SH
+DRUM Shielding
Schirm 8
X39 1 2 3 4
=SUPL/8.5 / 31_Econ 31_Econ / 39.1 1 2 3 4

WH
0,5
1 GNYE 2 SH
3x0,5
+
-B84 OUT
sensor acceleration left
Sensor Beschleunigung links -
0 1 2 3 4 5 6 7 8 9
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Economizer Mounting location Kind of Document
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Economizer
853
643 EPE /00
854
38.8 / X5.E:12
38.8 / X5.E:15
38.8 / X5.E:4
Circuit diagrams
A161
module CAN Gateway
Modul CAN Gateway
XA161 2 XA161 4 XA161 8 XA161 7 XA161 9

2 4 8 7 9
Power supply (9-30V) Analog Input 1 Analog Input 2 Can high 1 Can low 1
-A161 -A161 -A161 -A161 -A161
30 - Vcc 15 AE H1 L1
Power supply Power supply Configuration CAN high IN CAN low IN

Stromversorgung Stromversorgung Konfiguration CAN high Eingang CAN low Eingang
Ground CAN high OUT CAN low OUT

Masse CAN high Ausgang CAN low Ausgang
31 - Gnd H2 L2
-A161 -A161 -A161
Ground Can high 2 Can low 2
BW 220 D-5
6 1 3
XA161 6 XA161 1 XA161 3
Only at option preliminary setup VM31/VM38

Nur bei Option Vorrüstung VM31/VM38
38.2 / 31_Econ
=COM/16.9 / X5.E:1
=COM/16.9 / X5.E:2
0 1 2 3 4 5 6 7 8 9
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Economizer Mounting location Kind of Document
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Economizer 643 EPE /00
RD
=SUPL/9.9 / X7.C:1 1,5 mm²
=COM/16.9 / X5.E:2_2
=COM/16.9 / X5.E:1_2
WH
=SUPL/10.9 / X7.C:2 1,5 mm²
WH
1,5 mm²
WH
1,5 mm²
A162 -XA162 2 -XA162 4 -XA162 7 -XA162 9

module CAN Gateway 2 4 7 9
Modul CAN Gateway Power supply (9-30V) Analog Input 1 Can high 1 Can low 1
-A162 -A162 -A162 -A162
30 - Vcc 15 H1 L1
+DPL-X400:B
Power supply Power supply CAN high IN CAN low IN
Stromversorgung Stromversorgung CAN high Eingang CAN low Eingang
Ground Ground CAN high OUT CAN low OUT +DPL

Masse Masse CAN high Ausgang CAN low Ausgang
-A162:6
31 - Gnd AE H2 L2
-A162 -A162 -A162 -A162
Ground Analog Input 2 Can high 2 Can low 2
6 8 1 3
-XA162 6 -XA162 8 -XA162 1 -XA162 3
X110 X400
1 WH A
1,5 mm²
BW 220 D-5
R33 + Ub pot. 30
1 2 2 WH B
1,5 mm²
+ Ub pot. 15
121Ω/0,6W
5 F
CAN low
1 D
R34 CAN high
121Ω/0,6W E
2
4 Gnd
BN BN 3 BN
1,5 mm² 1,5 mm² 1,5 mm²
BN
1,5 mm²
=SUPL/8.7 / X7.C:4
0 1 2 3 4 5 6 7 8 9
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Interface measurement Mounting location Kind of Document
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Schnittstelle Messtechnik
855
643 EPE /00
856
=SUPL/9.9 / F22:2 +ARC
S26:13 / 42.0
=SUPL/9.9 / F19:2
=SUPL/10.9 / F05:2
+CAB/48.1
X4.E:9
Circuit diagrams
13
-S26
switch working lights rear 14
Schalter Arbeitsbeleuchtung hinten
Access without StvZO
illumination.
At cabin not connected X33 5
Anschluss ohne StvZO
Beleuchtung. Bei Kabine nicht
angeschlossen X33 5
active high
A15
X4.E 16 18
DIN1
X4.A 15
Illumination
X7.C-2 6 Beleuchtung
X22
X7.C-2 6
2 X7.C 6
X6.B 2 4 1
1 X22
+DPL +ROPS
WH WH
1,5 mm² 1,5 mm²
BW 220 D-5
1 1 1 1
E23 E25 E27 E28
12V 55W 2 12V 55W 2 12V 55W 2 12V 55W 2
+ 86 1
XS K06
green
D118
12V / max. 20A 12V/30A 2

- 85
BN
2,5 mm²
X22 2
Splice
Spleiss 87
BN
2,5 mm²
=DRIV+REFR/30.5 / 31_Db 31_Db / 42.0 X4.E 3 6
=VIB/31.8 / Gnd_PB Gnd_PB / 42.0
87
87a 30 =SUPL/9.4
Socket Working headlight, front left Working headlight, rear left Relay, headlights rear
Steckdose Arbeitsscheinwerfer vorne links Arbeitsscheinwerfer hinten links Relais Scheinwerfer hinten
Working headlight, front right Working headlight, rear right
Arbeitsscheinwerfer vorne rechts Arbeitsscheinwerfer hinten rechts
0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage =OPT Blatt41 von
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Rops - Lighting, Socket Mounting location Kind of Document
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Rops - Beleuchtung, Steckdose 643 EPE /00
=SUPL/9.9 / F07:2
=SUPL/10.9 / F08:2
X4.D 6
=SUPL/9.9 / F11:2 +ARC
+ARC
=SUPL/8.9 / S15:23
=SUPL/8.9 / S15:11
30 13 23 ‎
0 ‎
13 23
K16 -S14 -S37
WH Indicator lights
1,5 mm² /42.3 87a 87 switch hazard light 14 24 switch indicator 14 24
23 Relay, headlights front Schalter Blinker Schalter Blinker
012 31 11
Relais Scheinwerfer vorne Warnblinkanlage DIN2
-S15
32 12 24
switch lighting StVZO
Schalter Beleuchtung StVZO A15
X4.D 5 2 8
Access without StvZO illumination

X4.A
Anschluss ohne StvZO Beleuchtung

11 EN_WL active high
41.9 / S26:13
WH +CAB/48.1 X33 8
1,5 mm² X1
-H06 X33 8 -A2
12V 12V Wb LE RE 30
X2
module flasher
X4.D 7 Modul Blinker LA RA 31
X4.D 10 1
1 1
V052 1 X4.A 6
Fuse, parking and tail Fuse, parking and tail
light left F09 light right F10 X4.A
2 1 4
Sicherung Park- und 10A Sicherung Park- und 10A RB Wb
2 2
Schlussleuchte links Schlussleuchte rechts V06 31
Meldeleuchte Warnblinker
indicator light hazard light
RA
LA 30
WH LE
X2.B 2 X4.D 12 X4.D 9 X2.B 3 1,5 mm²
X4.D 3 X2.B 1 X4.D 11 X2.B 4
+REFR X11 6 X11 9

+DPL Splice
Spleiss 4 X11 7 X11 10
Splice
Spleiss 5
BW 220 D-5
X80 3 +DPL X81 3
X79 3 X82 3
/42.5 /42.5 X80 1 X81 1
1 1 1 1 86 1 87a 87
X79 5 X82 5 X79 2 X82 2
E13 E12 E14 E15 K16
D16
green
/42.5 /42.5 /42.5 /42.5
LED 2 5W 2 5W 2 LED 2 12V/20A 2 30 1 1 1 1 1 1
85
E16 E17 E08 E09 E10 E11
/42.4
55W 2 55W 2 21W 2 21W 2 21W 2 21W 2
X80 4 X81 4
X79 6 X82 6 2 2
/42.5
X80 X81
BN /42.5 BN
1,5 mm² 1,5 mm²
41.1 / 31_Db 31_Db

+CAB/47.1
31_Db_2
+REFR
+REFR
=DRIV+SEAT/26.2 X11
31_RFr BN 11 BN Splice
1,5 mm² 1,5 mm² Spleiss
=VIB/31.8 64
BN 8 BN Splice
1,5 mm² 1,5 mm² Spleiss
63
41.9 / Gnd_PB Gnd_PB

43.1
Tail light, left Parking light, right Relay, headlights front Headlight, left Indicator, front left Indicator, front right
Schlussleuchte links Parkleuchte rechts Relais Scheinwerfer vorne Scheinwerfer links Blinkleuchte vorne links Blinkleuchte vorne rechts
Parking light, left Tail light, right Headlight, right Indicator, rear left Indicator, rear right
Parkleuchte links Schlussleuchte rechts Scheinwerfer rechts Blinkleuchte hinten links Blinkleuchte hinten rechts
0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage =OPT Blatt 42 von
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 StVZO illumination Mounting location Kind of Document
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 StVZO Beleuchtung
857
643 EPE /00
858
=COM/17.8 / CAN1+ CAN1+ / +CAB/48.1
=COM/17.8 / CAN1- CAN1- / +CAB/48.1
42.9 / Gnd_PB Gnd_PB / 44.1
=COM/15.9 / F84:2
Circuit diagrams
=COM/17.8 / F148:2
X7.B 3 2 1 4 6
+DPL
A67
Keyboard
Tastatur
BW 220 D-5
X16
1
0 1 2 3 4 5 6 7 8 9
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Electronical Burglary protection Mounting location Kind of Document
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Elektronische Diebstahlsicherung 643 EPE /00
A124
ECU BOMAG TELEMATIC
ECU BOMAG TELEMATIC
+ARC
T14
antenna BOMAG TELEMATIC
Antenne BOMAG TELEMATIC
GPS GSM
GPS GSM
GSM
GPS
CAN_L CAN_H Pot. 30 Pot. 15 IN0 IN1 GND
4 3 12 2 8 11 1
GSM GPS
-XA124 4 3 12 2 8 11 1
BW 220 D-5
X6.D
8 8
=COM/17.8 / CAN2-_TM X6.D:8 / +MOT/45.0
7
=COM/17.8 / CAN2+_TM X6.D:7 / +MOT/45.0
4
=SUPL/10.9 / F243:2 X6.D:4 / +MOT/45.0
1
=SUPL/10.9 / F244:2
2
=MON/24.1 / D+ X6.D:2 / +MOT/45.0
D+ / +CAB/48.1
5
=ENGI/20.8 / StU_TM
6
=ENGI/19.8 / VIB_TM
3
43.9 / Gnd_PB X6.D:3 / +MOT/45.0
0 1 2 3 4 5 6 7 8 9
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 BOMAG Telematics Mounting location Kind of Document
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 BOMAG Telematik
859
643 EPE /00
860
-A175
Electronic system, Morey Telematics
Elektronik Morey Telematik
-A177
ECU ZTR telematics
Circuit diagrams
ECU ZTR Telematik
GPS Diagnostic SAT Cellular
Power
Ground
D+
Can H
Can L
8 10 16 1 2 4 11 12
-XA175 8 10 16 -XA177 1 2 4 11 12
RD WH BK
BW 220 D-5
RD WH BK
-X51 1 3 2
+EBOX/44.5 / X6.D:4
fuse MD+
Sicherung MD+
F129
Splice 88 1 2 Splice 89
+EBOX/44.5 / X6.D:2 Spleiss Spleiss
3A
+EBOX/44.5 / X6.D:3
+EBOX/44.5 / X6.D:7
+EBOX/44.5 / X6.D:8
0 1 2 3 4 5 6 7 8 9
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Morey Telematics, ZTR Telematics Mounting location Kind of Document
Einbauort +MOT Dokumentenart &EFS
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Morey Telematic, ZTR Telematic 643 EPE /00
WH
=SUPL+EBOX/10.9 / F103:2 1,5 mm²
WH
=SUPL+EBOX/9.9 / F68:2 2,5 mm²
A B
F320 F321
5A 1 5A 2
Fuse, timer additional heater Fuse, timer additional heater
(potential 30) (potential 15)
Sicherung Schaltuhr Sicherung Schaltuhr
Zusatzheizung (Potential 30) Zusatzheizung (Potential 15)
Start Low Medium High

POWER
Start niedrig Medium Hoch XS28.f 10
Power consumption
Energiebedarf [W] <100 8 16 30 40
12V
E30
heating unit XS28.f XS28.m 0,35RD
Heizgerät 1 1 0,22GYBK -S28 1 Kl 30
0,22GYBK
Kl 30 2 Kl 58
1 11 11 0,35RD Timer
1 0,22BN
S+ Schaltuhr 3 Kl 31
4 6 6
4 0,22BUWH
Temp. (+) 4 Diagnose
7 9 9
7 0,22VT
DIAG 5 DAT-Leitung
8 8 8 0,22BUWH
8 0,35YE
Temp. (-) 6 S+
6 12 12 0,22BN
6 0,22BNYE
PUMP 7 ADR
5 0,22VT
5 0,22WHRD
Kl 31 8 ADR
10 0,35YE
10 0,22BNWH
0,22BNYE 9 Temp. (-)
0,22GY
0,22WHRD 10 Temp. (+)
0,22BNWH
0,22GY
WH
2,5 mm²
4
X207.m X207.f XS28.f 2
1 RD 1 1
1,5 mm²
4 YE 4 4
0,5 mm²
BW 220 D-5
7 GRRD 7 7
0,5 mm²
8 BUYE 8 8
0,5 mm²
6 BNWH 6 6
0,5 mm²
5 GNRD 5 5
1 mm²
10 BN 10 10
1,5 mm²
+MOT X76 1
1
M57
pump fuel heating unit 2
Pumpe Kraftstoff Heizgerät
X76 2
BN
2,5 mm²
BN Splice
=SUPL+EBOX/8.7 / 31_AH 2,5 mm² Spleiss
79
0 1 2 3 4 5 6 7 8 9
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Cabin - Additional heater Mounting location Kind of Document
Einbauort +DPL Dokumentenart &EFS
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Kabine - Zusatzheizung
861
643 EPE /00
862
+EBOX
=SUPL+EBOX/10.9 / F29:2 WWF / 48.1
=SUPL+EBOX/10.9 / F40:2 WWR / 48.1
X6.C 2 4 X4.B 3 6 X6.B 3 1
WH WH
1,5 mm² 1,5 mm²
30
Circuit diagrams
K09 Splice
Spleiss 9
=SUPL+EBOX/8.7 87 87a
Relay, air conditioning
WH
Relais Klimaanlage 2,5 mm²
+SEAT
+DPL
X1.A 5
A108 -X10 1
Heating climatic unit
Heiz-Klima-Einheit Supply
WH
RD
X87, X99
1,5 mm²
+REFR
X68.f 1
2
-X68.m 1
BK BK/GN BK
-B104 1
pressure switch air conditioning P
LP HP Out Gnd
Druckschalter Klimaanlage
BK/YE
WH WH
-X68.m 2 1,5 mm² 1,5 mm²
-X10 4 2
X87 1 X99 1
X68.f 2
X87 1 X99 1
WH
1,5 mm²
WH Option
1,5 mm²
BW 220 D-5
3 Option 3
+MOT S29 S25
X12 1
Switch, suspension seat 4 Switch, heating operators seat 4
WH BN Schalter Luftfedersitz Schalter Fahrersitzheizung
X12 1 2 1,5 mm² 2,5 mm²
1 V04
Y15 1 + +
3,5A 1
1 1 1 1
XY15.2 X6.C
M10
M E159 M06 M07
BN
1,5 mm² 12V / < 9A 12V / 6,85A 2 2 3,5A 3,5A
Delivery equipment Sitz
Lieferumfang Sitz
31_Eng BN - -
1,5 mm² 2
=MON+EBOX/24.8
X87 2 X99 2
Only at air conditioning
Nur bei Klimaanlage X87 2 X99 2
BN BN
1,5 mm² 1,5 mm²
=EXC+EBOX/32.3 / 31_Ar
+EBOX/42.3 / 31_Db
Compressor, suspension operators seat Motor, windscreen washer front

Magnetic clutch, air conditioning compressor Kompressor Luftfedersitz Scheibenwaschermotor vorne
Magnetkupplung Klimakompressor heating operators seat Motor, windscreen washer rear
Heizung Fahrersitz Scheibenwaschermotor hinten
0 1 2 3 4 5 6 7 8 9
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Cabin - Heating, Air conditioning, Washer pumps Mounting location Kind of Document
Einbauort +CAB Dokumentenart &EFS
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Kabine - Heizung, Klimaanlage, Wascherpumpen 643 EPE /00
+EBOX
X4.E X4.E
14 14
=MEAS+EBOX/37.8 / RxD RxD / 53.6
4 4
=MEAS+EBOX/37.8 / TxD TxD / 53.6
8 8 WH
=MEAS+EBOX/37.8 / 15_GPS 1,5 mm² 15_GPS / 54.0
10 10
=COM+EBOX/16.9 / CAN3+ CAN3+ / 54.0
7 7
=COM+EBOX/16.9 / CAN3- CAN3- / 54.0
11 11
=DRIV+REFR/30.6 / Rev Rev / 55.1
X202 X202 -A178

1 1 9 9 module operator terminal cabin 1 Additional working lights left zusätzliche Arbeitsbeleuchtung links
+EBOX/43.9 / CAN1+
Modul Bedienkonsole Kabine
2 Illumination drum Bandagenbeleuchtung
2 2 10 10
+EBOX/43.9 / CAN1- Start Start
3
17 17 6 6 Stop Stop
+EBOX/44.1 / D+ 4
Print Drucken
DIG In
5
High active
5 5 4 4 Delete Löschen
+EBOX/42.4 / EN_WL 6
Reserve Reserve
DIG In
X7.C-2 X7.C-2 X7.C 7
High active
7 WH 7 7 9 9 WH 5 5 Additional working lights right zusätzliche Arbeitsbeleuchtung rechts
1,5 mm² 1,5 mm² 8
Windscreen wiper front Scheibenwischer vorne
DIG Out
+EBOX/41.2 / X4.E:9
9
10 Windscreen wiper rear Scheibenwischer hinten
15 15 WH 8 8
=SUPL+EBOX/8.9 / 15_CAB 1,5 mm² 15_PB_CAB / 49.1
11 Windscreen wascher front Scheibenwascher vorne
BW 220 D-5
13 13 3 3 Rotary beacon Rundumkennleuchte
47.9 / WWF WWF_PB_CAB / 51.1 12
12 12 1 1 13 Working headlights front Arbeitsscheinwerfer vorne
47.9 / WWR WWR_PB_CAB / 51.1
14 Cabin inside light Kabineninnenbeleuchtung
15 Working headlights rear Arbeitsscheinwerfer hinten

X8.A X8.A X200 X200
30 30 RD 30 30 Rear screen heating Heckscheibenheizung
=SUPL+EBOX/8.6 / X8.A 16 mm² 30_PB_CAB / 49.1 16
RADSOK® 8mm Amphenol RADSOK® 6mm
17 Windscreen wascher rear Scheibenwascher hinten
X8.B X8.B X201 X201
31 31 BN BN 31 31
=SUPL+EBOX/8.9 / X8.B 16 mm² 10 mm² GND_PB_CAB / 49.1
RADSOK® 6mm Amphenol RADSOK® 3,6mm
1 8
Optional
Optional
2 7
3 4 5 6
not used
GND_CAB / 50.0 wird nicht genutzt
9 10
1 3 2
-U200
Ground cabin
Masse Kabine
Ground cabin
-U200 = Masse Kabine
11 12 13 14 15 16 17
0 1 2 3 4 5 6 7 8 9
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Cabin - Supply Mounting location Kind of Document
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Kabine - Versorgung
863
643 EPE /00
864
48.4 / 30_PB_CAB
48.4 / 15_PB_CAB
30
F17 F264 F271
5A 10A 10A
Circuit diagrams
K32
/49.1 87 87a
Relay, cabin
Relais Kabine
Fuse, radio
Fuse, BCM05
Fuse, BCM-Net
Sicherung Radio
Sicherung BCM05
Sicherung BCM-Net
Fuses cabin
Sicherungen Kabine
F271:2 / 54.1
F264:2 / 54.1
F17:2 / 53.1
BW 220 D-5
F272 F27 F28 F143 F266 F150 F279
5A 15A 15A 20A 10A 5A 15A
86
Fuse, reserve
D2.1
K32
Sicherung Reserve
Fuse, GPS receiver
green
12V/20A 85
Relay, cabin
Sicherung GPS Receiver
Fuse, radio / tachograph
Relais Kabine
F279:2 / 51.1
Fuse, rear screen heating unit

Sicherung Radio / Tachograph
Sicherung Heckscheibenheizung F150:2 / 54.1
Fuse, controller console terminal cabin

Sicherung Wischer und Wascher vorne
Sicherung Wischer und Wascher hinten
Fuse, windscreen wiper and washer rear
Fuse, windscreen wiper and washer front

F266:2 / 53.1
Sicherung Controller Bedienkonsole Kabine

F143:2 / 52.1
48.4 / GND_PB_CAB GND_PB_CAB / 50.0
F28:2 / 52.1
87
87a 30 /49.2 F27:2 / 52.1
F272:2 / 50.0
0 1 2 3 4 5 6 7 8 9
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Cabin - Fuse protection Mounting location Kind of Document
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Kabine - Absicherung 643 EPE /00
A178
/48.5
module operator terminal cabin
Ub PWM Out PWM Out Gnd DIG Out DIG Out DIG Out DIG Out DIG Out DIG In DIG Out DIG Out DIG Out DIG Out
Low active
1 1
49.9 / F272:2 E29 E29
Inside light, cabin 2 1 2
Innenleuchte Kabine E72
Illumination, 2
switches
Beleuchtung
Bedienschalter
X206 1 6 2 4 9 X203 2 5 1 4 3 6
BW 220 D-5
+ 1 1 1 1
E32 E27 E28 E23 E25
12V 70W - 12V 55W 2 12V 55W 2 12V 55W 2 12V 55W 2
48.3 / GND_CAB GND_CAB / 52.1
Rotary beacon Working headlight, rear left Working headlight, front left
Rundumkennleuchte Arbeitsscheinwerfer hinten links Arbeitsscheinwerfer vorne links
Working headlight, rear right Working headlight, front right
Arbeitsscheinwerfer hinten rechts Arbeitsscheinwerfer vorne rechts
0 1 2 3 4 5 6 7 8 9
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Cabin - Lighting Mounting location Kind of Document
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Kabine - Beleuchtung
865
643 EPE /00
866
A178
/48.5
Circuit diagrams
DIG Out DIG Out DIG Out DIG Out DIG Out DIG Out
86 86 86
D2.2 D2.3 D2.4
K141 K20 K21
green green green
12V/20A 85 12V/20A 85 12V/20A 85
Automotive Micro Relay on socket Automotive Micro Relay on socket Automotive Micro Relay on socket
Automotive Mircrorelais auf Sockel Automotive Mircrorelais auf Sockel Automotive Mircrorelais auf Sockel
48.4 / WWF_PB_CAB Relay, heating rear screen Relay, windscreen wiper front Relay, windscreen wiper rear
Relais Heckscheibenheizung Relais Wischer vorne Relais Wischer hinten
48.4 / WWR_PB_CAB
49.9 / F279:2
max. 150 mA
X206 3 7 8
BW 220 D-5
87 87 87
87a 30 /52.7 87a 30 /52.3 87a 30 /52.5
0 1 2 3 4 5 6 7 8 9
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Cabin - Cabin equipment Mounting location Kind of Document
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Kabine - Kabinenausrüstung 643 EPE /00
49.9 / F143:2
49.9 / F28:2
49.9 / F27:2
87a 87 87a 87 30
K20 Relay, windscreen wiper front K21 Relay, windscreen wiper rear K141
/51.5 30 Relais Wischer vorne /51.6 30 Relais Wischer hinten /51.3 87 87a
Relay, heating rear screen
Relais Heckscheibenheizung
X203 7 8 9 10 11 12 13 14
WH WH WH WH WH WH WH WH
1,5 mm² 1,5 mm² 1,5 mm² 1,5 mm² 1,5 mm² 1,5 mm² 1,5 mm² 1,5 mm²
BW 220 D-5
Splice
53b 53 31b 53 Spleiss 77
[gy] [blu] [blu/wht] [blu]
WH
X66 3 2 5 X65 1 4 3 1,5 mm²
4 3
6 5 4
53a 31b 53 53a 31b 53 2 1 1
3 2 1
31 53a
M04 53a 31b 31 M05 [blk] [blk/blu] R80
4,7A [blu/blk] [blu/wht] [blk] 4,7A ca. 11 A
31 31 2
BN
X66 1 X65 2 1,5 mm²
Splice
Spleiss 76
BN BN BN
1,5 mm² 1,5 mm² 2,5 mm²
Motor, windscreen wiper front Motor, windscreen wiper rear Rear window heater
Scheibenwischermotor vorne Scheibenwischermotor hinten Heizung Heckscheibe
0 1 2 3 4 5 6 7 8 9
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Cabin - Cabin equipment Mounting location Kind of Document
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Kabine - Kabinenausrüstung
867
643 EPE /00
868
49.9 / F266:2
49.9 / F17:2
51.8 / GND_PB_CAB
A178
Circuit diagrams
/48.5
PWM Out PWM Out PWM Out
X205 1 2 3 4 6 5 X202 2
X205 1 2 3 4 6 5
X202:2 / 55.1
Splice
Spleiss 58
Splice
Spleiss 57
48.4 / TxD
Splice
Spleiss 56
48.4 / RxD
XP09.A
1 A1 Splice
antenna radio Spleiss 59
XP09.A P09 -T21 Antenne Radio
BW 220 D-5
2 A2
XP09.A 8 7 4
3 A3 XA12.A
XP09.A XA12.A
5 A5 -A12 8 7 4 5 Ant
31 15 30 Ctrl Ant
XP09.A 12V
6 A6 module radio
Modul Radio 1 2 5 4
XP09.C
3 C3
X94 1 2 5 4
A = white
XP09.B B = yellow RxD TxD Gnd Ub
3 B3 P11
C = red
rl+ rl- fl+ fl- fr+ fr- rr+ rr-
XP09.B 7 8 5 6 3 4 1 2
4 B4
XA12.B
Printer
Drucker
Tachograph XA12.B 7 8 1 2
Tachograph
B51.L B51.R
+ -
- +
Speaker radio Speaker radio

Lautsprecher Radio Lautsprecher Radio
AGND Only at VM29-Printer
Nur bei VM29-Drucker
X94 3
0 1 2 3 4 5 6 7 8 9
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Cabin - Radio, Tachograph, Printer measurement Mounting location Kind of Document
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Kabine - Radio, Tachograph, Drucker Messtechnik 643 EPE /00
49.9 / F271:2
49.9 / F150:2
49.9 / F264:2
X204 1 2 3 4
48.4 / 15_GPS
BN BN
1,5 mm² 1,5 mm²
X85 1 X85 2
USB-CAN Interface BCM 3 -A93
A87 USB-CAN Schnittstelle BCM GPS receiver
GPS Receiver
X85 X95.A X91
4 7 1
48.4 / CAN3+ 2
X85 3
4
5 2 2 SH
48.4 / CAN3-
BW 220 D-5
12 6 7 2 11
X211 -X93 C -X97
4 B A A B C D E
Gnd2
2
RxD2
3
TxD2
P15 X96.A
BCM05 Ub 1 1 -X210 -X92
Supply
BCM05 Versorgung 1 A
AGnd 1 A
2
Gnd 2
Splice
2 2 B B
Spleiss 200
X90
Gnd1 5 5 3 3 C C
GPS receiver
GPS Receiver 2 4 D
RxD1 2 4 D
3 5 E
TxD1 3 5 E
W10
7x1,0
0 1 2 3 4 5 6 7 8 9
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 BOMAG Compaction Management BCM, GPS Mounting location Kind of Document
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 BOMAG Verdichtungsmanagement BCM, GPS
869
643 EPE /00
870
53.8 / X202:2
54.7 / GND_CAB
48.4 / Rev
Circuit diagrams
P42
display back up monitoring
Anzeige Rückraumüberwachung
Pin 1 - 12/24V DC
Pin 2 - Gnd
Pin 3 - Trigger Cam 1
Pin 4 - Trigger Cam 2
X50.f X50.m Pin 5 - Trigger Cam 3
P32 1 1 RD
camera back up monitoring 2 2 BK
Kamera Rückraumüberwachung 3 3 WH
4 BU
5 BN
CA1 CA1
CA2
CA3
BW 220 D-5
0 1 2 3 4 5 6 7 8 9
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Back up monitoring Mounting location Kind of Document
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Rückraumüberwachung 643 EPE /00
Device tag list
Betriebsmittelliste BO_F03_001
Device tag Page Path Mounting location Higher-level characteristics

function Function text Funktionstext
BMK Blatt Pfad Einbauort Anlage Techn.-Kenngrößen
A2 42 8 +EBOX module flasher Modul Blinker 12V

A12 53 4 +CAB module radio Modul Radio 12V
A15 14 2 +ARC module monitoring Modul Überwachung ---> Pin overview
A34 11 3 +EBOX Driving Controller Fahrsteuerung ---> Pin overview
A48 21 0 +EBOX Engine-controller EMR3 (EDC 16) Motorsteuergerät EMR3 (EDC 16)
A67 43 5 +DPL Keyboard Tastatur
A83 12 3 +EBOX Measurement controller Messtechnik Steuerung ---> Pin overview
A87 54 2 +CAB USB-CAN Interface BCM USB-CAN Schnittstelle BCM
A93 54 7 +CAB GPS receiver GPS Receiver
A103 38 2 +REFR module ECONOMIZER Modul ECONOMIZER ---> Pin overview
A108 47 2 +CAB Heating climatic unit Heiz-Klima-Einheit
A124 44 3 +EBOX ECU BOMAG TELEMATIC ECU BOMAG TELEMATIC
A161 39 0 +EBOX module CAN Gateway Modul CAN Gateway ---> Pin overview
A162 40 0 +EBOX -"- -"- ---> Pin overview
A175 45 1 +MOT Electronic system, Morey Telematics Elektronik Morey Telematik
A177 45 5 +MOT ECU ZTR telematics ECU ZTR Telematik
B03 24 4 +MOT Maintenance switch, air cleaner Wartungsschalter Luftfilter
B11.1 30 1 +REFR Warning horn Signalhorn max. 3,5A
B11.2 30 4 +REFR -"- -"- max. 3,5A
BW 220 D-5
B11.3 30 1 +REFR -"- -"- max. 3,5A
B11.4 30 5 +REFR -"- -"- max. 3,5A
B21 24 5 +REFR Differential pressure switch, hydraulic oil filter Differenzdruckschalter Hydraulikölfilter
B51.L 53 4 +CAB Speaker radio Lautsprecher Radio
B51.R 53 5 +CAB -"- -"-
B55 24 2 +MOT Floating switch, coolant expansion tank Schwimmerschalter Kühlmittelausgleichsbehälter
B57 25 1 +EBOX sensor slope speed range selection Neigungssensor Stufenumschaltung 0,5-4,5V
B59 25 7 +DRUM Speed sensor, drum Drehzahlsensor Bandagengeschwindigkeit
B60 25 4 +REFR Speed sensor, axle Drehzahlsensor Achsgeschwindigkeit
B62 37 1 +DRUM Transducer, acceleration Aufnehmer Beschleunigung
B84 38 5 +DRUM sensor acceleration left Sensor Beschleunigung links
B88 23 2 +MOT sensor engine oil pressure Sensor Motoröldruck
B93 23 2 +MOT sensor fuel pressure rail Sensor Raildruck Kraftstoff
B97 33 5 +DRUM Sensor, adjustable motor Sensor Verstellmotor
B104 47 1 +REFR pressure switch air conditioning Druckschalter Klimaanlage
B113 23 5 +MOT temperature sensor coolant Temperatursensor Kühlmittel
B114 23 3 +MOT sensor engine speed Sensor Motordrehzahl
B124 21 7 +MOT Sensor, water separator fuel Sensor Wasserabscheider Kraftstoff
0 1 2 3 4 5 6 7 8 9
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101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Device tag list Kind of Document
Dokumentenart &EPB
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Betriebsmittelliste
871
643 EPE /00
872
Device tag list

B130 23 4 +MOT sensor engine speed Sensor Motordrehzahl

Circuit diagrams
B133 23 7 +MOT sensor charge air pressure and temperature Sensor Ladeluftdruck und Temperatur
B145 23 6 +MOT pressure sensor fuel Drucksensor Kraftstoff
B171 37 3 +DRUM Transducer, acceleration Aufnehmer Beschleunigung
B234 27 2 +PUMP Pressure sensor, travel pump axle MA Drucksensor Fahrpumpe Achse MA
B235 27 3 +PUMP Pressure sensor, travel pump axle MB Drucksensor Fahrpumpe Achse MB
B236 27 4 +PUMP Pressure sensor, travel pump drum MA Drucksensor Fahrpumpe Bandage MA
B237 27 4 +PUMP Pressure sensor, travel pump drum MB Drucksensor Fahrpumpe Bandage MB
B312 35 5 +REFR Sensor, height adjustment plates Sensor Höhenverstellung Platten 4...20mA
B313 35 6 +REFR Sensor, lateral adjustment plates Sensor Seitenverstellung Platten 4...20mA
D2.1 49 1 +CAB Indicator light, relay K32 Meldeleuchte Relais K32 green
D05 29 2 +EBOX Indicator light, relay K05 Meldeleuchte Relais K05 green
BW 220 D-5
Dx 9 1 +EBOX Indicator light, fuse test Meldeleuchte Sicherungstest green
E08 42 7 +DPL Indicator, front left Blinkleuchte vorne links 21W
E09 42 8 +REFR Indicator, rear left Blinkleuchte hinten links 21W
E10 42 8 +DPL Indicator, front right Blinkleuchte vorne rechts 21W
E11 42 8 +REFR Indicator, rear right Blinkleuchte hinten rechts 21W
E12 42 1 +DPL Parking light, left Parkleuchte links 5W
E13 42 1 +REFR Tail light, left Schlussleuchte links LED
E14 42 2 +DPL Parking light, right Parkleuchte rechts 5W
E15 42 2 +REFR Tail light, right Schlussleuchte rechts LED
0 1 2 3 4 5 6 7 8 9
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101
Dokumentenart &EPB
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Betriebsmittelliste 643 EPE /00
Device tag list

E16 42 4 +DPL Headlight, left Scheinwerfer links 55W

E17 42 5 +DPL Headlight, right Scheinwerfer rechts 55W
E23 41 3 +ROPS Working headlight, front left Arbeitsscheinwerfer vorne links 12V 55W
E23 50 8 +CAB -"- -"- 12V 55W
E25 41 3 +ROPS Working headlight, front right Arbeitsscheinwerfer vorne rechts 12V 55W
E25 50 9 +CAB -"- -"- 12V 55W
E27 41 4 +ROPS Working headlight, rear left Arbeitsscheinwerfer hinten links 12V 55W
E27 50 7 +CAB -"- -"- 12V 55W
E28 41 4 +ROPS Working headlight, rear right Arbeitsscheinwerfer hinten rechts 12V 55W
E28 50 8 +CAB -"- -"- 12V 55W
E29 50 1 +CAB Inside light, cabin Innenleuchte Kabine
E30 46 0 +DPL heating unit Heizgerät 12V
E32 50 6 +CAB Rotary beacon Rundumkennleuchte 12V 70W
E72 50 2 +CAB Illumination, switches Beleuchtung Bedienschalter
E159 47 7 +SEAT heating operators seat Heizung Fahrersitz 12V / 6,85A
F00 8 1 +REFR Fuse, main battery Hauptsicherung Batterie 125A
F05 10 4 +EBOX Fuse, socket Sicherung Steckdose 20A
F07 9 8 +EBOX Fuse, hazard light Sicherung Warnblinker 10A
F08 10 4 +EBOX Fuse, indicators Sicherung Blinker 10A
BW 220 D-5
F09 42 1 +EBOX Fuse, parking and tail light left Sicherung Park- und Schlussleuchte links 10A
F10 42 2 +EBOX Fuse, parking and tail light right Sicherung Park- und Schlussleuchte rechts 10A
F11 9 7 +EBOX Fuse, headlight left Sicherung Scheinwerfer links 15A
F13 9 1 +EBOX Fuse, ignition switch Sicherung Startschalter 15A
F17 49 4 +CAB Fuse, radio Sicherung Radio 5A
F19 9 4 +EBOX Fuse, working headlight front left Sicherung Arbeitsscheinwerfer vorne links 15A
F22 9 3 +EBOX Fuse, working lights rear Sicherung Arbeisscheinwerfer hinten 15A
F23 9 5 +EBOX Fuse, signal horns Sicherung Signalhörner 15A
F24 10 3 +EBOX Fuse, monitoring module Sicherung Überwachungsmodul 10A
F27 49 4 +CAB Fuse, windscreen wiper and washer front Sicherung Wischer und Wascher vorne 15A
F28 49 4 +CAB Fuse, windscreen wiper and washer rear Sicherung Wischer und Wascher hinten 15A
F29 10 7 +EBOX Fuse, compressor suspension seat Sicherung Kompressor Luftfedersitz 15A
F39 8 6 +EBOX Fuse, main cabin Hauptsicherung Kabine 80A
F40 10 6 +EBOX Fuse, heating unit cabin Sicherung Kabinenheizung 30A
F48 8 2 +REFR Fuse, glow plug system Sicherung Glühanlage 125A
F67 9 6 +EBOX Fuse, controller (potential 30) Sicherung Steuerung (Potential 30) 15A
F68 9 2 +EBOX Fuse, potential 30 Sicherung Potential 30 15A
F84 9 4 +EBOX Fuse, controller (Pin 54) Sicherung Steuerung (Kontakt 54) 10A
0 1 2 3 4 5 6 7 8 9
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101
Dokumentenart &EPB
Checked
Circuit diagrams
K. Brand
873
643 EPE /00
874
Device tag list

F91 10 3 +EBOX Fuse, sensors Sicherung Sensoren 5A

Circuit diagrams
F95 8 0 +REFR Fuse, engine controller Sicherung Motorsteuerung 30A

F103 10 1 +EBOX Fuse, potential 15 Sicherung Potential 15 15A
F122 10 2 +EBOX Fuse, engine controller Sicherung Motorsteuerung 10A
F124 10 5 +EBOX Fuse, fuel-pre-heating Sicherung Kraftstoffvorheizung 25A
F129 45 5 +MOT fuse MD+ Sicherung MD+ 3A
F143 49 5 +CAB Fuse, rear screen heating unit Sicherung Heckscheibenheizung 20A
F150 49 6 +CAB Fuse, GPS receiver Sicherung GPS Receiver 5A
F157 9 2 +EBOX Fuse, solenoid switch starter Sicherung Magnetschalter Anlasser 30A
F164 8 3 +REFR Fuse, B+ charge Sicherung B+ Ladeleitung 150A
F169 10 7 +EBOX Fuse, starting current Sicherung Startstrom 5A
F243 10 8 +EBOX Fuse, Bomag telematics (potential 30) Sicherung Bomag Telematik (Potential 30) 7,5A
F244 10 6 +EBOX Fuse, Bomag telematics (potential 15) Sicherung Bomag Telematik (Potential 15) 5A
F264 49 4 +CAB Fuse, BCM05 Sicherung BCM05 10A
F266 49 5 +CAB Fuse, radio / tachograph Sicherung Radio / Tachograph 10A
F268 9 8 +EBOX Fuse, fuel pump Sicherung Kraftstoffpumpe 20A
F271 49 5 +CAB Fuse, BCM-Net Sicherung BCM-Net 10A
BW 220 D-5
F272 49 3 +CAB Fuse, controller console terminal cabin Sicherung Controller Bedienkonsole Kabine 5A
F279 49 6 +CAB Fuse, reserve Sicherung Reserve 15A
F320 46 5 +DPL Fuse, timer additional heater (potential 30) Sicherung Schaltuhr Zusatzheizung (Potential 30) 5A
F321 46 6 +DPL Fuse, timer additional heater (potential 15) Sicherung Schaltuhr Zusatzheizung (Potential 15) 5A
Fx 9 1 +EBOX Fuseholder, fuse test Sicherungshalter Sicherungstest
FM1 13 2 +EBOX Fuse, sensors Sicherung Sensoren 1A
FM2 13 5 +EBOX -"- -"- 1A
G01 8 2 +BAT Battery Batterie 12V / 88Ah
G02 8 5 +MOT Generator Generator 14V / 70A
G03 8 1 +BAT Battery Batterie 12V / 88Ah
H06 42 6 +ARC indicator light hazard light Meldeleuchte Warnblinker 12V
H07 24 7 +ARC Warning buzzer, breakdown Warnsummer Betriebsstörung 70mA
H14 30 6 +REFR Back-up alarm buzzer Warnsummer Rückwärtsfahrt 300mA
K05 29 2 +EBOX Relay, starting current Relais Startstrom 12V/20A
K06 41 5 +EBOX Relay, headlights rear Relais Scheinwerfer hinten 12V/30A
K09 8 7 +EBOX Relay, air conditioning Relais Klimaanlage 12V/20A
K11 8 8 +EBOX Relay, potential 30 on 15 Relais Potential 30 auf 15 12V
K13 30 8 +EBOX Relay, warning horn Relais Signalhorn 12V/20A
0 1 2 3 4 5 6 7 8 9
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101
Dokumentenart &EPB
Checked K. Brand
Device tag list

K14 18 3 +MOT relay glow plug system Relais Vorglühen 12V

K16 42 3 +EBOX Relay, headlights front Relais Scheinwerfer vorne 12V/20A
K20 51 5 +CAB Relay, windscreen wiper front Relais Wischer vorne 12V/20A
K21 51 6 +CAB Relay, windscreen wiper rear Relais Wischer hinten 12V/20A
K22 30 9 +EBOX Relay, shut off solenoid engine Relais Hubmagnet Abschaltung Motor 12V/20A
K32 49 1 +CAB Relay, cabin Relais Kabine 12V/20A
K38 20 6 +EBOX Relay, starter control Relais Anlassteuerung 12V/40A
K41 20 3 +EBOX Relay, separation Trennrelais 12V/20A
K43 31 4 +EBOX Relay, vibration Relais Vibration 12V/20A
K48 29 3 +EBOX Relay, travel lever 0-position Relais, Fahrhebel 0-Stellung 12V/20A
K61 8 6 +EBOX Relay, charge control Relais Ladekontrolle 12V/20A
K141 51 3 +CAB Relay, heating rear screen Relais Heckscheibenheizung 12V/20A
K145 20 8 +EBOX Relay, solenoid starter Relais Hubmagnet Starter 12V/40A
K189 26 9 +SEAT relay brake Relais Bremse 12V/10A
K209 20 4 +EBOX Relay, fuel pump Relais Kraftstoffpumpe 12V/30A
M01 8 4 +MOT Starter Starter
M04 52 3 +CAB Motor, windscreen wiper front Scheibenwischermotor vorne 4,7A
M05 52 5 +CAB Motor, windscreen wiper rear Scheibenwischermotor hinten 4,7A
M06 47 8 +DPL Motor, windscreen washer front Scheibenwaschermotor vorne 3,5A
BW 220 D-5
M07 47 9 +DPL Motor, windscreen washer rear Scheibenwaschermotor hinten 3,5A
M10 47 6 +SEAT Compressor, suspension operators seat Kompressor Luftfedersitz 12V / < 9A
M57 46 5 +MOT pump fuel heating unit Pumpe Kraftstoff Heizgerät
P09 53 3 +CAB Tachograph Tachograph
P11 53 6 +CAB Printer Drucker
P15 54 1 +CAB BCM05 BCM05
P32 55 1 +CAB camera back up monitoring Kamera Rückraumüberwachung
P42 55 5 +CAB display back up monitoring Anzeige Rückraumüberwachung
P43 35 4 +PLA Operating hour meter plates Betriebsstundenzähler Platten
R03 24 8 +REFR Sender, level gauge Geber Tankanzeige 66 Ω / 64,2 Ω
R10 8 6 +EBOX Parallel resistor Parallelwiderstand 82Ω / 22W
R19 18 4 +MOT Heating flange Heizflansch 167A
R20 15 3 +EBOX Terminating resistor CAN Abschlußwiderstand CAN 120 Ω
R21 15 3 +EBOX -"- -"- 120 Ω
R22 15 5 +EBOX -"- -"- 120 Ω
R23 21 2 +EBOX -"- -"- 121Ω/0,6W
R24 15 7 +EBOX -"- -"- 120 Ω
R25 15 7 +EBOX -"- -"- 120 Ω
0 1 2 3 4 5 6 7 8 9
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101
Dokumentenart &EPB
Checked
Circuit diagrams
K. Brand
875
643 EPE /00
876
Device tag list

R26 16 7 +EBOX Terminating resistor CAN Abschlußwiderstand CAN 120 Ω

Circuit diagrams
R27 16 7 +EBOX -"- -"- 120 Ω

R28 17 6 +EBOX -"- -"- 120 Ω
R29 17 6 +EBOX -"- -"- 120 Ω
R33 40 4 +EBOX -"- -"- 121Ω/0,6W
R34 40 6 +EBOX -"- -"- 121Ω/0,6W
R40 26 3 +SEAT resistor Widerstand 18,2Ω/0,6W
R79 18 8 +MOT heating prefilter fuel Heizung Vorfilter Kraftstoff 200W
R80 52 7 +CAB Rear window heater Heizung Heckscheibe ca. 11 A
S00 8 7 +ARC switch ignition Schalter Motorstart
S01 9 4 +ARC switch emergency off Schalter Not Aus
S06 25 3 +SEAT Switch, seat contact Sitzkontaktschalter
S09 26 5 +SEAT switch vibration front Schalter Vibration vorne
S14 42 5 +ARC switch hazard light Schalter Warnblinkanlage
S15 42 2 +ARC switch lighting StVZO Schalter Beleuchtung StVZO
S25 47 7 +SEAT Switch, heating operators seat Schalter Fahrersitzheizung
S26 41 5 +ARC switch working lights rear Schalter Arbeitsbeleuchtung hinten
S28 46 7 +DPL Timer Schaltuhr
S29 47 6 +SEAT Switch, suspension seat Schalter Luftfedersitz
BW 220 D-5
S30 8 3 +BAT Disconnect switch, battery Batterietrennschalter 250A
S35 26 7 +ARC switch vibration low high Schalter Vibration klein gross
S36 26 5 +SEAT switch vibration Schalter Vibration
S37 42 8 +ARC switch indicator Schalter Blinker
S42 26 0 +ARC Switch, speed range selector Schalter Fahrstufen 4..20mA / 0-5V
S55 14 8 +SEAT switch control lever travel Schalter Steuerhebel Fahren ---> Pin overview
S107 32 3 +SEAT switch amplitude adjustment Schalter Amplitudenverstellung 4..20mA
S127 19 2 +ARC switch engine speed Schalter Motordrehzahl
S139 26 4 +SEAT Potentiometer, frequency plates Potentiometer Frequenzverstellung Anbauplatten
S439 32 6 +SEAT switch amplitude limiting Schalter Amplitudenbegrenzung
T14 44 5 +ARC antenna BOMAG TELEMATIC Antenne BOMAG TELEMATIC
T21 53 5 +CAB antenna radio Antenne Radio
V01 8 6 +EBOX diode Diode S5G-E3
V02 30 2 +REFR -"- -"- SF 64
V03 30 3 +REFR -"- -"- SF 64
V04 47 2 +MOT -"- -"- SF 64
V05 42 7 +ARC -"- -"- SF 64
V06 42 7 +ARC -"- -"- SF 64
0 1 2 3 4 5 6 7 8 9
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101
Dokumentenart &EPB
Checked K. Brand
Device tag list

V07 25 5 +EBOX diode Diode S1M

V08 25 5 +EBOX -"- -"- S1M
V09 25 7 +EBOX -"- -"- S1M
V10 25 7 +EBOX -"- -"- S1M
Y04 29 5 +REFR Solenoid valve, brake Magnetventil Bremse 2,41A
Y07 31 5 +PUMP Solenoid valve, vibration front high Magnetventil Vibration vorne gross 640...1580mA
Y08 31 6 +PUMP Solenoid valve, vibration front low Magnetventil Vibration vorne klein 640...1580mA
Y15 47 1 +MOT Magnetic clutch, air conditioning compressor Magnetkupplung Klimakompressor 3,5A
Y16 28 2 +PUMP Solenoid valve, travel direction forward Magnetventil Fahrtrichtung vorwärts 640...1580mA
Y17 28 3 +PUMP Solenoid valve, travel direction backward Magnetventil Fahrtrichtung rückwärts 640...1580mA
Y30 29 7 +REFR Solenoid valve, speed range selection drum Magnetventil Fahrstufe Bandage 2,41A
Y30 29 8 +DRUM -"- -"- 1,05A
Y31 29 4 +REFR Solenoid valve, speed range selection axle Magnetventil Fahrstufe Achse 1,05A
Y60 36 5 +REFR Solenoid valve, floating position Magnetventil Schwimmstellung
Y72 28 4 +PUMP Solenoid valve, travel direction forward Magnetventil Fahrtrichtung vorwärts 640...1580mA
Y73 28 5 +PUMP Solenoid valve, travel direction backward Magnetventil Fahrtrichtung rückwärts 640...1580mA
Y98 35 7 +MOT Solenoid valve, vibration pump plates Magnetventil Vibrationspumpe Platten 400-1200mA
Y102 34 4 +DRUM Solenoid valve, floating position Magnetventil Schwimmstellung
Y122 36 1 +REFR Solenoid valve, lift plates Magnetventil Platten heben
BW 220 D-5
Y123 36 2 +REFR Solenoid valve, let down plates Magnetventil Platten senken
Y137 23 9 +MOT solenoid valve adjustment EMR Magnetventil Arretierung EMR
Y140 33 7 +DRUM Solenoid valve, exciter up Magnetventil Erreger auf 400-1200mA
Y141 33 8 +DRUM Solenoid valve, exciter down Magnetventil Erreger ab 400-1200mA
Y142 36 3 +REFR Solenoid valve, plate displace left Magnetventil Plattenverschieben links
Y143 36 3 +REFR Solenoid valve, plate displace right Magnetventil Plattenverschieben rechts
Y144 36 5 +REFR Solenoid valve, plate floating position Magnetventil Platten Schwimmstellung
Y145 36 4 +REFR Solenoid valve, plate (priority) Magnetventil Platten (Priorität)
Y147 22 2 +MOT Injector A1 Injektor A1
Y378 34 3 +DRUM Solenoid valve, dozer blade priority Magnetventil Planierschild Priorität
Y379 34 5 +DRUM Solenoid valve, lift dozer blade Magnetventil Planierschild heben
Y380 34 6 +DRUM Solenoid valve, lower dozer blade Magnetventil Planierschild senken
0 1 2 3 4 5 6 7 8 9
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101
Dokumentenart &EPB
Checked
Circuit diagrams
K. Brand
877
643 EPE /00
878
Plug overview
Steckerübersicht BO_F22_002
Stecker -X0.A Einbauort +EBOX Stecker -X0.C Einbauort +EBOX Stecker -X1.B Einbauort +EBOX Stecker -X2.A Einbauort +EBOX
Function text Plug, supply potential 30 Function text Plug, supply potential 30 before battery disconnect switch Function text Plug, access harness engine controller Function text Plug, access harness rear frame
Funktionstext Stecker Versorgung Potential 30 Funktionstext Stecker Versorgung Potential 30 vor Batterietrennschalter Funktionstext Stecker Anschluß Kabelbaum Motorsteuergerät Funktionstext Stecker Anschluß Kabelbaum Hinterrahmen
Amphenol RADSOK® 8mm Amphenol RADSOK® 3,6mm AMP Junior Power Timer 18 pole blue AMP Junior Power Timer 15 pole green
Circuit diagrams

13 1
Kabelbaum Kabelbaum Kabelbaum Kabelbaum
15 9 3
Page Path Page Path Page Path Page Path
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
30 8 4 1 10 8 1 20 2 1 25 4
2 20 2 2 30 6
Plug Mounting location Plug Mounting location 3 20 2 3
Stecker -X0.A Einbauort +EBOX Stecker -X1.A Einbauort +EBOX 4 20 7 4 25 5
Function text Plug, supply potential 30 Function text Plug, access harness engine 5 20 2 5
Funktionstext Stecker Versorgung Potential 30 Funktionstext Stecker Anschluß Kabelbaum Motor 6 20 3 6
Plug type Plug type 7 20 8 7 29 5
Amphenol RADSOK® 8mm AMP Junior Power Timer 9 pole blue
Steckertyp Steckertyp 8 20 3 8
Wire harness Wire harness 9 20 5 9
Kabelbaum Kabelbaum 10 20 7 10 27 2
Page Path Page Path 11 20 6 11
Contact
Kontakt
Contact
Kontakt
Blatt Pfad Blatt Pfad 12 20 6 12 25 4
1 8 5 1 9 2 13 20 7 13
2 9 2 14 20 4 14 25 5
Plug Mounting location 3 18 6 15 20 7 15 24 8
Stecker -X0.B Einbauort +EBOX 4 20 5 16 20 5
Function text Plug supply ground 17 20 5 Plug Mounting location
5 47 1 -X2.A +EBOX
Funktionstext Stecker Versorgung Masse 18 20 8 Stecker Einbauort
6 18 6
Plug type Function text Plug, access harness rear frame
7 8 6
Steckertyp Plug Mounting location Funktionstext Stecker Anschluß Kabelbaum Hinterrahmen
8 18 8 -X1.B_f +EBOX
Stecker Einbauort Plug type
Wire harness 9 18 8 AMP Junior Power Timer 15 pole green
Function text Plug, access harness engine controller Steckertyp
Kabelbaum
Funktionstext Stecker Anschluß Kabelbaum Motorsteuergerät Wire harness
BW 220 D-5
Page Path Plug Mounting location
Stecker -X1.A_f Einbauort +EBOX Plug type Kabelbaum
Contact
Kontakt
Blatt Pfad AMP Junior Power Timer 18 pole blue
Steckertyp Page Path
Function text Plug, access harness engine
31 8 6 Wire harness
Contact
Kontakt
Funktionstext Stecker Anschluß Kabelbaum Motor Blatt Pfad

EMR 16 1
Plug type Kabelbaum

Plug Mounting location AMP Junior Power Timer 9 pole blue 18 12 9 3
1 25 4
Stecker -X0.B +EBOX Steckertyp Page Path 2 30 6
Einbauort
Contact
Kontakt
Wire harness Blatt Pfad 3
Function text Plug supply ground Motor 1
7
Funktionstext Stecker Versorgung Masse Kabelbaum 1 4 25 5
9 6 3
Plug type Page Path 2 5
Contact
Kontakt
Steckertyp Blatt Pfad 3 20 2 6
Wire harness 1 9 2 4 7 29 5
Kabelbaum 2 9 2 5 20 2 8
Page Path 3 6 20 3 9 25 5
7 20 8 10 27 2
Contact
Kontakt
Blatt Pfad 4
5 47 1 8 20 3 11
1 8 6 9 12 25 4
6
7 8 6 10 20 7 13 25 5
Stecker -X0.C +EBOX 8 18 8 11 20 6 14 25 5
Einbauort
9 18 8 12 20 6 15 24 8
Function text Plug, supply potential 30 before battery disconnect switch
Funktionstext Stecker Versorgung Potential 30 vor Batterietrennschalter
13 20 7
14
Plug type
Amphenol RADSOK® 3,6mm 15 20 7
Steckertyp
16 20 5
Wire harness
17
Kabelbaum
18 20 8
Page Path
Contact
Kontakt
Blatt Pfad
30 10 8
0 1 2 3 4 5 6 7 8 9
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Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Plug overview Kind of Document
Dokumentenart &EMA3
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Steckerübersicht 643 EPE /00
Plug overview
Stecker -X2.B Einbauort +EBOX Stecker -X4.A Einbauort +EBOX Stecker -X4.B Einbauort +EBOX Stecker -X4.D Einbauort +EBOX
Function text Plug, access harness StvZO illumination rear Function text Plug, access harness dashboard Function text Plug, access harness console seat Function text Plug, access harness StvZO illumination front
Funktionstext Stecker Anschluß Kabelbaum StvZO Beleuchtung hinten Funktionstext Stecker Anschluß Kabelbaum Bedienpult Funktionstext Stecker Anschluß Kabelbaum Konsole Sitz Funktionstext Stecker Anschluß Kabelbaum StvZO Beleuchtung vorne
AMP Junior Power Timer 6 pole green AMP Junior Power Timer 21 pole grey AMP Junior Power Timer 9 pole grey AMP Junior Power Timer 12 pole grey
4 1 19 1 Konsole Sitz 7 1
6 3 21 12 3 9 6 3
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
1 42 8 18 14 1 5 1 42 2
2 42 1 19 9 4 6 47 7 2 42 8
3 42 2 20 8 8 7 14 6 3 42 7
4 42 8 21 29 5 8 32 3 4
5 9 29 1 5 42 8
6 Plug Mounting location 6 42 8
Stecker -X4.A Einbauort +EBOX Plug Mounting location 7 42 4
Plug Mounting location Function text Plug, access harness dashboard Stecker -X4.B Einbauort +EBOX 8 42 9
Stecker -X2.B Einbauort +EBOX Funktionstext Stecker Anschluß Kabelbaum Bedienpult Function text Plug, access harness console seat 9 42 2
Function text Plug, access harness StvZO illumination rear Plug type Funktionstext Stecker Anschluß Kabelbaum Konsole Sitz 10 42 2
AMP Junior Power Timer 21 pole grey
Funktionstext Stecker Anschluß Kabelbaum StvZO Beleuchtung hinten Steckertyp Plug type 11 42 8
Plug type Wire harness Steckertyp 12 42 1
AMP Junior Power Timer 6 pole green
Steckertyp Kabelbaum Wire harness
Wire harness Page Path Kabelbaum Plug Mounting location
Kabelbaum Stecker -X4.E Einbauort +EBOX
Contact
Kontakt
Blatt Pfad Page Path
Contact
Kontakt
Page Path Blatt Pfad Function text Plug, access cabin and rops
1 10 2
Funktionstext Stecker Anschluß Kabine und Rops
Contact
Kontakt
Blatt Pfad 2 30 3 1 16 4
Plug type
1 42 8 3 8 8 2 25 3 AMP Junior Power Timer 18 pole grey
Steckertyp
2 42 1 4 42 8 3 47 7
3 42 2 5 24 8 4 16 5 Wire harness
16 1
Kabelbaum
4 42 8 6 42 8 5 18 12 9 3
5 7 29 5 6 47 7 Page Path
Contact
Kontakt
BW 220 D-5
6 8 7 14 6 Blatt Pfad
9 8 7 8 32 3 1 48 2
Plug Mounting location 10 9 4 9 29 1 2 48 2
Stecker -X4.A Einbauort +EBOX 11 42 3 3 41 3
Function text Plug, access harness dashboard 12 10 2 Plug Mounting location 4 48 2
Funktionstext Stecker Anschluß Kabelbaum Bedienpult 13 8 7 Stecker -X4.D Einbauort +EBOX 5 48 2
Plug type 14 16 2 Function text Plug, access harness StvZO illumination front 6 41 4
Steckertyp 15 41 5 Funktionstext Stecker Anschluß Kabelbaum StvZO Beleuchtung vorne 7 48 2
Wire harness 16 19 5 Plug type 8 48 2
19 1 AMP Junior Power Timer 12 pole grey
Kabelbaum 17 16 2 Steckertyp 9 48 2
21 12 3
Page Path 18 14 1 Wire harness 10 48 2
10 1
Kabelbaum
Contact
Kontakt
Blatt Pfad 19 9 4 11 48 2
12 9 6 3
1 10 2 20 8 8 Page Path 12 48 2
Contact
Kontakt
2 30 3 21 29 5 Blatt Pfad 13 48 2
3 8 8 1 42 2 14 48 2
Plug Mounting location 15 48 2
4 42 8 -X4.B +EBOX 2 42 8
Stecker Einbauort 16 41 3
5 24 8 3 42 7
Function text Plug, access harness console seat 17 48 2
6 42 8 4
Funktionstext Stecker Anschluß Kabelbaum Konsole Sitz 18 41 4
7 29 5 5 42 8
Plug type
8 AMP Junior Power Timer 9 pole grey 6 42 8
Steckertyp
9 8 7 7 42 4
10 9 4 Wire harness 8 42 9
Konsole Sitz 7 1
Kabelbaum
11 42 3 9 6 3
9 42 2
12 10 2 Page Path 10 42 2
Contact
Kontakt
13 8 7 Blatt Pfad 11 42 8
14 16 2 1 16 4 12 42 1
15 41 5 2 25 3
16 19 5 3 47 7
17 16 2 4 16 5
0 1 2 3 4 5 6 7 8 9
Page from
101
Dokumentenart &EMA3
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Steckerübersicht
879
643 EPE /00
880
Plug overview
Stecker -X4.E Einbauort +EBOX Stecker -X5.A Einbauort +EBOX Stecker -X5.B Einbauort +EBOX Stecker -X5.E Einbauort +EBOX
Function text Plug, access cabin and rops Function text Plug, access harness driving controller 1 Function text Plug, access harness driving controller 2 Function text Plug, access harness measurement controller
Funktionstext Stecker Anschluß Kabine und Rops Funktionstext Stecker Anschluß Kabelbaum Fahrsteuerung 1 Funktionstext Stecker Anschluß Kabelbaum Fahrsteuerung 2 Funktionstext Stecker Anschluß Kabelbaum Messtechnik Steuerung
AMP Junior Power Timer 18 pole grey AMP Junior Power Timer 21 pole brown AMP Junior Power Timer 12 pole brown AMP Junior Power Timer 15 pole brown
Circuit diagrams

Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
1 48 1 1 25 8 1 31 6 3 37 7
2 48 1 2 25 7 2 4 12 1
3 41 3 3 11 3 3 31 6 5 37 6
4 48 1 4 13 2 4 6 12 3
5 48 1 5 30 6 5 25 5 7 37 1
6 41 4 6 15 4 6 25 4 8 37 8
7 48 1 7 34 2 7 9 13 5
8 48 1 8 8 31 4 10 34 2
9 48 1 9 15 5 9 31 5 11 33 5
10 48 1 10 24 1 10 25 3 12 15 7
11 48 1 11 11 13 12 2
12 48 1 12 15 2 12 14 32 3
13 48 1 13 13 2 15 15 6
14 48 1 14 29 1 Plug Mounting location
15 48 1 15 15 3 Stecker -X5.E Einbauort +EBOX Plug Mounting location
16 41 3 16 25 7 Function text Plug, access harness measurement controller Stecker -X5.E2 Einbauort +EBOX
17 48 1 17 30 9 Funktionstext Stecker Anschluß Kabelbaum Messtechnik Steuerung Function text Plug, access harness measurement controller
18 41 4 18 11 2 Plug type Funktionstext Stecker Anschluß Kabelbaum Messtechnik Steuerung
AMP Junior Power Timer 15 pole brown
19 11 1 Steckertyp Plug type
Plug Mounting location 20 30 8 Wire harness Steckertyp
-X5.A +EBOX 13 1
Stecker Einbauort 21 29 5 Kabelbaum Wire harness Verkabelung Schnittstelle
15 9 3 13 1
Function text Plug, access harness driving controller 1 Page Path Kabelbaum Messtechnik
Funktionstext Stecker Anschluß Kabelbaum Fahrsteuerung 1 15 9 3
Contact
Kontakt
BW 220 D-5
Plug type Stecker -X5.B Einbauort +EBOX
Contact
Kontakt
AMP Junior Power Timer 21 pole brown 1 16 7 Blatt Pfad

Steckertyp Function text Plug, access harness driving controller 2
2 16 8 1 16 7
Wire harness Funktionstext Stecker Anschluß Kabelbaum Fahrsteuerung 2
19 1
3 37 7 2 16 8
Kabelbaum Plug type
21 12 3
AMP Junior Power Timer 12 pole brown 4 12 1 3 37 7
Page Path Steckertyp
5 37 6 4 12 1
Contact
Kontakt
Blatt Pfad Wire harness 6 12 3 5 37 6
10 1
Kabelbaum
1 25 8 12 9 6 3
7 37 1 6 12 3
2 25 7 Page Path 8 37 8 7 37 1
Contact
Kontakt
3 11 3 Blatt Pfad 9 13 5 8 37 8
4 13 2 1 31 6 10 9 13 5
5 30 6 2 11 33 5 10
6 15 4 3 31 6 12 15 7 11 33 5
7 4 13 12 2 12 15 7
8 5 25 5 14 32 3 13 12 2
9 15 5 6 25 4 15 15 6 14 32 3
10 24 1 7 15 15 6
11 8 31 4 Plug Mounting location
12 15 2 9 31 5 Stecker -X5.E Einbauort +EBOX Plug Mounting location
13 13 2 10 25 3 Function text Plug, access harness measurement controller Stecker -X5.E2 Einbauort +EBOX
14 29 1 11 Funktionstext Stecker Anschluß Kabelbaum Messtechnik Steuerung Function text Plug, access harness measurement controller
15 15 3 12 Plug type Funktionstext Stecker Anschluß Kabelbaum Messtechnik Steuerung
16 25 7 Steckertyp Plug type
17 30 9 Wire harness Steckertyp
18 11 2 Kabelbaum Wire harness Verkabelung Schnittstelle
1
19 11 1 Page Path Kabelbaum Messtechnik
3 9 15
Contact
Kontakt
20 30 8 Blatt Pfad Page Path

Contact
Kontakt
21 29 5 1 16 7 Blatt Pfad
2 16 8 1 16 7
0 1 2 3 4 5 6 7 8 9
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101
Dokumentenart &EMA3
Checked K. Brand
Plug overview
Stecker -X5.E2 Einbauort +EBOX Stecker -X6.B Einbauort +EBOX Stecker -X6.C Einbauort +EBOX Stecker -X7.A Einbauort +EBOX
Function text Plug, access harness measurement controller Function text Plug, access sockets Function text Plug, access harness heating-climatic unit Function text Plug, access CAN Gateways
Funktionstext Stecker Anschluß Kabelbaum Messtechnik Steuerung Funktionstext Stecker Anschluß Bordsteckdosen Funktionstext Stecker Anschluß Kabelbaum Heiz-Klimamodul Funktionstext Stecker Anschluß CAN Gateways
AMP Junior Power Timer 15 pole brown AMP Junior Power Timer 2 - 4 pole black AMP Junior Power Timer 2 - 6 pole black AMP Junior Power Timer 12 pole yellow
Wire harness Verkabelung Schnittstelle Wire harness Wire harness Wire harness
2 6 1
1 10
Kabelbaum Messtechnik Kabelbaum Kabelbaum Kabelbaum
1 5 12 9 6 3
3 9 15
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
2 16 8 1 47 9 5 1
3 37 7 2 41 1 6 2
4 12 1 3 47 8 3 17 4
5 37 6 4 41 1 Plug Mounting location 4 17 4
6 12 3 Stecker -X6.D Einbauort +EBOX 5 17 4
7 37 1 Plug Mounting location Function text Plug, access telematics 6 17 4
8 37 8 Stecker -X6.B Einbauort +EBOX Funktionstext Stecker Anschluß Telematik 7 17 6
9 13 5 Function text Plug, access sockets Plug type 8 17 5
AMP Junior Power Timer 2 - 8 pole black
10 Funktionstext Stecker Anschluß Bordsteckdosen Steckertyp 9 17 6
11 33 5 Plug type Wire harness 10 17 7
AMP Junior Power Timer 2 - 4 pole black 2 8
12 15 7 Steckertyp Kabelbaum 11
1 7
13 12 2 Wire harness Page Path 12
Kabelbaum
Contact
Kontakt
14 32 3 Blatt Pfad
15 15 6 Page Path Plug Mounting location
1 -X7.A +EBOX
Stecker Einbauort
Contact
Kontakt
Blatt Pfad 2 44 2
Plug Mounting location Function text Plug, access CAN Gateways
-X5.E3 +EBOX 1 47 9 3 44 2
Stecker Einbauort Funktionstext Stecker Anschluß CAN Gateways
2 41 1 4 44 2
Function text Plug, access harness measurement controller Plug type
3 47 8 5 44 2 AMP Junior Power Timer 12 pole yellow
Funktionstext Stecker Anschluß Kabelbaum Messtechnik Steuerung Steckertyp
4 41 1 6 44 2
Plug type Wire harness
AMP Junior Power Timer 15 pole brown 7 44 2
Steckertyp Kabelbaum
Wire harness Stecker -X6.C Einbauort +EBOX Page Path
Economizer 13 1
Kabelbaum
Contact
Kontakt
BW 220 D-5
Function text Plug, access harness heating-climatic unit Plug Mounting location Blatt Pfad
15 9 3
Page Path Funktionstext Stecker Anschluß Kabelbaum Heiz-Klimamodul Stecker -X6.D Einbauort +EBOX 1 17 2
Contact
Kontakt
Blatt Pfad Plug type Function text Plug, access telematics 2 17 2
1 16 7 Steckertyp Funktionstext Stecker Anschluß Telematik 3 17 4
2 16 8 Wire harness Plug type 4 17 4
2 6 AMP Junior Power Timer 2 - 8 pole black
3 Kabelbaum Steckertyp 5 17 4
1 5
4 12 1 Page Path Wire harness 6 17 4
Kabelbaum
Contact
Kontakt
5 Blatt Pfad 7 17 6
6 1 47 3 Page Path 8 17 5
Contact
Kontakt
7 2 47 3 Blatt Pfad 9 17 6
8 3 1 44 2 10 17 7
9 4 47 3 2 44 2 11
10 5 3 44 2 12
11 6 4 44 2
12 15 8 Plug Mounting location
5 44 2 -X7.B +EBOX
13 Stecker Einbauort
14 Stecker -X6.C Einbauort +EBOX 7 44 2 Function text Plug, access keyboard electronical burglary protection
15 15 7 Funktionstext Stecker Anschluß Tastatur elektronische Diebstahlsicherung
Function text Plug, access harness heating-climatic unit 8 44 2
Funktionstext Stecker Anschluß Kabelbaum Heiz-Klimamodul Plug type
AMP Junior Power Timer 6 pole yellow
Steckertyp
Plug type
AMP Junior Power Timer 2 - 6 pole black Wire harness
Steckertyp 1
4
Kabelbaum
Wire harness
6 3
Kabelbaum Page Path
Contact
Kontakt
Page Path Blatt Pfad
Contact
Kontakt
Blatt Pfad 1 43 3
1 47 3 2 43 3
2 47 3 3 43 3
3 4 43 3
4 47 3 5
0 1 2 3 4 5 6 7 8 9
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Created M. Vogt Blatt 66 von
101
Dokumentenart &EMA3
Checked
Circuit diagrams
K. Brand
881
643 EPE /00
882
Plug overview
Stecker -X7.B Einbauort +EBOX Stecker -X7.C Einbauort +EBOX Stecker -X7.C-2 Einbauort +EBOX Stecker -X7.D Einbauort +EBOX
Function text Plug, access keyboard electronical burglary protection Function text Plug, additional options Function text Plug, additional options Function text Plug, access diagnosis Interface Bomag
Funktionstext Stecker Anschluß Tastatur elektronische Diebstahlsicherung Funktionstext Stecker Zusatzoptionen Funktionstext Stecker Zusatzoptionen Funktionstext Stecker Anschluß Diagnosesteckdose Bomag
AMP Junior Power Timer 6 pole yellow AMP Junior Power Timer 2 - 14 pole black AMP Junior Power Timer 2 - 14 pole black AMP Junior Power Timer 15 pole yellow
Circuit diagrams
Wire harness Wire harness Wire harness Verkabelung Schnittstelle 1 13

Wire harness
4 1
Kabelbaum Kabelbaum Kabelbaum Messtechnik Kabelbaum
2 14
6 3
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
6 1 9 2 2 10 1 2 15 1
2 10 1 3 10 1 3 15 5
Stecker -X7.B Einbauort +EBOX 4 8 7 5 8 6 5 15 2
Function text Plug, access keyboard electronical burglary protection 5 8 6 6 41 6 6 15 4
Funktionstext Stecker Anschluß Tastatur elektronische Diebstahlsicherung 6 41 6 7 48 0 7 15 3
Plug type 7 48 1 8 8 15 8
Steckertyp 8 9 9
Wire harness 9 10 25 6 10 15 2
Kabelbaum 10 25 6 11 25 5 11 15 6
Page Path 11 25 5 12 29 5 12
Contact
Kontakt
Blatt Pfad 12 29 5 13 15 2 13 15 1
1 43 3 13 15 2 14 15 4 14
2 43 3 14 15 4 15 15 1
3 43 3 -X7.D +EBOX
Plug Mounting location Stecker Einbauort Plug Mounting location
4 43 3 -X7.C-2 +EBOX -X8.A +EBOX
Stecker Einbauort Function text Plug, access diagnosis Interface Bomag Stecker Einbauort
5
Function text Plug, additional options Funktionstext Stecker Anschluß Diagnosesteckdose Bomag Function text Plug, access supply cabin potential 30
6 43 3
Funktionstext Stecker Zusatzoptionen Plug type Funktionstext Stecker Anschluß Kabine Potential 30
Plug type Steckertyp Plug type
Plug Mounting location AMP Junior Power Timer 2 - 14 pole black Amphenol RADSOK® 8mm
Stecker -X7.C +EBOX Steckertyp Wire harness Steckertyp
Einbauort 1
13
Wire harness Verkabelung Schnittstelle Kabelbaum Wire harness
Function text Plug, additional options 2 14
15 9 3
Kabelbaum Messtechnik Kabelbaum
BW 220 D-5
Funktionstext Stecker Zusatzoptionen 13
Page Path
1
Contact
Kontakt
Plug type Page Path Blatt Pfad Page Path
Contact
Kontakt
Contact
Kontakt
Steckertyp Blatt Pfad 1 Blatt Pfad

Wire harness 2 14
1 9 2 2 15 1 30 48 2
Kabelbaum 2 10 1 3 15 5
1 13
Page Path 3 10 1 4 Plug Mounting location
Stecker -X8.A Einbauort +EBOX
Contact
Kontakt
Blatt Pfad 4 8 7 5 15 2
5 8 6 6 15 4 Function text Plug, access supply cabin potential 30
1 9 2
6 41 6 7 15 3 Funktionstext Stecker Anschluß Kabine Potential 30
2 10 1
7 48 1 8 15 8 Plug type
3 Amphenol RADSOK® 8mm
8 9 Steckertyp
4 8 7
5 9 10 15 2 Wire harness
10 25 6 11 15 6 Kabelbaum
6
7 11 25 5 12 Page Path
Contact
Kontakt
8 12 29 5 13 15 1 Blatt Pfad
9 13 15 2 14 30 48 1
10 14 15 4 15 15 1
11 Plug Mounting location
Plug Mounting location Plug Mounting location Stecker -X8.B Einbauort +EBOX
12 -X7.C-2 +EBOX -X7.D +EBOX
Stecker Einbauort Stecker Einbauort
13 Function text Plug, access supply cabin potential 31
Function text Plug, additional options Function text Plug, access diagnosis Interface Bomag Funktionstext Stecker Anschluß Kabine Potential 31
14
Funktionstext Stecker Zusatzoptionen Funktionstext Stecker Anschluß Diagnosesteckdose Bomag
Plug type
Plug type Plug type Amphenol RADSOK® 6mm
AMP Junior Power Timer 2 - 14 pole black AMP Junior Power Timer 15 pole yellow Steckertyp
Steckertyp Steckertyp
Wire harness
Wire harness Verkabelung Schnittstelle 1 13
Wire harness Kabelbaum
Kabelbaum Messtechnik Kabelbaum
2 14 Page Path
Page Path Page Path
Contact
Kontakt
Blatt Pfad
Contact
Kontakt
Contact
Kontakt
Blatt Pfad Blatt Pfad

31 48 2
1 9 2 1
0 1 2 3 4 5 6 7 8 9
Page from
101
Dokumentenart &EMA3
Checked K. Brand
Plug overview
Stecker -X8.B Einbauort +EBOX Stecker -X11 Einbauort +REFR Stecker -X14 Einbauort +SEAT Stecker -X21 Einbauort +DRUM
Function text Plug, access supply cabin potential 31 Function text Plug, connection rear frame - engine module Function text Plug, seat contact switch Function text Plug, transducer acceleration rear
Funktionstext Stecker Anschluß Kabine Potential 31 Funktionstext Stecker Verbindung Hinterrahmen - Motormodul Funktionstext Stecker Sitzkontaktschalter Funktionstext Stecker Beschleunigungsaufnehmer hinten
Amphenol RADSOK® 6mm Deutsch DT 12 pole Code A Deutsch DT 3 pole Deutsch DT 4 pole
Konsole Sitz
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
31 48 1 10 42 8 A 25 3 1 37 3
11 42 1 B 25 3 2 37 4
Plug Mounting location 12 C 3 37 4
Stecker -X10 Einbauort +CAB 4 37 3
Function text Plug, heating climatic unit Plug Mounting location Plug Mounting location
Funktionstext Stecker Heiz-Klima-Einheit Stecker -X11 Einbauort +REFR Stecker -X14 Einbauort +SEAT Plug Mounting location
Plug type Function text Plug, connection rear frame - engine module Function text Plug, seat contact switch Stecker -X22 Einbauort +EBOX
AMP HDSCS 4 pole Code A
Steckertyp Funktionstext Stecker Verbindung Hinterrahmen - Motormodul Funktionstext Stecker Sitzkontaktschalter Function text Plug, access rotary beacon ROPS
Wire harness Plug type Plug type Funktionstext Stecker Anschluß Rundumkennleuchte ROPS
Deutsch DT 3 pole
Kabelbaum Steckertyp Steckertyp Plug type
FASTIN-FASTON TAB housing 2 way
Page Path Wire harness Wire harness Steckertyp
Kabelbaum Kabelbaum
Contact
Kontakt
Blatt Pfad Wire harness
Page Path Page Path Kabelbaum
1 47 3
Contact
Kontakt
Contact
Kontakt
2 47 4 Blatt Pfad Blatt Pfad Page Path
Contact
Kontakt
3 1 24 8 A 25 3 Blatt Pfad
4 47 3 2 24 8 B 25 3 1 41 2
3 C 25 3 2 41 2
Plug Mounting location 4
Stecker -X10 Einbauort +CAB 5 Plug Mounting location Plug Mounting location
Function text Plug, heating climatic unit 6 42 1 Stecker -X16 Einbauort +DPL Stecker -X23 Einbauort +SEAT
Funktionstext Stecker Heiz-Klima-Einheit 7 42 8 Function text Plug, keyboard electronical burglary protection Function text Plug, supply travel lever
Plug type 8 42 1 Funktionstext Stecker Tastatur Elektronische Diebstahlsicherung Funktionstext Stecker Vorsorgung Fahrhebel
AMP HDSCS 4 pole Code A
BW 220 D-5
Steckertyp 9 42 2 Plug type Plug type
Deutsch DT 4 pole Deutsch DT 12 pole Code A
Wire harness 10 42 8 Steckertyp Steckertyp
Kabelbaum 11 42 1 Wire harness Wire harness
Konsole Sitz
Page Path 12 Kabelbaum Kabelbaum
Contact
Kontakt
Blatt Pfad Page Path Page Path
Contact
Kontakt
Contact
Kontakt
1 47 3 Blatt Pfad Blatt Pfad

Stecker -X12 Einbauort +MOT
2 47 4 1 43 5 1 14 6
Function text Plug, compressor air conditioning
3 2 43 5 2 14 5
Funktionstext Stecker Kompressor Klimaanlage
4 47 3 3 43 5 3 26 9
Plug type
Circular connector 4,6mm 4 43 5 4
Steckertyp
Stecker -X11 Einbauort +REFR Wire harness
Motor Plug Mounting location 6 16 4
Function text Plug, connection rear frame - engine module Kabelbaum Stecker -X20 Einbauort +DRUM 7 16 5
Funktionstext Stecker Verbindung Hinterrahmen - Motormodul Page Path Function text Plug, transducer acceleration front 8 26 2
Contact
Kontakt
Plug type Blatt Pfad Funktionstext Stecker Beschleunigungsaufnehmer vorne 9 14 6
Deutsch DT 12 pole Code A
Steckertyp 1 47 1 Plug type 10 14 7
Deutsch DT 4 pole
Wire harness Steckertyp 11 26 1
Kabelbaum Plug Mounting location Wire harness 12 26 4
Page Path Stecker -X12 Einbauort +MOT Kabelbaum
Contact
Kontakt
Blatt Pfad Function text Plug, compressor air conditioning Page Path
Funktionstext Stecker Kompressor Klimaanlage
Contact
Kontakt
1 24 8 Blatt Pfad
Plug type
2 24 8 Circular connector 4,6mm 1 37 1
Steckertyp
3 29 6 2 37 2
Kabelbaum
5 29 6 4 37 1
6 42 1 Page Path
Contact
Kontakt
7 42 8 Blatt Pfad
8 42 1 1 47 1
9 42 2
0 1 2 3 4 5 6 7 8 9
Page from
101
Dokumentenart &EMA3
Checked
Circuit diagrams
K. Brand
883
643 EPE /00
884
Plug overview
Stecker -X23.A Einbauort +SEAT Stecker -X24 Einbauort +SEAT Stecker -X26 Einbauort +SEAT Stecker -X28 Einbauort +REFR
Function text Plug, supply travel lever Function text Plug, IO´s travel lever Function text Plug, potentiometer frequency plates Function text Plug, sensor height adjustment plates
Funktionstext Stecker Vorsorgung Fahrhebel Funktionstext Stecker Ein-/Ausgänge Fahrhebel Funktionstext Stecker Potentiometer Frequenzverstellung Anbauplatten Funktionstext Stecker Sensor Höhenverstellung Platten
Deutsch DTM 12 pole Code A Deutsch DT 8 pole AMP Mateń´loc 3 pole white Deutsch DTM 3 pole
Circuit diagrams

Adapter Fahrhebel Konsole Sitz Konsole Sitz
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
1 14 6 6 32 7 1 26 4 1 35 5
2 14 5 7 2 26 4 2 35 5
3 26 9 8 3 26 4 3 35 5
4 26 0
5 26 3 Plug Mounting location Plug Mounting location Plug Mounting location
6 16 4 Stecker -X25 Einbauort +REFR Stecker -X26 Einbauort +SEAT Stecker -X29 Einbauort +REFR
7 16 5 Function text Plug, access double pump Function text Plug, potentiometer frequency plates Function text Plug, access lifting unit plates
8 26 2 Funktionstext Stecker Anschluß Doppelpumpe Funktionstext Stecker Potentiometer Frequenzverstellung Anbauplatten Funktionstext Stecker Anschluß Hubwerk Platten
9 14 6 Plug type Plug type Plug type
Deutsch DTM 8 pole AMP Mateń´loc 3 pole white Deutsch DTM 6 pole
10 14 7 Steckertyp Steckertyp Steckertyp
11 26 1 Wire harness Wire harness Wire harness
12 26 4 Kabelbaum Kabelbaum Kabelbaum
Page Path Page Path Page Path
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Blatt Pfad Blatt Pfad Blatt Pfad

Stecker -X23.B Einbauort +SEAT
6 28 4 1 26 4 1 35 7
Function text Plug, supply travel lever
1 27 2 2 26 4 2 35 6
Funktionstext Stecker Vorsorgung Fahrhebel
2 27 3 3 26 4 3 35 6
Plug type
Deutsch DT 12 pole Code A 3 27 4 4 35 4
Steckertyp
4 27 4 Plug Mounting location 5 35 6
Wire harness
Adapter Fahrhebel 5 27 2 Stecker -X27 Einbauort +PLA 6 35 6
Kabelbaum Function text Plug, quick connect coupling plates
7 28 4
Page Path 8 28 5 Funktionstext Stecker Schnellverschlußkupplung Platten Plug Mounting location
-X29 +REFR
Contact
Kontakt
BW 220 D-5
Blatt Pfad Plug type Stecker Einbauort
1 14 6 Plug Mounting location Steckertyp Function text Plug, access lifting unit plates
2 14 5 Stecker -X25 Einbauort +REFR Wire harness Funktionstext Stecker Anschluß Hubwerk Platten
3 26 9 Function text Plug, access double pump Kabelbaum Plug type
Deutsch DTM 6 pole
4 26 0 Funktionstext Stecker Anschluß Doppelpumpe Page Path Steckertyp
Plug type
Contact
Kontakt
5 26 3 Blatt Pfad Wire harness
Deutsch DTM 8 pole
6 16 4 Steckertyp Kabelbaum
1 35 5
7 16 5 Wire harness 2 35 5 Page Path
Kabelbaum
Contact
Kontakt
8 26 2 3 35 4 Blatt Pfad
9 14 6 Page Path 1 35 7
Contact
Kontakt
10 14 7 Blatt Pfad Plug Mounting location 2 35 6
11 26 1 1 27 2 Stecker -X28 Einbauort +REFR 3 35 6
12 26 4 2 27 3 Function text Plug, sensor height adjustment plates 4 35 4
3 27 4 Funktionstext Stecker Sensor Höhenverstellung Platten 5 35 6
Plug Mounting location Plug type
-X24 +SEAT 4 27 4 Deutsch DTM 3 pole
6 35 6
Stecker Einbauort Steckertyp
5 27 2
Function text Plug, IO´s travel lever Plug
6 28 4 Wire harness Mounting location
Funktionstext Stecker Ein-/Ausgänge Fahrhebel Stecker -X30 +REFR
7 28 4 Kabelbaum Einbauort
Plug type Function text Plug, backup alarm buzzer
Deutsch DT 8 pole 8 28 5 Page Path
Steckertyp Funktionstext Stecker Rückfahrwarnsummer
Contact
Kontakt
Blatt Pfad
Wire harness Plug type
Konsole Sitz 1 35 5 Deutsch DT 2 pole
Kabelbaum Steckertyp
Page Path 2 35 5
3 35 5 Wire harness
Contact
Kontakt
Blatt Pfad Kabelbaum
1 26 7 Page Path
Contact
Kontakt
2 26 8 Blatt Pfad
3 1 30 6
4 26 5 2 30 6
5 32 6
0 1 2 3 4 5 6 7 8 9
Page from
101
Dokumentenart &EMA3
Checked K. Brand
Plug overview
Stecker -X30 Einbauort +REFR Stecker -X34 Einbauort +EBOX Stecker -X35 Einbauort +EBOX Stecker -X39 Einbauort +DRUM
Function text Plug, backup alarm buzzer Function text Diagnosis interface BOMAG Function text Plug, ECU propulsion Function text Plug, transducer Economizer
Funktionstext Stecker Rückfahrwarnsummer Funktionstext Diagnosesteckdose BOMAG Funktionstext Stecker ECU Fahrantrieb Funktionstext Stecker Aufnehmer Economizer
Deutsch DT 2 pole Burndy 19 pole AMP 68 pole Deutsch DTM 4 pole
Aufnehmer Economizer
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
1 30 6 B 15 3 23 13 2 1 38 5
2 30 6 C 15 4 24 30 9 2 38 5
D 15 5 25 30 8 3 38 6
Plug Mounting location E 15 6 26 15 3 4 38 6
Stecker -X33 Einbauort +ARC F 15 8 27 15 2
Function text Plug, module monitoring G 28 11 1 Plug Mounting location
Funktionstext Stecker Modul Überwachung H 29 27 4 Stecker -X39 Einbauort +DRUM
Plug type J 15 2 30 27 4 Function text Plug, transducer Economizer
AMP Superseal 26 pole
Steckertyp K 31 35 6 Funktionstext Stecker Aufnehmer Economizer
Wire harness L 32 25 2 Plug type
Deutsch DTM 4 pole
Kabelbaum M 33 15 5 Steckertyp
Page Path N 15 1 34 31 3 Wire harness
Kabelbaum
Contact
Kontakt
Blatt Pfad P 15 1 35 25 6
1 R 15 1 36 24 3 Page Path
Contact
Kontakt
2 24 8 S 37 24 5 Blatt Pfad
3 24 7 T 38 24 4 1 38 5
4 19 5 U 39 24 2 2 38 5
5 41 7 V 40 3 38 6
6 41 4 38 6
7 -X35 +EBOX
8 42 7 Plug Mounting location
9 19 1 Function text Plug, ECU propulsion 44 Stecker -X41 Einbauort +EBOX
Funktionstext Stecker ECU Fahrantrieb
BW 220 D-5
10 19 2 45 36 5 Function text Plug, supply exhaust gas recirculation
Plug type 46 28 2 Funktionstext Stecker Versorgung Abgasrückführung
11 19 3 AMP 68 pole
Steckertyp 47 28 3
12 19 4 Plug type
Wire harness 48 31 4 EPC 12 pole
13 Steckertyp
Kabelbaum 49 31 5
14 Wire harness
15 Page Path 50 34 7 Kabelbaum
Contact
Kontakt
16 Blatt Pfad 51 34 8 Page Path
52
Contact
Kontakt
17 1 13 2 Blatt Pfad
18 2 29 4 53 15 4
54 11 2 1
19 3 29 7 2 22 8
20 4 55 11 5
56 11 3 3 22 8
21 16 2 5 4
22 16 2 6 27 2 57 11 4
58 11 5 5 22 8
23 7 27 3 6
24 8 35 5 59 11 6
60 11 6 7
25 14 1 9 24 1 8
26 14 1 10 35 6 61 30 6
62 34 3 9
11 34 4 10
Plug Mounting location 12 25 5 63 35 4
-X34 +EBOX 64 29 5 11
65 11 6 12
Function text Diagnosis interface BOMAG 14 29 1
Funktionstext Diagnosesteckdose BOMAG 15 25 3 66 11 7
Plug type 16 25 4 67 11 8
Burndy 19 pole 68 11 9
Steckertyp 17 25 7
Wire harness 18
Kabelbaum 19
Page Path 20 28 4
Contact
Kontakt
Blatt Pfad 21 28 5
A 15 2 22 35 7
0 1 2 3 4 5 6 7 8 9
Page from
101
Dokumentenart &EMA3
Checked
Circuit diagrams
K. Brand
885
643 EPE /00
886
Plug overview
Stecker -X41 Einbauort +EBOX Stecker -X44 Einbauort +EBOX Stecker -X45 Einbauort +EBOX Stecker -X45 Einbauort +EBOX
Function text Plug, access pre-heating relay Function text Plug, engine-controller motor-part Function text Plug, engine-controller machine-part Function text Plug, engine-controller machine-part
Funktionstext Stecker Anschluß Vorglührelais Funktionstext Stecker Motorsteuergerät Motorseite Funktionstext Stecker Motorsteuergerät Maschinenseite Funktionstext Stecker Motorsteuergerät Maschinenseite
EPC 12 pole Tyco MQS 60 pole Tyco MQS 94 pole Tyco MQS 94 pole
Circuit diagrams

EMR EMR EMR
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
1 29 9 61 21 3
2 22 8 30 10 62 21 3
3 22 8 31 22 2 11 63 21 7
4 32 22 3 12 64 21 7
5 22 8 33 22 3 13 65
6 34 22 8 14 66
7 35 15 67
8 36 16 68
9 37 17 69
10 38 18 70
11 39 19 71
12 40 23 8 20 72 21 1
41 23 6 21 73
Stecker -X44 Einbauort +EBOX 43 23 2 23 75
Function text Plug, engine-controller motor-part 44 24 76
Funktionstext Stecker Motorsteuergerät Motorseite 45 25 21 4 77
Plug type 46 22 3 26 78
Tyco MQS 60 pole
Steckertyp 47 22 2 27 79
Wire harness 48 22 2 28 21 2 80
Kabelbaum 49 23 9 29 81
Page Path 50 23 4 30 82 21 3
Contact
Kontakt
BW 220 D-5
Blatt Pfad 51 23 2 31 83
1 22 4 52 32 84
2 22 7 53 23 8 33 85
3 22 5 54 23 7 34 86
4 22 6 55 35 87
5 22 6 56 23 1 36 88
6 22 5 57 23 6 37 89
7 23 5 58 23 5 38 90
8 23 2 59 39 91
9 22 6 60 40 92
10 23 3 41 93
Plug Mounting location 42 94
11 23 6 -X45 +EBOX
Stecker Einbauort 43
12 23 5
Function text Plug, engine-controller machine-part 44 Plug Mounting location
13 23 2 -X46 +MOT
Funktionstext Stecker Motorsteuergerät Maschinenseite 45 Stecker Einbauort
14 23 8
Plug type 46 Function text Plug, engine EMR
15 Tyco MQS 94 pole
Steckertyp 47 Funktionstext Stecker Motor EMR
16 22 1
Wire harness 48 Plug type
17 EMR EPC 42 pole
Kabelbaum 49 Steckertyp
18
19 23 9 Page Path 50 Wire harness
Kabelbaum
Contact
Kontakt
20 23 4 Blatt Pfad 51
21 22 8 1 21 0 52 Page Path
Contact
Kontakt
22 2 21 5 53 Blatt Pfad
23 23 7 3 21 0 54 1 23 5
24 22 8 4 21 5 55 2
25 5 21 1 56 3
26 23 3 6 21 5 57 4
27 23 4 7 58 5
28 8 59 6
60 21 4
0 1 2 3 4 5 6 7 8 9
Page from
101
Dokumentenart &EMA3
Checked K. Brand
Plug overview
Stecker -X46 Einbauort +MOT Stecker -X46 Einbauort +MOT Stecker -X50.f Einbauort +CAB Stecker -X51 Einbauort +MOT
Function text Plug, engine EMR Function text Plug, engine EMR Function text Plug, access display back up monitoring Function text Plug, electronic system ZTR telematics
Funktionstext Stecker Motor EMR Funktionstext Stecker Motor EMR Funktionstext Stecker Anschluß Monitor Rückraumüberwachung Funktionstext Stecker Elektronik System ZTR Telematic
EPC 42 pole EPC 42 pole Code B Deutsch DT 6 pole Deutsch DT 8 pole Code A
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
7 1 23 5 1 55 5 1 45 2
8 2 2 55 5 2 45 2
9 23 4 3 3 55 5 3 45 2
10 23 6 4 4 4
11 5 5 5
12 6 6 6
13 23 4 7 7
14 23 3 8 Plug Mounting location 8
15 23 4 9 23 4 Stecker -X50.m Einbauort +CAB
16 23 7 10 23 6 Function text Plug, access display back up monitoring Plug Mounting location
17 23 6 11 Funktionstext Stecker Anschluß Monitor Rückraumüberwachung Stecker -X55 Einbauort +PUMP
18 12 Plug type Function text Plug, pressure sensor travel pump axle MA
Deutsch DT 6 pole
19 23 9 13 23 4 Steckertyp Funktionstext Stecker Drucksensor Fahrpumpe Achse MA
20 23 9 14 23 3 Wire harness Plug type
AMP Superseal 3pol
21 23 5 15 23 4 Kabelbaum Steckertyp
22 23 8 16 23 7 Page Path Wire harness
Kabelbaum
Contact
Kontakt
23 23 8 17 23 6 Blatt Pfad
24 23 6 18 1 55 5 Page Path
Contact
Kontakt
25 23 2 19 23 9 2 55 5 Blatt Pfad
26 23 1 20 23 9 3 55 5 1 27 2
27 23 2 21 23 5 4 55 5 2 27 2
28 23 7 22 23 8 5 55 5 3
BW 220 D-5
29 23 8 23 23 8 6
31 23 2 25 23 2 Plug Mounting location Stecker -X56 Einbauort +PUMP
32 23 3 26 23 1 Stecker -X51 Einbauort +MOT Function text Plug, pressure sensor travel pump axle MB
33 23 2 27 23 2 Function text Plug, electronic system ZTR telematics Funktionstext Stecker Drucksensor Fahrpumpe Achse MB
34 22 1 28 23 7 Funktionstext Stecker Elektronik System ZTR Telematic Plug type
35 22 2 29 23 8 AMP Superseal 3pol
Plug type Steckertyp
36 22 3 30 23 5 Deutsch DT 8 pole Code A
Steckertyp Wire harness
37 22 2 31 23 2 Wire harness Kabelbaum
38 32 23 3 Kabelbaum Page Path
39 22 3 33 23 2
Contact
Kontakt

40 22 2 34 22 1
Contact
Kontakt
Blatt Pfad 1 27 3
41 22 3 35 22 2
42 22 4 36 22 3 1 45 2 2 27 3
34 22 5 37 22 2 2 45 2 3
35 22 5 38 3 45 2
37 22 6 39 22 3 Stecker -X57 +PUMP
5 Einbauort
40 22 6 40 22 2
6 Function text Plug, pressure sensor travel pump drum MA
41 22 6 41 22 3 Funktionstext Stecker Drucksensor Fahrpumpe Bandage MA
42 22 7 42 22 4 7
8 Plug type
34 22 5 AMP Superseal 3pol
Steckertyp
35 22 5
Wire harness
37 22 6
Kabelbaum
40 22 6
41 22 6 Page Path
Contact
Kontakt
42 22 7 Blatt Pfad
1 27 4
2 27 4
3
0 1 2 3 4 5 6 7 8 9
Page from
101
Dokumentenart &EMA3
Checked
Circuit diagrams
K. Brand
887
643 EPE /00
888
Plug overview
Stecker -X58 Einbauort +PUMP Stecker -X67.m Einbauort +MOT Stecker -X72.f Einbauort +MOT Stecker -X76 Einbauort +MOT
Function text Plug, pressure sensor travel pump drum MB Function text Plug access heating prefilter fuel Function text Plug, floating switch coolant expansion tank Function text Plug, access fuel pump additional heater
Funktionstext Stecker Drucksensor Fahrpumpe Bandage MB Funktionstext Stecker Anschluß Heizung Vorfilter Kraftstoff Funktionstext Stecker Schwimmerschalter Kühlmittelausgleichsbehälter Funktionstext Stecker Anschluss Kraftstoffpumpe Zusatzheizung
AMP Superseal 3pol Deutsch DT 2 pole PKC 2 way Deutsch DTM 2 pole
Circuit diagrams

Motor
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
1 27 4 1 18 8 1 24 2 1 46 5
2 27 4 2 18 8 2 24 2 2 46 5
3
Plug Mounting location Plug Mounting location Plug Mounting location
Plug Mounting location Stecker -X68.f Einbauort +REFR Stecker -X72.m Einbauort +MOT Stecker -X76 Einbauort +MOT
Stecker -X65 Einbauort +CAB Function text Plug, pressure switch air conditioning Function text Plug, floating switch coolant expansion tank Function text Plug, access fuel pump additional heater
Function text Plug, windscreen wiper motor rear Funktionstext Stecker Druckschalter Klimaanlage Funktionstext Stecker Schwimmerschalter Kühlmittelausgleichsbehälter Funktionstext Stecker Anschluss Kraftstoffpumpe Zusatzheizung
Funktionstext Stecker Scheibenwischermotor hinten Plug type Plug type Plug type
Deutsch DT 4 pole Deutsch DTM 2 pole
Plug type Steckertyp Steckertyp Steckertyp
P4NAT
Steckertyp Wire harness Wire harness Wire harness
Motor
Wire harness Kabelbaum Kabelbaum Kabelbaum
Kabelbaum Page Path Page Path Page Path
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Page Path Blatt Pfad Blatt Pfad Blatt Pfad
Contact
Kontakt
Blatt Pfad 1 47 1 1 24 2 1 46 5
1 52 5 2 47 1 2 24 2 2 46 5
2 52 5 3
3 52 5 4 Plug Mounting location Plug Mounting location
4 52 5 Stecker -X73 Einbauort +MOT Stecker -X79 Einbauort +DPL
Plug Mounting location Function text Plug, WaterInFuel Sensor Function text Plug, headlight front left
Plug Mounting location Stecker -X68.m Einbauort +REFR Funktionstext Stecker Sensor Wasser im Kraftstoff Funktionstext Stecker Scheinwerfer vorne links
Stecker -X66 Einbauort +CAB Function text Plug, pressure switch air conditioning Plug type Plug type
Tyco Junior Power Timer 2 pole Deutsch DT 6 pole
Function text Plug windscreen wiper motor front Funktionstext Stecker Druckschalter Klimaanlage Steckertyp Steckertyp
BW 220 D-5
Funktionstext Stecker Scheibenwischermotor vorne Plug type Wire harness Wire harness
Deutsch DT 4 pole Motor
Plug type Steckertyp Kabelbaum Kabelbaum
P6SNAT
Steckertyp Wire harness Page Path Page Path
Wire harness Kabelbaum
Contact
Kontakt
Contact
Kontakt

Kabelbaum Page Path 1 21 7 2 42 7
Contact
Kontakt
Page Path Blatt Pfad 2 21 7 3 42 1
Contact
Kontakt
Blatt Pfad 1 47 1 5 42 4
1 52 3 2 47 1 Plug Mounting location 6 42 1
2 52 3 3 Stecker -X73 Einbauort +MOT
3 52 3 4 Function text Plug, WaterInFuel Sensor Plug Mounting location
4 Funktionstext Stecker Sensor Wasser im Kraftstoff Stecker -X80 Einbauort +REFR
5 52 3 Plug Mounting location Plug type Function text Plug, tail light rear left
-X69 +REFR Tyco Junior Power Timer 2 pole
6 Stecker Einbauort Steckertyp Funktionstext Stecker Rückleuchte links
Function text Plug, sender level gauge Wire harness Plug type
Deutsch DT 4 pole
Plug Mounting location Funktionstext Stecker Tauchrohrgeber Kabelbaum Steckertyp
Stecker -X67.f Einbauort +MOT Plug type Page Path Wire harness
AMP Superseal 3pol
Function text Plug access heating prefilter fuel Steckertyp Kabelbaum
Contact
Kontakt
Blatt Pfad
Funktionstext Stecker Anschluß Heizung Vorfilter Kraftstoff Wire harness Page Path
1 21 7
Plug type Kabelbaum
Contact
Kontakt
Deutsch DT 2 pole 2 21 7 Blatt Pfad

Steckertyp Page Path 1 42 8
Wire harness
Contact
Kontakt
Motor
Blatt Pfad 2 42 8
Kabelbaum
1 3 42 1
Page Path 2 24 8 4 42 1
Contact
Kontakt
Blatt Pfad 3 24 8
1 18 8
2 18 8
0 1 2 3 4 5 6 7 8 9
Page from
101
Dokumentenart &EMA3
Checked K. Brand
Plug overview
Stecker -X80 Einbauort +REFR Stecker -X85 Einbauort +CAB Stecker -X87 Einbauort +SEAT Stecker -X88 Einbauort +EBOX
Function text Plug, tail light rear left Function text Plug, access BCM-system Function text Plug, suspension seat Function text Plug, measurement controller
Funktionstext Stecker Rückleuchte links Funktionstext Stecker Anschluß BCM-System Funktionstext Stecker Luftfedersitz Funktionstext Stecker Messtechniksteuerung
Deutsch DT 4 pole FASTIN-FASTON TAB housing 2 way AMP 68 pole
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
1 42 8 1 54 5 1 47 6 39
2 42 8 2 54 5 2 47 6 40
3 42 1 3 54 6 41
4 42 1 4 54 1 Plug Mounting location 42
5 54 1 Stecker -X88 Einbauort +EBOX 43
Plug Mounting location 6 Function text Plug, measurement controller 44
Stecker -X81 Einbauort +REFR Funktionstext Stecker Messtechniksteuerung 45
Function text Plug, tail light rear right Plug Mounting location Plug type 46 33 8
-X85 +CAB AMP 68 pole
Funktionstext Stecker Rückleuchte rechts Stecker Einbauort Steckertyp 47 33 7
Plug type Function text Plug, access BCM-system Wire harness 48
Deutsch DT 4 pole
Steckertyp Funktionstext Stecker Anschluß BCM-System Kabelbaum 49
Wire harness Plug type Page Path 50
Deutsch DT 6 pole
Contact
Kontakt
Blatt Pfad 51
Page Path Wire harness 1 13 6 52
Kabelbaum
Contact
Kontakt
Blatt Pfad 2 53 16 7
1 42 8 Page Path 3 54 12 2
Contact
Kontakt
2 42 8 Blatt Pfad 4 37 6 55 12 5
3 42 2 1 5 37 7 56 12 3
4 42 2 2 54 5 6 57 12 4
3 54 6 7 37 3 58 12 5
Stecker -X81 Einbauort +REFR 5 54 1 9 33 5 60 12 6
BW 220 D-5
Function text Plug, tail light rear right 6 10 61 33 9
Funktionstext Stecker Rückleuchte rechts 11 62
Plug type Plug Mounting location 12 63
Deutsch DT 4 pole -X86 +DRUM 64
Steckertyp Stecker Einbauort 13
Wire harness Function text Plug, sensor adjustable motor 14 65 12 6
Kabelbaum Funktionstext Stecker Sensor Verstellmotor 15 66 12 7
Page Path Plug type 16 67 12 8
Deutsch DTM 3 pole 68 12 9
Steckertyp
Contact
Kontakt
Blatt Pfad 17
1 42 8 Wire harness 18
Kabelbaum Plug Mounting location
2 42 8 19 -X90 +CAB
Stecker Einbauort
3 42 2 Page Path 20
Function text Plug, access GPS - BCM
Contact
Kontakt
4 42 2 Blatt Pfad 21
Funktionstext Stecker Anschluß GPS - BCM
1 33 5 22
Plug type
Plug Mounting location 2 33 5 23 13 5 SUB-D 9 pole
Steckertyp
Stecker -X82 Einbauort +DPL 3 33 5 24
25 37 8 Wire harness
Function text Plug, headlight front right Kabelbaum
Funktionstext Stecker Scheinwerfer vorne rechts Plug Mounting location 26 15 7
Stecker -X87 +SEAT 27 15 6 Page Path
Plug type Einbauort
Contact
Kontakt
Deutsch DT 6 pole 28 12 1 Blatt Pfad

Steckertyp Function text Plug, suspension seat
Wire harness Funktionstext Stecker Luftfedersitz 29 37 2 1
Kabelbaum Plug type 30 37 4 2 54 5
FASTIN-FASTON TAB housing 2 way 31 37 1 3 54 5
32 32 3 4
Contact
Kontakt
Konsole Sitz 33 16 8 5 54 5
Kabelbaum
2 42 8 34 6
3 42 2 Page Path
35 7
Contact
Kontakt
5 42 5 Blatt Pfad
36 8
6 42 2 1 47 6 37 9
2 47 6 38
0 1 2 3 4 5 6 7 8 9
Page from
101
Dokumentenart &EMA3
Checked
Circuit diagrams
K. Brand
889
643 EPE /00
890
Plug overview
Stecker -X90 Einbauort +CAB Stecker -X92 Einbauort +CAB Stecker -X94 Einbauort +CAB Stecker -X96.A Einbauort +CAB
Function text Plug, access GPS - BCM Function text Plug, access GPS-Receiver Function text Plug, printer Function text Plug, supply BCM
Funktionstext Stecker Anschluß GPS - BCM Funktionstext Stecker Anschluß GPS-Antenne Funktionstext Stecker Drucker Funktionstext Stecker Versorgung BCM
SUB-D 9 pole Burndy 12 pole AMP Mateń´loc 6 pole white Deutsch DT 2 pole
Circuit diagrams

Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
1 A 54 8 1 53 6 1 54 5
2 54 5 B 54 8 2 53 7 2 54 5
3 54 5 C 54 8 3 53 7
4 D 54 8 4 53 8 Plug Mounting location
5 54 5 E 54 8 5 53 7 Stecker -X96.A Einbauort +CAB
6 F 6 Function text Plug, supply BCM
7 G Funktionstext Stecker Versorgung BCM
8 H Plug Mounting location Plug type
-X95.A +CAB Deutsch DT 2 pole
9 J Stecker Einbauort Steckertyp
K Function text Plug, CAN BCM Dongle Wire harness
Plug Mounting location L Funktionstext Stecker CAN BCM Dongle Kabelbaum
Stecker -X91 Einbauort +CAB M Plug type Page Path
SUB-D 9 pole
Function text Plug, USB BCM Dongle Steckertyp
Contact
Kontakt
Blatt Pfad
Funktionstext Stecker USB BCM Dongle Plug Mounting location Wire harness
-X93 +CAB 1 54 5
Plug type Stecker Einbauort Kabelbaum
USB 2 54 5
Steckertyp Function text Plug, supply GPS System Page Path
Wire harness Funktionstext Stecker Spannungsversorgung GPS System
Contact
Kontakt
Blatt Pfad Plug Mounting location
Kabelbaum Plug type Stecker -X97 Einbauort +CAB
Deutsch DT 3 pole 1
2 54 2 Function text Plug, GPS-Receiver StarFire
Contact
Kontakt
Blatt Pfad Wire harness 3 Funktionstext Stecker GPS-Antenne StarFire
Kabelbaum Plug type
1 54 4 4 Deutsch DT 12 pole
2 54 4 Page Path 5 Steckertyp
Contact
Kontakt
BW 220 D-5
3 54 4 Blatt Pfad 6 Wire harness
4 54 4 A 54 6 7 54 2 Kabelbaum
SH 54 4 B 54 6 8 Page Path
Contact
Kontakt
C 54 6 9 Blatt Pfad
-X92 +CAB 2 54 9
Stecker Einbauort Plug Mounting location Plug Mounting location
-X94 +CAB -X95.A +CAB 6 54 9
Function text Plug, access GPS-Receiver Stecker Einbauort Stecker Einbauort
7 54 9
Funktionstext Stecker Anschluß GPS-Antenne Function text Plug, printer Function text Plug, CAN BCM Dongle
11 54 9
Plug type Funktionstext Stecker Drucker Funktionstext Stecker CAN BCM Dongle
Burndy 12 pole 12 54 8
Steckertyp Plug type Plug type
AMP Mateń´loc 6 pole white SUB-D 9 pole
Wire harness Steckertyp Steckertyp
Kabelbaum Wire harness Wire harness Stecker -X99 Einbauort +SEAT
Page Path Kabelbaum Kabelbaum Function text Plug, heating operators seat
Contact
Kontakt
Blatt Pfad Page Path Page Path Funktionstext Stecker Sitzheizung
Contact
Kontakt
Contact
Kontakt
A 54 7 Blatt Pfad Blatt Pfad Plug type

FASTIN-FASTON TAB housing 2 way
B 54 7 1 53 6 1 Steckertyp
C 54 7 2 53 7 2 54 2 Wire harness
Konsole Sitz
D 54 7 3 3 Kabelbaum
E 54 7 4 53 8 4 Page Path
Contact
Kontakt
F 5 53 7 5 Blatt Pfad
G 6 6 1 47 7
H 7 54 2 2 47 7
J 8
T 9
L
M
0 1 2 3 4 5 6 7 8 9
Page from
101
Dokumentenart &EMA3
Checked K. Brand
Plug overview
Stecker -X99 Einbauort +SEAT Stecker -X101.f Einbauort +EBOX Stecker -X102 Einbauort +EBOX Stecker -X103 Einbauort +EBOX
Function text Plug, heating operators seat Function text Plug, connection Driving controller - Engine Function text Plug, connection Armatures - Console seat Function text Plug, connection Driving controller - Rear frame
Funktionstext Stecker Sitzheizung Funktionstext Stecker Verbindung Fahrsteuerung - Motor Funktionstext Stecker Verbindung Armaturen - Konsole Sitz Funktionstext Stecker Verbindung Fahrsteuerung - Hinterrahmen
FASTIN-FASTON TAB housing 2 way AMP Junior Power Timer 12 pole blue AMP Junior Power Timer 15 pole grey AMP Junior Power Timer 18 pole green
Motor 10 1 Konsole Sitz 13 1 16 1
12 9 6 3 15 9 3 18 12 9 3
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
1 47 7 5 10 9 29 4
2 47 7 6 11 10 29 7
7 12 11 24 5
Plug Mounting location 8 13 12 31 5
Stecker -X100 Einbauort +EBOX 9 14 13 31 6
Function text Plug, connection Driving controller - Console seat 10 15 14
Funktionstext Stecker Verbindung Fahrsteuerung - Konsole Sitz 11 15
Plug type 12 Plug Mounting location 16
AMP Junior Power Timer 6 pole grey -X102 +EBOX
Steckertyp Stecker Einbauort 17
Wire harness Plug Mounting location Function text Plug, connection Armatures - Console seat 18
4 1 +EBOX
Kabelbaum Stecker -X101.m Einbauort Funktionstext Stecker Verbindung Armaturen - Konsole Sitz
6 3
Page Path Function text Plug, connection Driving controller - Engine Plug type Plug Mounting location
AMP Junior Power Timer 15 pole grey -X103 +EBOX
Funktionstext Stecker Verbindung Fahrsteuerung - Motor Steckertyp Stecker Einbauort
Contact
Kontakt
Blatt Pfad
Plug type Wire harness Function text Plug, connection Driving controller - Rear frame
1 AMP Junior Power Timer 12 pole blue 1
Steckertyp Kabelbaum Funktionstext Stecker Verbindung Fahrsteuerung - Hinterrahmen
2 3 9 15
Wire harness Page Path Plug type
3 Fahrsteuerung 1 AMP Junior Power Timer 18 pole green
Contact
Kontakt
4 Blatt Pfad
3 6 9 12
5 Page Path 1 26 1 Wire harness
1
Kabelbaum
Contact
Kontakt
6 Blatt Pfad 2 26 1
3 9 12 18
1 24 2 3 26 1 Page Path
Contact
Kontakt
Plug Mounting location 2 24 3 4 26 1 Blatt Pfad

Stecker -X100 Einbauort +EBOX 3 24 4 5 26 3 1 27 2
BW 220 D-5
Function text Plug, connection Driving controller - Console seat 4 6 26 7 2 27 3
Funktionstext Stecker Verbindung Fahrsteuerung - Konsole Sitz 5 7 26 7 3 27 4
Plug type 6 8 4 27 4
Steckertyp 7 9 5 28 2
Wire harness 8 10 6 28 3
1
Kabelbaum 9 11 7 28 4
3 6
Page Path 10 12 8 28 5
Contact
Kontakt
Blatt Pfad 11 13 9 29 4
1 25 4 12 14 10 29 7
2 15 11 24 5
3 -X102 +EBOX
Stecker Einbauort Plug Mounting location 13 31 6
4 -X103 +EBOX
Function text Plug, connection Armatures - Console seat Stecker Einbauort 14
5
Funktionstext Stecker Verbindung Armaturen - Konsole Sitz Function text Plug, connection Driving controller - Rear frame 15
6
Plug type Funktionstext Stecker Verbindung Fahrsteuerung - Hinterrahmen 16
Steckertyp Plug type 17
Plug Mounting location AMP Junior Power Timer 18 pole green
Stecker -X101.f +EBOX Wire harness Steckertyp 18
Einbauort Konsole Sitz 1
13
Function text Plug, connection Driving controller - Engine Kabelbaum Wire harness
15 9 3 16 1
Funktionstext Stecker Verbindung Fahrsteuerung - Motor Page Path Kabelbaum Plug Mounting location
18 12 9 3 Stecker -X104 +EBOX
Einbauort
Contact
Kontakt
Plug type Blatt Pfad Page Path
Contact
Kontakt
Steckertyp Blatt Pfad Function text Plug, connection Driving controller - Front frame
1 26 1
Funktionstext Stecker Verbindung Fahrsteuerung - Vorderrahmen
Wire harness 2 1 27 2
Motor 10 1 Plug type
Kabelbaum 3 26 1 2 27 3 AMP Junior Power Timer 9 pole purple
12 9 6 3 Steckertyp
Page Path 4 26 1 3 27 4
Wire harness
Contact
Kontakt
Blatt Pfad 5 26 3 4 27 4 7 1
Kabelbaum
1 24 2 6 26 7 5 28 2 9 6 3
7 26 7 6 28 3 Page Path
2
Contact
Kontakt
8 7 28 4 Blatt Pfad
3 24 4
4 9 8 28 5 1 25 7
0 1 2 3 4 5 6 7 8 9
Page from
Created M. Vogt Blatt76 von 101
Dokumentenart &EMA3
Checked
Circuit diagrams
K. Brand
891
643 EPE /00
892
Plug overview
Stecker -X104 Einbauort +EBOX Stecker -X105 Einbauort +EBOX Stecker -X106 Einbauort +EBOX Stecker -X108.f Einbauort +EBOX
Function text Plug, connection Driving controller - Front frame Function text Plug, connection Driving controller - Front frame dozer blade Function text Plug, connection Driving controller - Front frame sensor speed vibration
Function text Plug, connection Engine - Engine Controller
Funktionstext Stecker Verbindung Fahrsteuerung - Vorderrahmen Funktionstext Stecker Verbindung Fahrsteuerung - Vorderrahmen PlanierschildFunktionstext Stecker Verbindung Fahrsteuerung - Vorderrahmen DrehzahlaufnehmerFunktionstext
Vibration
Stecker Verbindung Motor - Motorsteuergerät
AMP Junior Power Timer 9 pole purple AMP Junior Power Timer 18 pole purple AMP Junior Power Timer 6 pole purple AMP Junior Power Timer 15 pole blue
Circuit diagrams

7 1 16 1 1 Motor 13 1
9 6 3 18 12 9 3 3 6 15 9 3
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
2 13 35 5 6 31 2 1 21 7
3 25 7 14 35 6 2 21 7
5 25 6 16 36 5 Stecker -X107 Einbauort +EBOX 4
6 25 7 17 Function text Plug, connection Measurement controller - Front frame 5
7 29 8 18 Funktionstext Stecker Verbindung Messrechner - Vorderrahmen 6 22 8
8 29 8 Plug type 7 22 8
AMP Junior Power Timer 12 pole purple
9 Plug Mounting location Steckertyp 8 22 8
Stecker -X105 Einbauort +EBOX Wire harness 9
10 1
Plug Mounting location Function text Plug, connection Driving controller - Front frame dozer blade Kabelbaum 10
Stecker -X104 +EBOX 12 9 6 3
Einbauort Funktionstext Stecker Verbindung Fahrsteuerung - Vorderrahmen Planierschild Page Path 11
Function text Plug, connection Driving controller - Front frame Plug type
Contact
Kontakt
Blatt Pfad 12
Funktionstext Stecker Verbindung Fahrsteuerung - Vorderrahmen Steckertyp 13
1 37 1
Plug type Wire harness 14
AMP Junior Power Timer 9 pole purple 1
2 37 2
Steckertyp Kabelbaum 15
3 37 1
3 9 12 18
Wire harness Page Path 4 37 2
1
Kabelbaum Plug
Contact
Kontakt
Blatt Pfad 5 37 3 Mounting location
Page Path 3 6 9 Stecker -X108.m Einbauort +EBOX
1 34 3 6 37 4
Contact
Kontakt
Blatt Pfad Function text Plug, connection Engine - Engine Controller
2 34 4 7 33 5
Funktionstext Stecker Verbindung Motor - Motorsteuergerät
1 25 7 3 34 5 8 33 5
Plug type
2 25 7 4 34 6 9 33 7 AMP Junior Power Timer 15 pole blue
Steckertyp
3 25 7 5 34 7 10 33 8
Wire harness
BW 220 D-5
4 25 8 6 34 8 11 EMR 1
Kabelbaum
5 25 6 7 34 3 12 33 7 3 9 15
6 25 7 8 35 7 Page Path
Contact
Kontakt
7 29 8 9 35 4 Plug Mounting location Blatt Pfad

8 29 8 10 34 4 Stecker -X107 Einbauort +EBOX 1 21 7
9 11 35 1 Function text Plug, connection Measurement controller - Front frame 2 21 7
12 34 4 Funktionstext Stecker Verbindung Messrechner - Vorderrahmen 3
Plug Mounting location 13 35 5 Plug type 4
-X105 +EBOX AMP Junior Power Timer 12 pole purple
Stecker Einbauort 14 35 6 Steckertyp 5
Function text Plug, connection Driving controller - Front frame dozer blade 15 35 6 Wire harness 6 22 8
1
Funktionstext Stecker Verbindung Fahrsteuerung - Vorderrahmen Planierschild 16 36 5 Kabelbaum 7 22 8
Plug type 3 6 9 12
17 Page Path 8 22 8
Steckertyp
Contact
18 Kontakt Blatt Pfad 9
Wire harness 1 37 1 10
16 1
Kabelbaum Plug Mounting location 11
18 12 9 3 -X106 +EBOX 2 37 2
Page Path Stecker Einbauort 12
3 37 1
Contact
Kontakt
Blatt Pfad Function text Plug, connection Driving controller - Front frame sensor speed vibration 13
4 37 2
Funktionstext Stecker Verbindung Fahrsteuerung - Vorderrahmen Drehzahlaufnehmer Vibration 14
1 34 3 5 37 3
Plug type 15
2 34 4 AMP Junior Power Timer 6 pole purple 6 37 4
Steckertyp
3 34 5 7 33 5
1
Kabelbaum
5 34 7 3 6
9 33 7
6 34 8 Page Path 10 33 8
Contact
Kontakt
7 34 3 Blatt Pfad 11 33 9
8 35 7 1 31 2 12 33 7
9 35 4 2 31 1
10 34 4 3 31 3
11 35 1 4
12 34 4 5 31 2
0 1 2 3 4 5 6 7 8 9
Page from
101
Dokumentenart &EMA3
Checked K. Brand
Plug overview
Stecker -X109.f Einbauort +EBOX Stecker -X110 Einbauort +EBOX Stecker -X201 Einbauort +CAB Stecker -X202 Einbauort +CAB
Function text Plug, access transducer acceleration Economizer Function text Plug, access interface meassurement Function text Plug supply ground Function text Plug, signals from/to central electric
Funktionstext Stecker Anschluss Beschleunigungsaufnehmer Economizer Funktionstext Stecker Anschluß Schnittstelle Messtechnik Funktionstext Stecker Versorgung Masse Funktionstext Stecker, Signale von/zur Zentralelektrik
AMP Junior Power Timer 12 pole purple AMP Junior Power Timer 6 pole brown Amphenol RADSOK® 3,6mm AMP Junior Power Timer 2 - 10 pole black
Wire harness Wire harness Kabelbaum Schnittstelle Wire harness Wire harness
Economizer 10 1 4 1
Kabelbaum Kabelbaum Messtechnik Kabelbaum Kabelbaum
12 9 6 3 6 3
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
1 38 5 6 31 48 3 7
2 38 5 8 48 3
3 38 6 Plug Mounting location Plug Mounting location 9 48 3
4 38 6 Stecker -X110 Einbauort +EBOX Stecker -X201 Einbauort +CAB 10 48 3
5 Function text Plug, access interface meassurement Function text Plug supply ground
6 Funktionstext Stecker Anschluß Schnittstelle Messtechnik Funktionstext Stecker Versorgung Masse Plug Mounting location
7 Plug type Plug type Stecker -X203 Einbauort +CAB
AMP Junior Power Timer 6 pole brown Amphenol RADSOK® 3,6mm
8 Steckertyp Steckertyp Function text Plug access cabin equipment
9 Wire harness Verkabelung Schnittstelle Wire harness Funktionstext Stecker Anschluß Kabinenausrüstung
1
10 Kabelbaum Messtechnik Kabelbaum Plug type
3 6
11 Page Path Page Path Steckertyp
Contact
Kontakt
Contact
Kontakt
12 Blatt Pfad Blatt Pfad Wire harness 2 14
Kabelbaum
1 40 7 31 48 3 1 13
Plug Mounting location Page Path
+EBOX 2 40 7
Stecker -X109.m Einbauort
Contact
Kontakt
3 40 7 Plug Mounting location Blatt Pfad

Function text Plug, access transducer acceleration Economizer
4 40 7 Stecker -X202 Einbauort +CAB 1 50 7
Funktionstext Stecker Anschluss Beschleunigungsaufnehmer Economizer
5 40 7 Function text Plug, signals from/to central electric 2 50 6
Plug type Funktionstext Stecker, Signale von/zur Zentralelektrik
AMP Junior Power Timer 12 pole purple 6 3 50 8
Steckertyp
Plug type 4 50 8
Wire harness AMP Junior Power Timer 2 - 10 pole black
Aufnehmer Economizer 1
Plug Mounting location Steckertyp 5
Kabelbaum Stecker -X200 Einbauort +CAB Wire harness 6 50 9
3 6 9 12 2 10
Page Path Function text Plug, supply potential 30 Kabelbaum 7 52 3
1 9
Contact
Kontakt
BW 220 D-5
Blatt Pfad Funktionstext Stecker Versorgung Potential 30 Page Path 8 52 3
Plug type
Contact
Kontakt
1 38 5 Amphenol RADSOK® 6mm
Blatt Pfad 9 52 3
2 38 5 Steckertyp 10 52 5
1 48 3
3 38 6 Wire harness 2 53 8 11 52 5
4 38 6 Kabelbaum 12 52 5
3 48 3
5 Page Path 4 48 3 13 52 7
Contact
Kontakt
6 Blatt Pfad 5 48 3 14 52 7
7 30 48 3 6 48 3
7 -X203 +CAB
9 Stecker Einbauort
10 Stecker -X200 Einbauort +CAB 9 48 3 Function text Plug access cabin equipment
11 Funktionstext Stecker Anschluß Kabinenausrüstung
Function text Plug, supply potential 30 10 48 3
12 Funktionstext Stecker Versorgung Potential 30 Plug type
Steckertyp
Plug type Plug Mounting location
Plug Mounting location Amphenol RADSOK® 6mm -X202 +CAB Wire harness
Steckertyp Stecker Einbauort
Stecker -X110 Einbauort +EBOX Kabelbaum
Wire harness Function text Plug, signals from/to central electric
Function text Plug, access interface meassurement Kabelbaum Funktionstext Stecker, Signale von/zur Zentralelektrik Page Path
Funktionstext Stecker Anschluß Schnittstelle Messtechnik
Contact
Kontakt
Page Path Plug type Blatt Pfad

Plug type AMP Junior Power Timer 2 - 10 pole black
Steckertyp
Contact
Kontakt
AMP Junior Power Timer 6 pole brown Blatt Pfad 1 50 7
Steckertyp
Wire harness Kabelbaum Schnittstelle Kabelbaum 3 50 8
4 1
Kabelbaum Messtechnik
6 3
Page Path 4 50 8
Page Path
Contact
Kontakt
Blatt Pfad 5 50 7
Contact
Kontakt
Blatt Pfad 6 50 9
1 48 3
1 40 7 2 53 8 7 52 3
2 40 7 3 48 3 8 52 3
3 40 7 4 48 3 9 52 3
4 40 7 5 48 3 10 52 5
5 40 7 6 48 3 11 52 5
0 1 2 3 4 5 6 7 8 9
Page from
101
Dokumentenart &EMA3
Checked
Circuit diagrams
K. Brand
893
643 EPE /00
894
Plug overview
Stecker -X203 Einbauort +CAB Stecker -X205 Einbauort +CAB Stecker -X207.f Einbauort +DPL Stecker -X211 Einbauort +CAB
Function text Plug access cabin equipment Function text Plug access radio and tachograph Function text Plug, heating unit additional heater Function text Plug, access temperature sensor asphalt
Funktionstext Stecker Anschluß Kabinenausrüstung Funktionstext Stecker Anschluß Radio und Tachograph Funktionstext Stecker Heizgerät Zusatzheizung Funktionstext Stecker Anschluß Asphalttemperatursensor
AMP Junior Power Timer 2 - 14 pole black AMP Junior Power Timer 2 - 6 pole black AMP Junior Power Timer 16 pole DTM 4 pole
Circuit diagrams

Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
12 52 5 1 53 0 15 1
13 52 7 2 53 1 16 2 54 5
14 52 7 3 53 1 3 54 5
4 53 2 Plug Mounting location 4 54 5
Plug Mounting location 5 53 2 Stecker -X207.m Einbauort +DPL
Stecker -X204 Einbauort +CAB 6 53 2 Function text Plug, heating unit additional heater Plug Mounting location
Function text Plug supply BCM System, printer Funktionstext Stecker Heizgerät Zusatzheizung Stecker -X400 Einbauort +DPL
Funktionstext Stecker Versorgung BCM System, Drucker Plug Mounting location Plug type Function text Interface measurement
-X206 +CAB Tyco JPT 16 pole
Plug type Stecker Einbauort Steckertyp Funktionstext Schnittstelle Messtechnik
Steckertyp Function text Plug, access additional headlights, reserve funktions Wire harness Plug type
Burndy 12 pole
Wire harness Funktionstext Stecker Anschluß Zusatzscheinwerfer, Reservefunktionen Kabelbaum Steckertyp
2 6
Kabelbaum Plug type Page Path Wire harness Kabelbaum Schnittstelle
1 5 AMP Junior Power Timer 9 pole grey
Steckertyp Kabelbaum Messtechnik
Contact
Kontakt
Contact
Kontakt
Blatt Pfad Wire harness 1 46 2 Page Path
Kabelbaum
Contact
Kontakt
1 54 5 2 Blatt Pfad
2 54 6 Page Path 3 A 40 8
Contact
Kontakt
3 54 6 Blatt Pfad 4 46 2 B 40 8
4 1 50 3 5 46 2 C
2 50 4 6 46 2 D 40 8
Plug Mounting location 3 51 7 7 46 2 E 40 8
Stecker -X204 Einbauort +CAB 4 50 5 8 46 2 F 40 8
Function text Plug supply BCM System, printer 5 9 G
BW 220 D-5
Funktionstext Stecker Versorgung BCM System, Drucker 6 50 4 10 46 2 H
Plug type 7 51 7 11 J
Steckertyp 8 51 7 12 T
Wire harness 9 50 5 13 L
Kabelbaum 14 M
Page Path Plug Mounting location 15
Stecker -X207.f Einbauort +DPL Plug
Contact
Kontakt
Blatt Pfad 16 Mounting location
Function text Plug, heating unit additional heater Stecker -XGnd Einbauort +SEAT
1 54 5
Funktionstext Stecker Heizgerät Zusatzheizung Plug Mounting location Function text Plug ground control lever travel
2 54 6 -X210 +CAB
Plug type Stecker Einbauort Funktionstext Stecker Masse Steuerhebel fahren
3 54 6 AMP Junior Power Timer 16 pole
Steckertyp Function text Plug, access GPS-Receiver Plug type
4 54 7 FASTON 6,3mm
Wire harness Funktionstext Stecker Anschluß GPS-Antenne Steckertyp
Plug Kabelbaum Plug type Wire harness
Mounting location Deutsch DTM 6 pole Adapter Fahrhebel
Stecker -X205 +CAB Page Path Steckertyp Kabelbaum
Einbauort
Contact
Kontakt
Function text Plug access radio and tachograph Blatt Pfad Wire harness Page Path
Kabelbaum
Contact
Kontakt
Funktionstext Stecker Anschluß Radio und Tachograph 1 46 3 Blatt Pfad

Plug type 2 Page Path 1 14 9
Contact
Kontakt
Steckertyp 3 Blatt Pfad

Wire harness 4 46 3 1 54 7 Plug Mounting location
2 6 -XA12.A +CAB
Kabelbaum 5 46 3 2 54 7 Stecker Einbauort
1 5
Page Path 6 46 3 3 54 7 Function text Plug, A radio supply
Funktionstext Stecker A Radio Versorgung
Contact
Kontakt
Blatt Pfad 7 46 3 4 54 7
8 46 3 5 54 7 Plug type
1 53 0 ISO-Current 8 pole
9 6 Steckertyp
2 53 1
3 53 1 10 46 3 Wire harness
11 Kabelbaum
4 53 2
5 53 2 12 Page Path
Contact
Kontakt
14 1
0 1 2 3 4 5 6 7 8 9
Page from
101
Dokumentenart &EMA3
Checked K. Brand
Plug overview
Stecker -XA12.A Einbauort +CAB Stecker -XA103 Einbauort +REFR Stecker -XA161 Einbauort +EBOX Stecker -XA177 Einbauort +MOT
Function text Plug, A radio supply Function text Plug, monitoring module Function text Relay socket, gateway economizer Function text Plug, ECU ZTR telematics
Funktionstext Stecker A Radio Versorgung Funktionstext Stecker Überwachungsmodul Funktionstext Relaissockel Gateway Economizer Funktionstext Stecker ECU ZTR Telematik
ISO-Current 8 pole AMP Superseal 26 pole Car minirelay socket Deutsch DT 12 pole Code A
Economizer Economizer
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
2 15 6 39 2 3
3 16 7 39 6 4 45 6
4 53 5 17 8 39 4 5
5 18 9 39 6 6
6 19 7
8 53 4 21 Stecker -XA162 Einbauort +EBOX 9
22 Function text Relay socket A162 10
Plug Mounting location 23 Funktionstext Relaissockel A162 11 45 6
Stecker -XA12.B Einbauort +CAB 24 38 6 Plug type 12 45 6
socket minirelay 9 pole
Function text Plug, B radio speaker 25 38 7 Steckertyp
Funktionstext Stecker B Radio Lautsprecher 26 38 1 Wire harness Verkabelung Schnittstelle Plug Mounting location
Plug type Kabelbaum Messtechnik Stecker -XB03 Einbauort +MOT
ISO-speaker 8 pole
Steckertyp Plug Mounting location Page Path Function text Plug, maintenance switch air cleaner
Wire harness Stecker -XA124 Einbauort +EBOX Funktionstext Stecker Wartungsschalter Luftfilter
Contact
Kontakt
Blatt Pfad
Kabelbaum Function text Plug ECU BOMAG TELEMATIC Plug type
1 40 4 Tyco Junior Power Timer 2 pole
Page Path Funktionstext Stecker ECU BOMAG TELEMATIC Steckertyp
2 40 2
Plug type
Contact
Kontakt
Blatt Pfad 3 40 5 Wire harness
Deutsch DTM 12 pole Code A Motor
Steckertyp Kabelbaum
1 53 5 4 40 3
2 53 5 Wire harness 5 Page Path
Kabelbaum
Contact
Kontakt
3 6 40 2 Blatt Pfad
4 Page Path 7 40 4 1 24 4
Contact
Kontakt
BW 220 D-5
5 Blatt Pfad 8 40 3 2 24 4
6 1 44 4 9 40 5
8 53 5 3 44 3 Plug Mounting location Stecker -XF48.2 Einbauort +REFR
4 44 3 Stecker -XA175 Einbauort +MOT Function text Plug, fuse glow plug system pin 2
Plug Mounting location 5 Function text Plug, electronic system Morey telematics Funktionstext Stecker Sicherung Glühanlage Anschluss 2
Stecker -XA103 Einbauort +REFR 6 Funktionstext Stecker Elektronik System Morey Telematic Plug type
Tubular cable lug M8
Function text Plug, monitoring module 7 Plug type Steckertyp
16 pole Morey
Funktionstext Stecker Überwachungsmodul 8 44 4 Steckertyp Wire harness
Glühkerzen
Plug type 9 Wire harness Kabelbaum
AMP Superseal 26 pole
Steckertyp 10 Kabelbaum Page Path
Wire harness
Contact
Kontakt
Economizer
11 44 4 Page Path Blatt Pfad
Kabelbaum
Contact
12 44 3 Kontakt Blatt Pfad 1 8 2
Page Path 8 45 2
Plug
Contact
Kontakt
Blatt Pfad Mounting location 10 45 2 Plug Mounting location
Stecker -XA161 Einbauort +EBOX Stecker -XG02.D+ Einbauort +MOT
1 38 4 16 45 2
Function text Relay socket, gateway economizer Function text Plug, D+ generator
2 38 5
Funktionstext Relaissockel Gateway Economizer Funktionstext Stecker D+ Generator
Plug type Stecker -XA177 Einbauort +MOT Plug type
4 Car minirelay socket Cable lug ring form A5
Steckertyp Steckertyp
5 38 5 Function text Plug, ECU ZTR telematics
6 38 4 Wire harness Funktionstext Stecker ECU ZTR Telematik Wire harness
Economizer Motor
Kabelbaum Plug type Kabelbaum
7 Deutsch DT 12 pole Code A
8 Page Path Steckertyp Page Path
Contact
Kontakt
Contact
Kontakt
9 Blatt Pfad
10 1 39 6 Kabelbaum
1 8 6
11 2 39 2 Page Path
Contact
Kontakt
13 38 1 4 39 3 1 45 5
14 5 2 45 6
0 1 2 3 4 5 6 7 8 9
Page from
101
Dokumentenart &EMA3
Checked
Circuit diagrams
K. Brand
895
643 EPE /00
896
Plug overview
Stecker -XK14 Einbauort +MOT Stecker -XK189 Einbauort +SEAT Stecker -XP09.B Einbauort +CAB Stecker -XR79 Einbauort +MOT
Function text Plug coil relay glow plug system Function text Relay socket K189 Function text Plug, B tachograph Function text Plug heating prefilter fuel
Funktionstext Stecker Spule Relais Vorglühen Funktionstext Relaissockel K189 Funktionstext Stecker B Tachograph Funktionstext Stecker Heizung Vorfilter Kraftstoff
Tyco Superseal 2 pole socket microrelay 5 pole Tyco JPT 8 pole yellow AMP 2,5mm 4 way black Code 1
Circuit diagrams

Motor Adapter Fahrhebel Radio_Tachograph
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
1 18 3 2 6 1 18 8
2 18 3 3 7 2 18 8
4 8 3
Plug Mounting location 5 4
Stecker -XK14.3_1 Einbauort +MOT Plug Mounting location
Function text Plug, sense relay glow plug system Plug Mounting location Stecker -XP09.C Einbauort +CAB Plug Mounting location
Funktionstext Stecker Rückmeldung Relais Vorglühen Stecker -XM01.50 Einbauort +MOT Function text Plug, C tachograph Stecker -XS Einbauort +DPL
Plug type Function text Plug, starter terminal 50 Funktionstext Stecker C Tachograph Function text Socket
Cable lug ring form A5
Steckertyp Funktionstext Stecker Starter Anschluss 50 Plug type Funktionstext Steckdose
Tyco JPT 8 pole red
Wire harness Plug type Steckertyp Plug type
Motor FASTON 6,3mm
Kabelbaum Steckertyp Wire harness Steckertyp
Radio_Tachograph
Page Path Wire harness Kabelbaum Wire harness
Motor
Kabelbaum Kabelbaum
Contact
Kontakt
Contact
Kontakt
1 18 4 Page Path Blatt Pfad Page Path
Contact
Kontakt
Contact
Kontakt
Blatt Pfad 1 Blatt Pfad

Plug Mounting location 1 8 4 2 41 1
Stecker -XK14.3_2 Einbauort +MOT 3 53 3
Function text Plug, relay glow plug system pin 3 Plug Mounting location 4 Plug Mounting location
Funktionstext Stecker Relais Vorglühen Anschluss 3 Stecker -XP09.A Einbauort +CAB 5 Stecker -XS01.11 Einbauort +ARC
Plug type Function text Plug, A tachograph 6 Function text Plug, switch S127 pin 11
Steckertyp Funktionstext Stecker A Tachograph 7 Funktionstext Stecker Schalter S127 Pin 11
Wire harness Plug type 8 Plug type
Glühkerzen Tyco JPT 8 pole white FASTON 6,3mm
BW 220 D-5
Kabelbaum Steckertyp Steckertyp
Page Path Wire harness Plug Mounting location Wire harness
Radio_Tachograph -XR19 +MOT Armaturen
Kabelbaum Stecker Einbauort Kabelbaum
Contact
Kontakt
Blatt Pfad
Page Path Function text Plug, heating flange Page Path
1 18 4
Funktionstext Stecker Heizflansch
Contact
Kontakt
Contact
Kontakt

Plug Plug type
Mounting location 1 53 3 Tubular cable lug M6 1 9 4
Stecker -XK14.5 +MOT Steckertyp
Einbauort 2 53 3
Function text Plug, relay glow plug system pin 4 3 53 3 Wire harness Plug Mounting location
Glühkerzen
Funktionstext Stecker Relais Vorglühen Anschluss 4 Kabelbaum Stecker -XS01.12 Einbauort +ARC
4
Plug type 5 53 3 Page Path Function text Plug, switch S127 pin 12
Contact
Kontakt
Steckertyp 6 53 3 Blatt Pfad Funktionstext Stecker Schalter S127 Pin 12
Wire harness 7 1 18 4 Plug type
Glühkerzen FASTON 6,3mm
Kabelbaum 8 Steckertyp
Page Path Plug Mounting location Wire harness
-XR79 +MOT Armaturen
Plug Stecker Einbauort Kabelbaum
Contact
Kontakt
Blatt Pfad Mounting location
Stecker -XP09.B Einbauort +CAB Function text Plug heating prefilter fuel Page Path
1 18 4
Function text Plug, B tachograph Funktionstext Stecker Heizung Vorfilter Kraftstoff
Contact
Kontakt
Blatt Pfad
Funktionstext Stecker B Tachograph Plug type
Plug Mounting location AMP 2,5mm 4 way black Code 1 1 9 4
Stecker -XK189 +SEAT Plug type Steckertyp
Einbauort Tyco JPT 8 pole yellow
Steckertyp Wire harness
Function text Relay socket K189
Funktionstext Relaissockel K189 Wire harness Kabelbaum
Radio_Tachograph
Plug type Kabelbaum Page Path
socket microrelay 5 pole
Contact
Kontakt
Steckertyp Page Path Blatt Pfad
Contact
Kontakt
Wire harness Blatt Pfad 1 18 8
Adapter Fahrhebel
Kabelbaum 1 2 18 8
Page Path 2 3
Contact
Kontakt
Blatt Pfad 3 53 3 4
1 4 53 3
5
0 1 2 3 4 5 6 7 8 9
Page from
101
Dokumentenart &EMA3
Checked K. Brand
Plug overview
Stecker -XS01.21 Einbauort +ARC Stecker -XS09.14 Einbauort +SEAT Stecker -XS35.13 Einbauort +ARC Stecker -XS36.14 Einbauort +SEAT
Function text Plug, switch S127 pin 21 Function text Plug, switch S09 pin 14 Function text Plug, switch S35 pin 13 Function text Plug, switch S36 pin 14
Funktionstext Stecker Schalter S127 Pin 21 Funktionstext Stecker Schalter S09 Pin 14 Funktionstext Stecker Schalter S35 Pin 13 Funktionstext Stecker Schalter S36 Pin 14
FASTON 6,3mm FASTON 6,3mm FASTON 6,3mm FASTON 6,3mm
Armaturen Konsole Sitz Armaturen Konsole Sitz
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
1 10 2 1 26 5 1 26 7 1 26 5
Stecker -XS01.22 Einbauort +ARC Stecker -XS28.f Einbauort +DPL Stecker -XS35.14 Einbauort +ARC Stecker -XS42 Einbauort +ARC
Function text Plug, switch S127 pin 22 Function text Plug, timer additional heater Function text Plug, switch S35 pin 14 Function text Plug, switch speed range selector
Funktionstext Stecker Schalter S127 Pin 22 Funktionstext Stecker Schaltuhr Zusatzheizung Funktionstext Stecker Schalter S35 Pin 14 Funktionstext Stecker Schalter Fahrstufen
FASTON 6,3mm AMP Junior Power Timer 12 pole grey FASTON 6,3mm AMP GET 6 way
Armaturen 10 1 Armaturen Armaturen
12 9 6 3
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt

1 10 2 1 46 6 1 26 7 1 26 0
2 46 4 2 26 1
Plug Mounting location 3 Plug Mounting location 3 26 1
Stecker -XS01.A1 Einbauort +ARC 4 46 5 Stecker -XS35.23 Einbauort +ARC 4 26 1
Function text Plug, switch S127 pin A1 5 Function text Plug, switch S35 pin 23 5 26 1
Funktionstext Stecker Schalter S127 Pin A1 6 46 6 Funktionstext Stecker Schalter S35 Pin 23 6 26 1
Plug type 7 Plug type
FASTON 6,3mm FASTON 6,3mm
Steckertyp 8 46 6 Steckertyp Plug Mounting location
Wire harness 9 46 6 Wire harness Stecker -XS55.Gnd Einbauort +SEAT
Armaturen Armaturen
Kabelbaum 10 46 6 Kabelbaum Function text Plug ground control lever travel
BW 220 D-5
Page Path 11 46 6 Page Path Funktionstext Stecker Masse Steuerhebel fahren
Plug type
Contact
Kontakt
Contact
Kontakt
Blatt Pfad 12 46 6 Blatt Pfad FASTON 6,3mm
Steckertyp
1 29 5 1 26 7
Plug Mounting location Wire harness
+DPL Konsole Sitz
Stecker -XS28.m Einbauort Kabelbaum
Plug Mounting location Plug Mounting location
Stecker -XS01.A2 Einbauort +ARC Function text Plug, heating unit additional heater Stecker -XS35.24 Einbauort +ARC Page Path
Funktionstext Stecker Heizgerät Zusatzheizung
Contact
Kontakt
Function text Plug, switch S127 pin A2 Function text Plug, switch S35 pin 24 Blatt Pfad
Funktionstext Stecker Schalter S127 Pin A2 Plug type Funktionstext Stecker Schalter S35 Pin 24
AMP Junior Power Timer 12 pole grey 1 14 9
Steckertyp
Plug type Plug type
FASTON 6,3mm Wire harness FASTON 6,3mm
Steckertyp 1
Steckertyp Plug Mounting location
Kabelbaum Stecker -XS107 Einbauort +SEAT
Wire harness Wire harness
Armaturen 3 6 9 12 Armaturen
Kabelbaum Page Path Kabelbaum Function text Plug switch amplitude adjustment
Contact
Kontakt
Page Path Blatt Pfad Page Path Funktionstext Stecker Schalter Amplitudenverstellung
Plug type
Contact
Kontakt
Contact
Kontakt
Blatt Pfad 1 46 6 Blatt Pfad Tyco Superseal 3 pole
2 Steckertyp
1 29 5 1 26 7
3 Wire harness
Konsole Sitz
Plug 4 Plug Kabelbaum
Mounting location Mounting location
Stecker -XS09.13 Einbauort +SEAT 5 Stecker -XS36.13 Einbauort +SEAT Page Path
Contact
Kontakt
Function text Plug, switch S09 pin 13 6 46 6 Function text Plug, switch S36 pin 13 Blatt Pfad
Funktionstext Stecker Schalter S09 Pin 13 7 Funktionstext Stecker Schalter S36 Pin 13 1 32 3
Plug type 8 46 6 Plug type 2 32 3
FASTON 6,3mm 9 46 6 FASTON 6,3mm
Steckertyp Steckertyp 3 32 3
Wire harness 10 Wire harness
Konsole Sitz 11 46 6 Konsole Sitz
Kabelbaum Kabelbaum
Page Path 12 46 6 Page Path
Contact
Kontakt
Contact
Kontakt

1 26 5 1 26 5
0 1 2 3 4 5 6 7 8 9
Page from
101
Dokumentenart &EMA3
Checked
Circuit diagrams
K. Brand
897
643 EPE /00
898
Plug overview
Stecker -XS127.13 Einbauort +ARC Stecker -XS299.14 Einbauort +ARC Stecker -XS439.A1 Einbauort +SEAT Stecker -XU600.8 Einbauort +EBOX
Function text Plug, switch S127 pin 13 Function text Plug, switch S299 pin 14 Function text Plug, switch S439 pin A1 Function text Plug ground harness console seat
Funktionstext Stecker Schalter S127 Pin 13 Funktionstext Stecker Schalter S299 Pin 14 Funktionstext Stecker Schalter S439 Pin A1 Funktionstext Stecker Masse Kabelbaum Konsole Sitz
FASTON 6,3mm FASTON 6,3mm FASTON 6,3mm Cable lug ring form A10
Circuit diagrams

Armaturen Armaturen Konsole Sitz Konsole Sitz
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
1 19 2 1 19 3 1 32 7 1 8 4
Stecker -XS127.14 Einbauort +ARC Stecker -XS299.23 Einbauort +ARC Stecker -XS439.A2 Einbauort +SEAT Stecker -XU600.10 Einbauort +EBOX
Function text Plug, switch S127 pin 14 Function text Plug, switch S299 pin 23 Function text Plug, switch S439 pin A2 Function text Plug ground harness economizer
Funktionstext Stecker Schalter S127 Pin 14 Funktionstext Stecker Schalter S299 Pin 23 Funktionstext Stecker Schalter S439 Pin A2 Funktionstext Stecker Masse Kabelbaum Economizer
FASTON 6,3mm FASTON 6,3mm FASTON 6,3mm Cable lug ring form A8
Armaturen Armaturen Konsole Sitz Economizer
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt

1 19 2 1 19 4 1 32 7 1 8 4
Stecker -XS127.23 Einbauort +ARC Stecker -XS299.24 Einbauort +ARC Stecker -XU600.2 Einbauort +EBOX Stecker -XY15.2 Einbauort +MOT
Function text Plug, switch S127 pin 23 Function text Plug, switch S299 pin 24 Function text Plug, ground harness ground powerboard Function text Plug, ground compressor air conditioning(Kopie)
Funktionstext Stecker Schalter S127 Pin 23 Funktionstext Stecker Schalter S299 Pin 24 Funktionstext Stecker Masse Kabelbaum Masse Powerboard Funktionstext Stecker Masse Kompressor Klimaanlage
FASTON 6,3mm FASTON 6,3mm Tubular cable lug M10 Cable lug ring form A4
Armaturen Armaturen Economizer Motor
BW 220 D-5
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt

1 19 2 1 19 4 1 8 4 1 47 1

Stecker -XS127.24 Einbauort +ARC Stecker -XS439.13 Einbauort +SEAT Stecker -XU600.3 Einbauort +EBOX
Function text Plug, switch S127 pin 24 Function text Plug, switch S439 pin 13 Function text Plug, ground harness engine
Funktionstext Stecker Schalter S127 Pin 24 Funktionstext Stecker Schalter S439 Pin 13 Funktionstext Stecker Masse Kabelbaum Motor
Plug type Plug type Plug type
FASTON 6,3mm FASTON 6,3mm Cable lug ring form A10
Steckertyp Steckertyp Steckertyp
Wire harness Wire harness Wire harness
Armaturen Konsole Sitz Motor
Kabelbaum Kabelbaum Kabelbaum
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
1 19 2 1 32 6 1 8 4

Stecker -XS299.13 Einbauort +ARC Stecker -XS439.14 Einbauort +SEAT Stecker -XU600.4 Einbauort +EBOX
Function text Plug, switch S299 pin 13 Function text Plug, switch S439 pin 14 Function text Plug, ground harness engine controller
Funktionstext Stecker Schalter S299 Pin 13 Funktionstext Stecker Schalter S439 Pin 14 Funktionstext Stecker Masse Kabelbaum Motorsteuergerät
Plug type Plug type Plug type
FASTON 6,3mm FASTON 6,3mm Cable lug ring form A10
Steckertyp Steckertyp Steckertyp
Wire harness Wire harness Wire harness
Armaturen Konsole Sitz EMR
Kabelbaum Kabelbaum Kabelbaum
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt

1 19 3 1 32 6 1 8 4
0 1 2 3 4 5 6 7 8 9
Page from
101
Dokumentenart &EMA3
Checked K. Brand
BO_F09_002
Cable name
Kabelname W1
Cable type
Kabeltyp LÜTZE SUPERFLEX® N PUR 12x0,75 mm²
Free conductors W1
Freie Adern 1
Mounting location Page Path Source Quelle Target Ziel Page Path Mounting location
Name Contact Connection Name Contact Connection
Einbauort Blatt Pfad Name Kontakt Anschluß Name Kontakt Anschluß Blatt Pfad Einbauort
Drum
37 1 SP6 2 1 1 X20 1 37 1 DRUM Bandage
Drum
37 2 SP7 2 2 2 X20 2 37 2 DRUM Bandage
Central electric Drum
Zentralelektrik EBOX 37 2 X107 4 3 3 X20 3 37 2 DRUM Bandage
Drum
37 3 SP6 2 5 5 X21 1 37 3 DRUM Bandage
Drum
37 4 SP7 2 6 6 X21 2 37 4 DRUM Bandage
Drum
33 5 SP7 2 10 10 X86 2 33 5 DRUM Bandage
GNYE GNYE
Cable name
Kabelname W2
Cable type
Kabeltyp LÜTZE-SILFLEX® N PUR 7x1 mm²
Free conductors W2
Freie Adern 3
Zentralelektrik EBOX 33 7 X107 9 1 1 Y140 1 33 7 DRUM Bandage
Drum
33 7 SP8 2 2 2 Y140 2 33 7 DRUM Bandage
BW 220 D-5
Drum
33 8 SP8 2 4 4 Y141 2 33 8 DRUM Bandage
5 5
6 6
GNYE GNYE
Cable name
Kabelname W3
Cable type
Kabeltyp LÜTZE-SILFLEX® N PUR 7x1 mm²
Free conductors W3
Freie Adern 1
Zentralelektrik EBOX 25 7 X104 1 3 3 B59 4 25 7 DRUM Bandage
GNYE GNYE
0 1 2 3 4 5 6 7 8 9
Page from
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Cable diagram W1, W2, W3 Kind of Document
Dokumentenart &EMB2
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Kabelplan W1, W2, W3
899
643 EPE /00
900
BO_F09_002
Cable name
Kabelname W4
Cable type
Free conductors W4
Freie Adern 4
Circuit diagrams
Drum
34 3 SP2 1 2 2 Y378 2 34 3 DRUM Bandage
Drum
34 4 SP2 1 4 4 Y102 2 34 4 DRUM Bandage
Drum
34 5 SP2 1 6 6 Y379 2 34 5 DRUM Bandage
Drum
34 6 SP2 1 8 8 Y380 2 34 6 DRUM Bandage
9 9
10 10
11 11
GNYE GNYE
Cable name
Kabelname W6
Cable type
Kabeltyp LÜTZE-SILFLEX® B 3x0,75 mm²
Free conductors W6
Freie Adern 0
Rear frame Vibratory plate compactor
Hinterrahmen REFR 35 5 X29 6 BN BN X27 1 35 5 PLA Anbauplatten
Hinterrahmen REFR 35 4 X29 4 BK BK X27 3 35 4 PLA Anbauplatten
BW 220 D-5
Hinterrahmen REFR 35 5 X29 5 GY GY X27 2 35 5 PLA Anbauplatten
Cable name
Kabelname W7
Cable type
Kabeltyp BINDER Sensorcable M12 90° 4x0,5 mm²
Free conductors W7
Freie Adern 1
Rear frame Rear frame
Hinterrahmen REFR 35 6 X29 1 BN BN B313 1 35 6 REFR Hinterrahmen
WH WH
Hinterrahmen REFR 35 6 X29 2 BU BU B313 3 35 6 REFR Hinterrahmen
Hinterrahmen REFR 35 6 X29 3 BK BK B313 4 35 6 REFR Hinterrahmen
Cable name
Kabelname W8
Cable type
Free conductors W8
Freie Adern 1
Hinterrahmen REFR 35 5 X28 1 BN BN B312 1 35 5 REFR Hinterrahmen
0 1 2 3 4 5 6 7 8 9
Page from
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Cable diagram W4, W6, W7, W8 Kind of Document
Dokumentenart &EMB2
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Kabelplan W4, W6, W7, W8 643 EPE /00
BO_F09_002
Cable name
Kabelname W8
Cable type
Free conductors W8
Freie Adern 1
WH WH
Hinterrahmen REFR 35 5 X28 2 BU BU B312 3 35 5 REFR Hinterrahmen
Hinterrahmen REFR 35 5 X28 3 BK BK B312 4 35 5 REFR Hinterrahmen
Cable name
Kabelname W9
Cable type
Kabeltyp ÖLFLEX® FD CLASSIC 810 P 2X0,75 mm²
Free conductors W9
Freie Adern 0
Vibratory plate compactor Vibratory plate compactor
Anbauplatten PLA 35 4 X27 1 1 1 P43 - 35 4 PLA Anbauplatten
Vibratory plate compactor Vibratory plate compactor
Anbauplatten PLA 35 4 X27 3 2 2 P43 + 35 4 PLA Anbauplatten
Cable name
Kabelname W10
Cable type
Free conductors W10
Freie Adern 2
Cabin Cabin
1 1
BW 220 D-5
Kabine CAB 54 7 X92 A X210 1 54 7 CAB Kabine
Cabin Cabin
Kabine CAB 54 7 X92 B 2 2 X210 2 54 7 CAB Kabine
Cabin Cabin
Kabine CAB 54 7 X92 C 3 3 X210 3 54 7 CAB Kabine
Cabin Cabin
Kabine CAB 54 7 X92 D 4 4 X210 4 54 7 CAB Kabine
Cabin Cabin
Kabine CAB 54 7 X92 E 5 5 X210 5 54 7 CAB Kabine
6 6
GNYE GNYE
Cable name
Kabelname W17
Cable type
Kabeltyp LÜTZE-SILFLEX® N (C) Y 3x0,75 mm²
Free conductors W17
Freie Adern 0
Zentralelektrik EBOX 38 5 X109.f 1 1 1 X39 1 38 5 DRUM Bandage
38 6 SP-SH7 1 SH SH SP-SH8 1 38 6
0 1 2 3 4 5 6 7 8 9
Page from
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Cable diagram W8, W9, W10, W17 Kind of Document
Dokumentenart &EMB2
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Kabelplan W8, W9, W10, W17
901
643 EPE /00
902
BO_F09_002
Cable name
Kabelname W18
Cable type
Kabeltyp LÜTZE-SILFLEX® N (C) Y 3x0,75 mm²
Free conductors W18
Freie Adern 0
Central electric Rear frame
Zentralelektrik EBOX 38 4 X109.m 1 1 1 XA103 6 38 4 REFR Hinterrahmen
Circuit diagrams

38 7 SP-SH10 1 SH SH SP-SH9 1 38 7
BW 220 D-5
0 1 2 3 4 5 6 7 8 9
Page from
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Cable diagram W18 Kind of Document
Dokumentenart &EMB2
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Kabelplan W18 643 EPE /00
Pin overview
Pin Übersicht BO_F19_001
module monitoring
A15 Modul Überwachung
X33 1 0...1500 Ω
X33 2 24 8 0...140Ω Fuel level Tankfüllstand
X33 3 24 7 +UB, max 1,5A Warning buzzer, breakdown Warnsummer Betriebsstörung
X33 4 19 5 +UB, max 1,5A Vibration Telematics Vibration Telematik
X33 5 41 7 active high Illumination Beleuchtung
X33 6 configuration Pin RXD
X33 7 configuration Pin TXD
X33 8 42 7 active high Indicator lights Blinker
X33 9 19 1 active high Switch, engine speed Sx. 1 Schalter Motordrehzahl Sx. 1
X33 10 19 2 active high Switch, engine speed Sx. 2 Schalter Motordrehzahl Sx. 2
X33 11 19 3 active high Switch, regeneration Sy. 1 Schalter Regeneration Sy. 1
X33 12 19 4 active high Switch, regeneration Sy. 2 Schalter Regeneration Sy. 2
X33 13 active high
X33 14 active high
X33 15 active high
X33 16 active high
X33 17 active high
X33 18 active low
BW 220 D-5
X33 19 active low
X33 20 active low
X33 21 16 2 CAN high CAN high CAN high
X33 22 16 2 CAN low CAN low CAN low
X33 23 active low
X33 24 active high
0 1 2 3 4 5 6 7 8 9
Page from
101
Erstellt 16.07.2019 BW 211-226 D, DH, BVC-5 Pin overview A15 Kind of Document
Dokumentenart &EFA1
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Pin Übersicht A15
903
643 EPE /00
904
Pin overview
Driving Controller
A34 Fahrsteuerung
Circuit diagrams
X35 54 11 2 +UE / 0..32V Power Supply (Electronic) Spannungsvers. (Elektronik)

X35 56 11 3 +UB / 0..32V Power Supply (Outputs) Spannungsvers. (Ausgänge)
X35 57 11 4 +UB / 0..32V -"- -"-
X35 58 11 5 +UB / 0..32V -"- -"-
X35 59 11 6 +UB / 0..32V -"- -"-
X35 60 11 6 +UB / 0..32V -"- -"-
X35 28 11 1 +Ignition / 0..32V Ignition Zündung
X35 55 11 5 GND Ground Electronic Masse Elektronik
X35 65 11 6 GND -"- -"-
X35 66 11 7 GND -"- -"-
X35 67 11 8 GND -"- -"-
X35 68 11 9 GND -"- -"-
X35 26 15 3 CAN1_L CAN 1 low CAN 1 low
X35 27 15 2 CAN1_H CAN 1 high CAN 1 high
X35 4 RxD_1
X35 5 TxD_1
BW 220 D-5
X35 23 13 2 8.5VEXT 8,5V Sensor Power 8,5V Sensor Spannung
X35 1 13 2 AGND AGND Analogmasse
X35 24 30 9 OUT9 / 2,5A curr.-feedb. Relay, shut off solenoid engine Relais Hubmagnet Abschaltung Motor
X35 2 29 4 OUT10 / 2,5A curr.-feedb. Travel motor axle Fahrmotor Achse
X35 25 30 8 OUT11 / 2,5A curr.-feedb. Warning horn Signalhorn
X35 3 29 7 OUT12 / 2,5A curr.-feedb. Travel motor drum Fahrmotor Bandage
X35 61 30 6 OUT6 / 4A Back-up alarm buzzer Warnsummer Rückwärtsfahrt
X35 62 34 3 OUT7 / 2,5A curr.-feedb. Dozer blade priority Planierschild Priorität
X35 63 35 4 OUT8 / 2,5A curr.-feedb. Hour meter plates Stundenzähler Platten
X35 45 36 5 OUT19 / 2,5A curr.-feedb. Floating position plates Schwimmstellung Anbauplatten
X35 11 34 4 OUT20 / 2,5A curr.-feedb. Floating position dozer blade Schwimmstellung Planierschild
X35 50 34 7 OUT21 / 5A curr.-feedb. Adjustment left plates Verschiebung links Platten
X35 51 34 8 OUT22 / 5A curr.-feedb. Adjustment right plates Verschiebung rechts Platten
X35 46 28 2 OUT1 / 4A curr.-measur. Travel pump axle forward Fahrpumpe Achse vorwärts
X35 47 28 3 OUT2 / 4A curr.-measur. Travel pump axle backward Fahrpumpe Achse rückwärts
X35 48 31 4 OUT3 / 4A curr.-measur. Vibration pump low/high Vibrationspumpe klein/groß
X35 49 31 5 OUT4 / 4A curr.-measur. Vibration pump PWM Vibrationspumpe PWM
X35 64 29 5 OUT5 / 4A curr.-measur. Valve brake Ventil Bremse
X35 42 34 5 OUT13 / 4A curr.-measur. Dozer blade up Planierschild anheben
0 1 2 3 4 5 6 7 8 9
Page from
101
Dokumentenart &EFA1
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Pin Übersicht A34 643 EPE /00
Pin overview
Driving Controller
A34 Fahrsteuerung
X35 20 28 4 OUT14 / 4A curr.-measur. Travel pump drum forward Fahrpumpe Bandage vorwärts
X35 43 34 6 OUT15 / 4A curr.-measur. Dozer blade down Planierschild absenken
X35 21 28 5 OUT16 / 4A curr.-measur. Travel pump drum backward Fahrpumpe Bandage rückwarts
X35 44 OUT17 / 4A curr.-measur.
X35 22 35 7 OUT18 / 4A curr.-measur. Vibration pump plates Vibrationspumpe Platten
X35 34 31 3 DIN1 / 0..32V, DRZ Speed vibration drum Drehzahl Vibration Bandage
X35 12 25 5 DIN2 / 0..32V, DRZ Speed axle Geschwindigkeit Achse
X35 35 25 6 DIN3 / 0..32V, DRZ Speed drum Geschwindigkeit Bandage
X35 16 25 4 DIN10 / 0..32V, DRZ Proximity switch, arm rest right Näherungsinitiator Armlehne rechts
X35 40 DIN13 / 0..32V, DRZ
X35 18 DIN14 / 0..32V, DRZ
X35 41 DIN15 / 0..32V, DRZ
X35 19 DIN16 / 0..32V, DRZ
X35 13 25 4 DIN4 / 0..32V Direction axle Drehrichtung Achse
X35 36 24 3 DIN5 / 0..32V Water in Fuel Wasserabscheider
X35 14 29 1 DIN6 / 0..32V BTS brake BTS Bremse
X35 37 24 5 DIN7 / 0..32V Hydraulic oil filter Hydraulikölfilter
X35 15 25 3 DIN8 / 0..32V Seat contact Sitzkontakt
BW 220 D-5
X35 38 24 4 DIN9 / 0..32V Maintenance switch, air cleaner Wartungsschalter Luftfilter
X35 39 24 2 DIN11 / 0..32V Coolant level Kühlmittelfüllstand
X35 17 25 7 DIN12 / 0..32V Direction drum Drehrichtung Bandage
X35 52 DIN17 / 0..32V
X35 10 35 6 DIN18 / 0..32V Plate pump enable Freigabe Plattenpumpe
X35 6 27 2 AIN1 / 10V 25mA Pressure sensor, travel pump axle MA Drucksensor Fahrpumpe Achse MA
X35 7 27 3 AIN3 / 10V 25mA Pressure sensor, travel pump axle MB Drucksensor Fahrpumpe Achse MB
X35 8 35 5 AIN5 / 10V 25mA Sensor, height adjustment plates Sensor Höhenverstellung Platten
X35 9 24 1 AIN7 / 10V 25mA D+ Alternator D+ Generator
X35 29 27 4 AIN2 / 10V 25mA Pressure sensor, travel pump drum MA Drucksensor Fahrpumpe Bandage MA
X35 30 27 4 AIN4 / 10V 25mA Pressure sensor, travel pump drum MB Drucksensor Fahrpumpe Bandage MB
X35 31 35 6 AIN6 / 10V 25mA Sensor, lateral adjustment plates Sensor Seitenverstellung Platten
X35 32 25 2 AIN8 / 10V 25mA Slope sensor Neigungssensor
0 1 2 3 4 5 6 7 8 9
Page from
101
Dokumentenart &EFA1
Checked
Circuit diagrams
K. Brand
905
643 EPE /00
906
Pin overview
Measurement controller
A83 Messtechnik Steuerung
Circuit diagrams
X88 54 12 2 +UE / 0..32V Power Supply (Electronic) Spannungsvers. (Elektronik)

X88 56 12 3 +UB / 0..32V Power Supply (Outputs) Spannungsvers. (Ausgänge)
X88 57 12 4 +UB / 0..32V -"- -"-
X88 58 12 5 +UB / 0..32V -"- -"-
X88 59 12 6 +UB / 0..32V -"- -"-
X88 60 12 6 +UB / 0..32V -"- -"-
X88 28 12 1 +Ignition / 0..32V Ignition Zündung
X88 55 12 5 GND Ground Electronic Masse Elektronik
X88 65 12 6 GND -"- -"-
X88 66 12 7 GND -"- -"-
X88 67 12 8 GND -"- -"-
X88 68 12 9 GND -"- -"-
X88 4 37 6 RxD_1 RxD Printer RxD Drucker
X88 5 37 7 TxD_1 TxD Printer TxD Drucker
BW 220 D-5
X88 23 13 5 8.5VEXT 8,5V Sensor Power 8,5V Sensor Spannung
X88 1 13 6 AGND AGND Analogmasse
X88 24 OUT9 / 2,5A curr.-feedb.
X88 25 37 8 OUT11 / 2,5A curr.-feedb. Power supply GPS Spannungsversorgung GPS
X88 61 33 9 OUT6 / 4A Exciter priority Erreger Priorität
X88 46 33 8 OUT1 / 4A curr.-measur. Exciter down Erreger ab
X88 47 33 7 OUT2 / 4A curr.-measur. Exciter up Erreger auf
X88 34 DIN1 / 0..32V, DRZ
X88 12 DIN2 / 0..32V, DRZ
X88 35 DIN3 / 0..32V, DRZ
X88 16 DIN10 / 0..32V, DRZ
X88 40 DIN13 / 0..32V, DRZ
X88 18 DIN14 / 0..32V, DRZ
X88 41 DIN15 / 0..32V, DRZ
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Pin overview
Measurement controller
A83 Messtechnik Steuerung
X88 19 DIN16 / 0..32V, DRZ

X88 13 DIN4 / 0..32V
X88 36 DIN5 / 0..32V
X88 14 DIN6 / 0..32V
X88 37 DIN7 / 0..32V
X88 15 DIN8 / 0..32V
X88 38 DIN9 / 0..32V
X88 39 DIN11 / 0..32V
X88 17 DIN12 / 0..32V
X88 6 AIN1 / 10V 25mA
X88 7 37 3 AIN3 / 10V 25mA Transducer Acceleration rear 20g Beschleunigungsaufn. hinten 20g
X88 8 AIN5 / 10V 25mA
X88 9 33 5 AIN7 / 10V 25mA Sensor, adjustable motor Sensor Verstellmotor
X88 29 37 2 AIN2 / 10V 25mA Transducer Acceleration front 15g Beschleunigungsaufn. vorne 15g
X88 30 37 4 AIN4 / 10V 25mA Transducer Acceleration rear 15g Beschleunigungsaufn. hinten 15g
X88 31 37 1 AIN6 / 10V 25mA Transducer Acceleration front 20g Beschleunigungsaufn. vorne 20g
X88 32 32 3 AIN8 / 10V 25mA switch amplitude adjustment Schalter Amplitudenverstellung
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Circuit diagrams
K. Brand
907
643 EPE /00
908
Pin overview
module ECONOMIZER
A103 Modul ECONOMIZER
Circuit diagrams
XA103 1 38 4 CAN low CAN low CAN low

XA103 2 38 5 CAN high CAN high CAN high
XA103 4 0...5V
XA103 5 38 5 0...5V Transducer acceleration Beschleunigungsaufnehmer
XA103 6 38 4 +5V supply Sensors Supply 5V sensors Versorgung 5V Sensoren
XA103 7 Power supply (8...32V)
XA103 8 +UB
XA103 10 active high
XA103 11 active high
XA103 13 38 1 Power supply (8...32V) Power supply Stromversorgung
XA103 24 38 6 Ground Ground Masse
XA103 25 38 7 Ground -"- -"-
XA103 26 38 1 Ground -"- -"-
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module CAN Gateway

A161 Modul CAN Gateway
2 39 2 Power supply (9-30V) Power supply Stromversorgung

6 39 2 Ground Ground Masse
7 39 6 Can high 1 CAN high IN CAN high Eingang
9 39 6 Can low 1 CAN low IN CAN low Eingang
1 39 6 Can high 2 CAN high OUT CAN high Ausgang
3 39 6 Can low 2 CAN low OUT CAN low Ausgang
4 39 3 Analog Input 1 Power supply Stromversorgung
5 LIN Bus (optional)
8 39 4 Analog Input 2 Configuration Konfiguration
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910
Pin overview
module CAN Gateway

A162 Modul CAN Gateway
Circuit diagrams
2 40 2 Power supply (9-30V) Power supply Stromversorgung

6 40 2 Ground Ground Masse
7 40 4 Can high 1 CAN high IN CAN high Eingang
9 40 5 Can low 1 CAN low IN CAN low Eingang
1 40 4 Can high 2 CAN high OUT CAN high Ausgang
3 40 5 Can low 2 CAN low OUT CAN low Ausgang
4 40 3 Analog Input 1 Power supply Stromversorgung
5 LIN Bus (optional)
8 40 3 Analog Input 2 Ground Masse
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switch control lever travel

S55 Schalter Steuerhebel Fahren

X23 3 26 9 Signal "Brake" relay brake Relais Bremse
X23 4 Digital OUT
X23 5 26 3 Output voltage supply Supply analog selectors Versorgung Analoge Wahlschalter
"+5V"
X23 6 16 4 CAN bus high CAN high CAN high
X23 7 16 5 CAN bus low CAN low CAN low
X23 8 26 2 Ground / 0V / reference Ground analog selectors Masse Analoge Wahlschalter
to PIN 5
X23 9 14 6 Digital IN 7 Ground Masse
X23 10 14 7 Digital IN 8 -"- -"-
X23 11 26 1 Analog IN 1 Switch, speed range selector 2 Schalter Fahrstufen 2
X23 12 26 4 Analog IN 2 Frequency adjustment plates Frequenzverstellung Anbauplatten
X24 1 26 7 Digital IN 1 Switch, vibration low/off (on/off) Schalter Vibration klein/aus (an/aus)
X24 2 26 8 Digital IN 2 Switch, vibration off/high Schalter Vibration aus/groß
X24 3 Digital IN 3 Floating position plates Schwimmstellung Anbauplatten
X24 4 26 5 Digital IN 4 Vibration plates Vibration Anbauplatten
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X24 5 32 6 Digital IN 5 switch amplitude limiting Schalter Amplitudenbegrenzung
X24 6 32 7 Digital IN 6 -"- -"-
X24 7 Output +Ub
X24 8 Output GND
XS55.GND GND 14 9 Ground housing
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Circuit diagrams
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912
Circuit diagrams
A48 S55
A15 A178 P15
+EBOX +SEAT +ARC +CAB +CAB
+EBOX
X34
CAN 2
CAN 1
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A87
A67
+DPL +CAB
+DPL
A161 A162
A103 X400
CAN 4
A124 CAN 3
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Circuit diagrams
K. Brand
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913
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914
Top view
Draufsicht
Circuit diagrams
BW 220 D-5
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BW 220 D-5
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Circuit diagrams
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915
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916
Circuit diagrams
BW 220 D-5
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Geprüft 16.07.2019 Deutz TCD 2012/13 Tier 3 Übersicht Powerboard 643 EPE /00
Circuit diagrams
A.2 Hydraulic diagram
BW 220 D-5 917

Service Manual BW220D-5

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Service Manual

S/N 961 587 61 1001>

Single drum roller

008 403 78 EN © 05/2021

3.3 Hydraulic system........................................................................................................................ 97

5.3.2 Travel motor, H1....................................................................................................................... 332

6.5 Drive axle................................................................................................................................... 555

7.3 Troubleshooting, electrical systems....................................................................................... 646

Copyright Information and illustrations in this manual must not be reproduced

1.2 Concerning your safety

1.2.1.2 Explanation of signal words used

Sections marked accordingly indicate technical

1.2.1.3 Personal protective equipment

Protective gloves They protect the hands against scrapes, punctures or

Hearing protection This protects against extreme noise.

Respiratory protection This protects the airways against substances or parti-

1.2.1.4 Intended use

1.2.1.5 Improper use

Examples of improper use are:

1.2.1.6 Estimated service life of the machine

1.2.2 Definition of responsible persons

1.2.2.2 Expert / qualified person

1.2.2.3 Driver / operator

1.2.3 Basic safety regulations for safe operation

All persons remaining in the area of the machine must be informed

1.2.3.2 Regular safety inspections

1.2.3.3 Modifications and alterations to the machine

1.2.3.4 Damage, defects, misuse of safety devices

Machines with cabin already have ROPS/FOPS as

The frame of the machine must not be warped, bent or cracked in

A defective ROPS/FOPS must always be replaced with an original

1.2.4 Handling fuels and lubricants

Should pressure fluid penetrate the skin, imme-

1.2.5 Load/transport the machine

1.2.6 Starting up the machine

1.2.6.2 Starting the engine

1.2.6.3 Starting the engine with jump leads

1.2.7 Driving the machine; working operation

If the machine has touched high-voltage power lines:

1.2.7.2 Driving up and down slopes

1.2.7.4 Working with vibration

1.2.7.5 Parking the machine

Static charges may be generated in the fuel as it passes through

1.2.9 Emergency procedures

1.2.9.2 Disconnecting the battery

1.2.9.3 Towing the machine

Before starting towing operations make sure that the fastening

1.2.10 Maintenance work

1.2.10.2 Working on hydraulic lines

1.2.10.3 Working on the engine

1.2.10.4 Maintenance work on electric components and battery

1.2.10.5 Working on the air conditioning

1.2.10.6 Working on wheels and tyres

Do not drive with damaged wheels or tyres.

1.2.10.7 Cleaning work

1.2.10.8 Measures for longer shut-down periods

1.2.10.9 After maintenance work

Repairs must only be performed by an expert/qualified person.