ST BW219DH-5 101586341001-UP 00840097EN.f16

Service Training
BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 /

BW 226 PDH-5
S/N 101 586 34 1001> / S/N 101 586 38 1001> / S/N 101 586 41 1001> / S/N 101 586 59 1001>
Single drum roller
008 400 97 EN © 06/2016

2
Table of contents
Table of contents
1 General................................................................................................................................................... 9
1.1 General......................................................................................................................................... 10
1.2 Concerning your safety.............................................................................................................. 11
1.2.1 General prerequisites................................................................................................................. 11
1.2.2 Definition of responsible persons............................................................................................... 14
1.2.3 Fundamentals for safe operation............................................................................................... 15
1.2.4 Handling fuels and lubricants..................................................................................................... 16
1.2.5 What to do in events of emergency............................................................................................ 21
1.2.6 Park the machine in secured condition...................................................................................... 22
1.2.7 Maintenance and repair............................................................................................................. 23
1.3 Fuels and lubricants................................................................................................................... 27
1.3.1 Fuels and lubricants................................................................................................................... 27
1.4 List of fuels and lubricants........................................................................................................ 34
1.4.1 List of fuels and lubricants.......................................................................................................... 34
2 Technical data..................................................................................................................................... 37
2.1 Technical data, BW 219 DH-5..................................................................................................... 38
2.1.1 Technical data............................................................................................................................ 38
2.2 Technical data, BW 219 PDH-5.................................................................................................. 41
2.2.1 Technical data............................................................................................................................ 41
2.3 Technical data, BW 226 DH-5..................................................................................................... 45
2.3.1 Technical data............................................................................................................................ 45
2.4 Technical data, BW 226 PDH-5.................................................................................................. 48
2.4.1 Technical data............................................................................................................................ 48
2.5 Additional technical data............................................................................................................ 52
3 Overview of machine.......................................................................................................................... 55
3.1 Electric systems.......................................................................................................................... 59
3.2 Diesel engine............................................................................................................................... 60
3.3 Hydraulic system........................................................................................................................ 61
3.4 Drum............................................................................................................................................. 64
3.5 Signage........................................................................................................................................ 65
4 Electric systems.................................................................................................................................. 69
4.1 Overview of electric system....................................................................................................... 70
4.2 Table of fuels and lubricants..................................................................................................... 75
4.3 Wiring........................................................................................................................................... 83
4.4 CAN BUS overview..................................................................................................................... 96
4.5 Central electrics.......................................................................................................................... 98
4.6 Control console cabin ............................................................................................................. 107
4.7 Fuse assignment....................................................................................................................... 110
4.7.1 Notes on safety........................................................................................................................ 110
4.7.2 Central electrics....................................................................................................................... 110
4.7.3 Main fuses................................................................................................................................ 111
4.7.4 Fuse, cabin............................................................................................................................... 112
4.8 Operator’s stand....................................................................................................................... 113
4.8.1 Instrument cluster..................................................................................................................... 114
BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 / BW 226 PDH-5 3

Table of contents
4.9 Telemecanique switch.............................................................................................................. 117

4.10 Deutsch plug, series DT and DTM......................................................................................... 119
4.11 Acceleration transducer, B62 & B171................................................................................... 123
4.12 Checking the main battery switch......................................................................................... 125
4.13 Starting the engine with jump leads...................................................................................... 126
4.14 Differential pressure switch for hydraulic oil filter, B21...................................................... 127
4.15 Air filter vacuum switch, B03................................................................................................. 128
4.16 Sensor, water in fuel filter, B124............................................................................................ 129
4.17 Float switch, coolant compensation tank, B55.................................................................... 130
4.18 Level sensor in diesel tank (R03).......................................................................................... 131
4.19 Charge control lamp............................................................................................................... 132
4.20 Inspection and maintenance work........................................................................................ 133
4.20.1 Maintenance Table................................................................................................................. 133
4.20.2 Every 500 operating hours..................................................................................................... 133
5 Diesel engine..................................................................................................................................... 135
5.1 Overviews.................................................................................................................................. 136
5.2 Lubrication oil circuit TCD 4.1 / 6.1......................................................................................... 140
5.3 Coolant circuit TCD 4.1 / 6.1..................................................................................................... 142
5.4 Common Rail System (CRS).................................................................................................... 144
5.5 Wastegate charge pressure controller.................................................................................... 152
5.6 Exhaust gas recirculation........................................................................................................ 153
5.7 Engine electrics......................................................................................................................... 155
5.7.1 CAN BUS overview.................................................................................................................. 156
5.7.2 EMR4 system overview............................................................................................................ 158
5.7.3 EMR4 system components...................................................................................................... 164
5.8 Inspection and maintenance work.......................................................................................... 175
5.8.1 Maintenance Table................................................................................................................... 175
5.8.2 Checks prior to start up............................................................................................................ 176
5.8.3 Every 250 operating hours....................................................................................................... 177
5.8.8 As required............................................................................................................................... 189
6 Hydraulic system.............................................................................................................................. 195
6.1 Overview of hydraulics............................................................................................................. 196
6.2 Open and closed hydraulic circuit.......................................................................................... 199
6.3 Hydraulic units.......................................................................................................................... 201
6.3.1 Travel/vibration pump, H1........................................................................................................ 201
6.3.2 Swash plate principle, pump.................................................................................................... 205
6.3.3 Travel motor, H1...................................................................................................................... 207
6.3.4 Vibration motor A2FM.............................................................................................................. 209
6.3.5 Swash plate principle, motor.................................................................................................... 211
6.3.6 External gear pumps................................................................................................................ 213
6.3.7 Steering valve.......................................................................................................................... 215
6.4 Charge circuit............................................................................................................................ 217
4 BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 / BW 226 PDH-5

Table of contents
6.5 Travel circuit.............................................................................................................................. 219

6.6 Vibration circuit......................................................................................................................... 227
6.7 Steering circuit.......................................................................................................................... 233
6.8 Flushing and bleeding.............................................................................................................. 237
6.8.1 Flushing - general.................................................................................................................... 237
6.8.2 Drum drive................................................................................................................................ 240
6.8.3 Axle drive................................................................................................................................. 246
6.8.4 Vibration circuit......................................................................................................................... 252
6.8.5 Bleeding the travel circuit......................................................................................................... 257
6.8.6 Bleeding the vibration circuit.................................................................................................... 259
6.9.2 Checks prior to start up............................................................................................................ 261
7 Air conditioning................................................................................................................................. 267
7.1 Overview.................................................................................................................................... 268
7.2 Physical principles.................................................................................................................... 269
7.3 Refrigerant R134a..................................................................................................................... 272
7.4 Compressor oil / refrigeration oil............................................................................................ 275
7.5 Working principle of the air conditioning system.................................................................. 278
7.6 Monitoring devices................................................................................................................... 279
7.7 Description of components...................................................................................................... 280
7.8 Compressor............................................................................................................................... 286
7.9 Emptying in case of repair....................................................................................................... 288
7.10 Drying and evacuation............................................................................................................ 289
7.11 Filling instructions.................................................................................................................. 290
7.12 Steam table for R134a............................................................................................................. 295
7.13.4 Every 1000 operating hours................................................................................................... 303
7.13.5 As required............................................................................................................................. 306
8 Oscillating articulated joint.............................................................................................................. 307
8.1 Overview.................................................................................................................................... 308
9 Drum................................................................................................................................................... 309
9.1 Repair overview for drum......................................................................................................... 310
9.2.4 As required............................................................................................................................... 317

Table of contents
10 Drive axle........................................................................................................................................... 319

10.1 Drive axle................................................................................................................................. 320
10.2 Checks prior to start up.......................................................................................................... 321
10.2.1 Checking wheels and tyres.................................................................................................... 321
10.3 Every 250 operating hours..................................................................................................... 322
10.3.1 Checking the oil level in the drive axle................................................................................... 322
10.3.2 Checking the oil level in the drive axle reduction gear........................................................... 322
10.3.3 Checking the oil level in the wheel hubs................................................................................ 323
10.4 Every 1000 operating hours................................................................................................... 324
10.4.1 Change the oil in the drive axle.............................................................................................. 324
10.4.2 Change the oil in the drum drive reduction gear.................................................................... 325
10.4.3 Changing the oil in the wheel hubs........................................................................................ 326
10.4.4 Retightening the fastening of the axle on the frame............................................................... 327
10.4.5 Tighten the wheel nuts........................................................................................................... 327
10.5 As required.............................................................................................................................. 328
10.5.1 Adjust the parking brake........................................................................................................ 328
11 Optional heating, AIRTRONIC.......................................................................................................... 329
11.1 Overview.................................................................................................................................. 330
11.2.2 Monthly................................................................................................................................... 334
11.2.3 Heating season...................................................................................................................... 334
12 Trouble shooting............................................................................................................................... 335
12.1 Preliminary remarks................................................................................................................ 336
12.2 Emergency procedures.......................................................................................................... 337
12.2.1 Actuating the emergency stop switch..................................................................................... 337
12.2.2 Disconnecting the battery....................................................................................................... 337
12.2.3 Towing the machine............................................................................................................... 338
12.2.4 After towing............................................................................................................................ 340
12.3 Troubleshooting, electrical systems..................................................................................... 343
12.3.1 Preliminary remarks............................................................................................................... 343
12.3.2 Starting the engine with jump leads....................................................................................... 346
12.3.3 Servicing the battery, checking the main battery isolation..................................................... 347
12.3.4 Fuse assignment.................................................................................................................... 348
12.3.5 Understanding electric circuit diagrams................................................................................. 350
12.3.6 Measuring method................................................................................................................. 364
12.3.7 ESX, checking the electric power supply............................................................................... 368
12.3.8 Diagnostics concept............................................................................................................... 376
12.3.9 Electrics training machine control.......................................................................................... 378
12.4 Trouble shooting, diesel engine............................................................................................ 476
12.4.1 Starting the engine with jump leads....................................................................................... 476
12.4.2 Engine malfunctions............................................................................................................... 477
12.4.3 DTC error code list, EMR4..................................................................................................... 480
12.5 Trouble shooting, hydraulics................................................................................................. 540
12.5.1 Insufficient hydraulic power.................................................................................................... 540
12.5.2 Trouble shooting axial piston pumps...................................................................................... 543

Table of contents
12.5.3 Trouble shooting axial piston motors..................................................................................... 545

12.6 Trouble shooting, air conditioning system.......................................................................... 547
12.6.1 Trouble shooting in refrigerant circuit, basic principles.......................................................... 547
12.6.2 Trouble shooting procedure................................................................................................... 554
12.6.3 Leak test................................................................................................................................. 563
12.6.4 Checking the magnetic clutch ............................................................................................... 564
12.7 Troubleshooting, additional heating..................................................................................... 566
12.7.1 Control and safety elements.................................................................................................. 567
12.7.2 Trouble shooting.................................................................................................................... 568
12.7.3 Diagnostics with the module clock......................................................................................... 569
12.7.4 Check the fuel supply............................................................................................................. 572
12.7.5 Circuit diagram, AIRTRONIC D2/D4...................................................................................... 574
12.7.6 Fault code, AIRTRONIC D2/D4............................................................................................. 578
13 Special tools...................................................................................................................................... 583
13.1 Special tools, electrics........................................................................................................... 584
13.2 Special tools, hydraulic system............................................................................................. 585
13.2.1 Special tools, tests and adjustments...................................................................................... 585
13.2.2 Special tools for flushing........................................................................................................ 587
13.3 Special tools for oscillating articulated joint........................................................................ 592
13.4 Special tools, drum................................................................................................................. 594
13.5 List of special tools................................................................................................................. 596
14 Index................................................................................................................................................... 597
Appendix............................................................................................................................................ 605
A Circuit diagrams............................................................................................ 607
A.A Hydraulic diagram, 372............................................................................. 608
A.B Hydraulic diagram, 374............................................................................. 620
A.C Wiring diagram, 354.................................................................................. 632

Table of contents

General
1 General

General – General
1.1 General
General This manual:
n addresses the BOMAG customer service or professionally
trained personnel.
n explains the design of the machine and its functions.
n serves as
– document to be used during the training course
– reference book for the purpose of repeating or deepening
the training contents you have learned.
This manual describes components, assemblies and the essential
functions of the machine. (As far as required for the BOMAG After
Sales Service)
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)
Genuine BOMAG spare parts

Use only genuine BOMAG spare parts.
Spare parts needed for repairs can be taken from the spare parts
catalogue for the 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.

General – Concerning your safety
1.2 Concerning your safety

1.2.1 General prerequisites
1.2.1.1 General
This BOMAG machine has been built in compliance with the latest
technical standard and complies with the applicable regulations
and technical 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 customer must obtain the relevant signa-
tures as confirmation.
Furthermore, the following obviously also applies:
n applicable accident prevention instructions,
n generally accepted safety and road traffic regulations,
n country 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 amnd 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 warning signs:
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 sit-
uation that could lead to fatal or severe injuries, if this
warning is disregarded.

CAUTION!
Danger of injury if failing to comply!
Sections marked accordingly indicate a dangerous sit-
uation 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 infor-

mation or notes on using the machine or its compo-
nents.
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 protects against
being caught by moving components.
Safety shoes To protect against heavy falling parts and slipping on

slippery ground.
Protective gloves To protect the hands against excoriation, punctures or

deep injuries, against irritating and caustic substances
as well as against burns.

Safety goggles To protect the eyes against airborne particles and fluid
squirts.
Face protection To protect the face against airborne particles and fluid
squirts.
Hard hat To protect the head against falling parts and to protect
against injuries.
Hearing protection To protect the hearing against too loud noise.
1.2.1.4 Intended use

This machine must only be used for:
n Compaction work in earth construction and road bases.
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 from the machine when it is used for purposes
other than the one it is intended for.
Any danger caused by improper use is the sole responsibility of the
operating company or driver/operator, the manufacturer cannot be
made liable.
Examples for improper use are:
n work with vibration on hard concrete, cured bitumen layers or
extremely frozen ground
n driving on unstable subbases or too small contact area (danger
of tipping over)
n Using the machine for towing
n use to pull down walls or demolish buildings
transporting persons, except the machine driver, is prohibited.

starting and operation of the machine in explosive environments

and in underground mining is prohibited.
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
his company. It must then take appropriate action to ensure health
and safety at work for his employees and point out any remaining
dangers.
The operating company must determine whether there are special
operation hazards such as a toxic atmosphere or limiting soil con-
ditions. Such conditions requires 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.
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 these machines.
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, medicine 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 Fundamentals 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.
All persons remaining ion 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 (capable 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 Protective Structure (ROPS)
On machines with cab the ROPS is an integral part of

the cab.
The frame of the machine must not be warped, bent or cracked in

the area of the ROPS fastening.
The ROPS must not show any rust, damage, hairline cracks or
open fractures.
The real machine weight must never exceed the testing weight for
the ROPS.
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 must therefore also not be straightened or repaired if it
is damaged.
A defect ROPS must generally 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
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 (protec-
tive 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 sub-
stance
– Always keep diesel fuel in proper containers.
– Immediately bind spilled diesel fuel with an oil-
binding agent.
– Dispose of diesel fuel and fuel filters according to
regulations.

1.2.4.3 Safety regulations and environmental protection regulations for handling AdBlue®/DEF
CAUTION!
Health hazard caused by ammonia vapours!
– Wear your protective outfit (protective gloves, pro-
tective clothing).
– Do not inhale ammonia vapours.
– Avoid contact and consumption.
AdBlue®/DEF has not been classified as environmen-

Fig. 2 tally harmful.
1.2.4.4 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 com-
ponents.
Fig. 3 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 regulations.

1.2.4.5 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.
tive gloves, protective clothing, goggles).
Fig. 4 Should pressure fluid penetrate the skin, immediate

medical help is required.
WARNING!
Danger of burning by ignited hydraulic oil!
– Do not allow hydraulic oil to come into contact with
hot components.
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 regulations.

1.2.4.6 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. 5 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.
– Immediately bind spilled coolant with an oil-binding
agent and dispose of it according to regulations.
– Dispose of coolant according to regulations.

1.2.4.7 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. 6
Rinse acid off clothes, skin or eyes immediately with
lots of clear water.
Immediately call for medical advice in case of cauteri-
zation.
WARNING!
Danger of injury caused by exploding gas mixture!
– 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 sub-
stance
– Dispose of battery and battery acid according to
regulations.
1.2.5 What to do in events of emergency

1.2.5.1 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 shoudl therefore never use the emergency stop as a
service brake.
1.2.5.2 Disconnect 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.
1.2.5.3 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 towing vehicle with sufficient traction and braking power for
the unbraked towed load.
If no tow bar is used, towing is only permitted uphill.
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.
1.2.6 Park the machine in secured condition.

1. Drive the machine onto level and firm ground.
2. To stop the machine return the travel lever to middle position
and shift it to the right to lock (parking brake position).
ð The parking brake warning lamp lights up.
Fig. 7

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 2 minutes.
3. Turn the ignition key to position “0” and pull it out.

4. Open and secure the engine hood.
Fig. 8
5. Turn the main battery switch counter-clockwise and pull it

out.
6. Close the engine hood and lock it if necessary.
Fig. 9
1.2.7 Maintenance and repair

1.2.7.1 Preliminary remarks and safety notes
DANGER!
Danger to life caused by an operationally unsafe
machine!
– The machine must only be serviced by qualified
and authorized personnel.
– Follow the safety regulations for maintenance
work.
WARNING!
Health hazard caused by fuels and lubricants!
– Safety regulations and environmental protection
regulations when handling fuels and lubricants
must be followed Ä Chapter 1.2.4 ‘Handling fuels
and lubricants’ on page 16.

The terms right/left always correspond with travel direction forward.

1. Thoroughly clean machine and engine before starting main-
tenance work.
2. Park the machine on horizontal, level, firm ground.
3. For all maintenance work park the machine is secured condi-
tion Ä Chapter 1.2.6 ‘Park the machine in secured condition.’
on page 22.
4. Wear your personal protective equipment.
5. Do not touch hot components.
6. Always remove the main battery switch for all maintenance
work.
7. Perform maintenance work only with the engine shut down.
8. Dump the pressure from hydraulic lines before working on
them.
9. Before working on electric parts disconnect the battery and
cover it with insulation material.
10. After all maintenance work is completed reinstall all guards
and safety installations.
11. Close all maintenance flaps and doors after maintenance
work has been completed.
1.2.7.2 Work on hydraulic lines

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 advice when
injured by hydraulic oil.
Do not step in front of or behind the wheels 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 caught and disposed of in an environ-
mentally friendly manner.
Always catch and dispose of hydraulic oils separately.
Do not start the engine after draining 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 BOMAG replacement hydraulic hoses ensure that
the correct hose type (pressure range) is used at the right location.

1.2.7.3 Working on the engine

Do not work on the fuel system while the engine is running -
danger to life due to high pressures!
Wait until the engine has stopped, then wait another approx. 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 environmen-
tally.
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 with high temperatures. Keep
combustible materials away and do not touch any hot surfaces.
Check and change coolant only when the engine is cold. Catch
coolant and dispose of it environmentally.
1.2.7.4 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 - fire hazard!
When working on the battery do not smoke, do not use open fire.
Do not let acid come in contact with hands or clothes. When
injured by acid, flush off with clear water and seek medical advice.
Metal objects (e.g. tools, rings, watch straps) must not come in
contact with the battery poles – danger of short circuit and burning!
When recharging non-serviceable batteries remove all plugs, to
avoid the accumulation of explosive gases.
Switch off the charging current before removing the charging
clamps.
Ensure sufficient ventilation, especially if the battery is to be
charged in a closed room.
Dispose of old batteries according to regulations.
1.2.7.5 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 clean the condenser in the air conditioning system with a
hot water jet. Danger of explosion!
Do not release refrigerant into the atmosphere, but dispose of envi-
ronmentally.
1.2.7.6 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.
Do not use gasoline or other easily inflammable substances for
cleaning.
When cleaning with a high pressure cleaner do not direct the wter
jet to electrical insulation material or cover it beforehand.
Do not guide the water jet into the exhaust pipe and into the air
filter.

General – Fuels and lubricants
1.3 Fuels and lubricants
1.3.1 Fuels and lubricants

1.3.1.1 Engine oil
1.3.1.1.1 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

1.3.1.1.2 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. 10: Oil viscosity diagram
1.3.1.1.3 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 %
1.3.1.2 Fuel
1.3.1.2.1 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.

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
1.3.1.2.2 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.
1.3.1.2.3 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.
1.3.1.3 Coolant
1.3.1.3.1 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.

1.3.1.3.2 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.
1.3.1.3.3 Cooling system protection agent

As a protection against frost, corrosion and boiling point anti-freeze
agents must be used under 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 our BOMAG cooling system pro-
tection agent.

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 in the

Internet under the following address:
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 A.
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 corrosion pro-
tection.
The mixing ratio must not be below or exceed the following

value:
Cooling system Fresh water Cold protection

protection agent 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 causes a drop in cooling power.
– The use of corrosion protection oils as cooling
system protection agents is not permitted.

1.3.1.4 Hydraulic oil

1.3.1.4.1 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).
For topping up or for oil changes use only hydraulic oil, type HVLP
according to DIN 51524, part 3, or hydraulic oils type HV according
to ISO 6743/3.
The viscosity index (VI) should be at least 150 (observe informa-
tion of manufacturer).
1.3.1.4.2 Bio-degradable hydraulic oil

The hydraulic system can also be operated with a synthetic ester
based biodegradable hydraulic oil.
The biologically quickly degradable hydraulic oil Panolin HLP
Synth.46 meets all demands of a mineral oil based hydraulic oil
according to DIN 51524.
In hydraulic systems filled with Panolin HLP Synth.46 always use
the same oil to top up.
When changing from mineral oil based hydraulic oil to an ester
based biologically degradable oil, you should consult the lubrica-
tion oil service of the oil manufacturer, or our customer service for
details.
NOTICE!
Risk of damage!
– Check the filter more frequently after this change.
– Perform regular oil analyses for content of water
and mineral oil.
– Replace the hydraulic oil filter element every 500
operating hours.
1.3.1.5 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).
1.3.1.6 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).

It is a hypoid lubricant of highest quality class for transmissions

under extreme strain.

General – List of fuels and lubricants
1.4 List of fuels and lubricants
1.4.1 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 13 l
Specification: Ä Chapter 1.3.1.1 ‘Engine oil’ 20 l (3.4 gal us)
on page 27
SAE 15W-40
SAE 10W-30
SAE 30 SAE 10W
Fuel Diesel Winter diesel fuel 235 l
Specification: Ä Chapter 1.3.1.2 ‘Fuel’ (62 gal us)
on page 28
Coolant Mixture of water and anti-freeze agent 009 940 08 26 l
Specification: Ä Chapter 1.3.1.3 ‘Coolant’ 20 l (6.9 gal us)
on page 29
Hydraulic system Hydraulic oil (ISO), HVLP 46 009 930 09 75 l
Specification: Ä Chapter 1.3.1.4.1 ‘Mineral oil 20 l (20 gal us)
based hydraulic oil’ on page 32
or ester based biodegradable hydraulic oil
Specification: Ä Chapter 1.3.1.4.2 ‘Bio-
degradable hydraulic oil’ on page 32
Exciter housing Gear oil SAE 75W-90 009 925 05 1 l each
Specification: Ä Chapter 1.3.1.5 ‘Gear oil 20 l (0.26 gal us)
SAE 75W-90’ on page 32
Drum drive reduction Gear oil SAE 80W-140 009 925 07 5l
gear
Drive axle Gear oil SAE 80W-140 009 925 07 12.5 l
Axle reduction gear Gear oil SAE 80W-140 009 925 07 1.9 l
Wheel hubs Gear oil SAE 80W-140 009 925 07 3.7 l each

Assembly group Fuel or lubricant Spare parts Filling quantity

number
Summer Winter Observe the
level mark!
Tires Water + calcium chloride 295 l + 100 kg
(80 gal us +
220 lbs)
or water + magnesium chloride 308 l + 87 kg
(81 gal us +
192 lbs)
Air conditioning Refrigerant R134a 1500 g
(3.3 lbs)


Technical data
2 Technical data

Technical data – Technical data, BW 219 DH-5
2.1 Technical data, BW 219 DH-5

2.1.1 Technical data
Dimensions
Fig. 11
A B D H H2 K L O1/2 S W
3255 2300 1600 2295 3034 495 6500 85 40 2130
(128) (91) (63) (90) (119) (19.5) (256) (3.3) (1.6) (84)
Dimensions in millimetres
(Dimensions in inch)
Weights
Max. operating weight 22000 kg
(48502) (lbs)
Operating weight with ROPS cabin (CECE) 19400 kg
(42770) (lbs)
Axle load, drum (CECE) 12800 kg
(28219) (lbs)
Axle load, wheels (CECE) 6600 kg
(14550) (lbs)
Static linear load 60.1 kg/cm
(337) (pli)

Travel characteristics
Travel speed 0 – 10 km/h
(0 – 6.2) (mph)
Max. gradability without/with vibration (soil dependent) 60/57 %
Drive
Engine manufacturer Deutz
Type TCD 6.1 L6
Cooling Fluid
Number of cylinders 6
Rated power ISO 3046 150 kW
Rated power SAE J 1995 202 hp
Rated speed 2300 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
Steering
Type of steering Oscill.-articul.
Steering angle +/- 35 °
Oscillation angle +/- 12 °
Inner track radius 4120 mm
(162) (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) 328/266 kN
(73737/59799) (lbf)
Filling capacities
Fuel (diesel) 280 l
(74) (gal us)
2.1.1.1 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 EC Machine Directive edition 2006/42/EC
n Noise Emission Directive 2000/14/EC, Noise Protection Direc-
tive 2003/10/EC
n Vibration Protection Directive 2002/44/EC
During operation these values may vary because of the prevailing
operating conditions.
2.1.1.1.1 Noise data

Sound pressure level on the opera- LpA = 74 dB(A), determined acc. to ISO 11204 and EN 500
tor's stand
Guaranteed sound power level LWA = 110 dB(A), determined acc. to ISO 3744 and EN 500
2.1.1.1.2 Vibration data

Vibration of the entire body The weighted effective acceleration value determined according to
(driver’s seat) ISO 7096 is ≤ 0.5 m/s2.
Hand-arm vibration The weighted effective acceleration value determined according to

EN 500/ISO 5349 is ≤ 2.5 m/s2.

Technical data – Technical data, BW 219 PDH-5
2.2 Technical data, BW 219 PDH-5

Dimensions
Fig. 12
3255 2300 1500 2295 3034 495 6500 85 35 2130
(128) (91) (59) (90) (119) (19.5) (256) (3.3) (1.4) (84)
Weights
(46297) (lbs)
(44092) (lbs)
(29101) (lbs)
(14991) (lbs)

Travel speed 0 – 10 km/h
(0 – 6.2) (mph)
Drive
Type TCD 6.1 L6
Cooling Fluid
Electric system
Voltage 12 V
Padfoot drum
Padfeet, quantity 150
Area of one padfoot 137 cm2
21.2 (in2)
Height of padfeet 100 mm
(3.9) (in)
Tyres
Air pressure, nominal value 1.4 bar
(20) (psi)
Brakes

Steering
(162) (in)
Exciter system
(1560/1860) (vpm)
Amplitude (1/2) 1.90/1.10 mm
(0.075/0.043) (in)
(73737/55078) (lbf)
Filling capacities
Fuel (diesel) 280 l
(74) (gal us)

tive 2003/10/EC

tor's stand



EN 500/ISO 5349 is ≤ 2.5 m/s2.

2.3 Technical data, BW 226 DH-5

Dimensions
Fig. 13
3355 2500 1600 2339 3078 430 6740 185 40 2130
(132) (98) (63) (92) (121) (16.9) (265) (7.3) (1.6) (84)
Weights
(58885) (lbs)
(55116) (lbs)
(37633) (lbs)
(17483) (lbs)
Static linear load 80.1 kg/cm
(448) (pli)

Travel speed 0-9 km/h
(0 - 5.6) (mph)
Drive
Type TCD 6.1 L6
Cooling Fluid
Electric system
Voltage 12 V
Tyres
Air pressure, nominal value 2 bar
(29) (psi)
Brakes
Steering
(168) (in)

Exciter system
(1560/1560) (vpm)
Amplitude (1/2) 2.10/1.20 mm
(0.083/0.047) (in)
(73737/42039) (lbf)
Filling capacities
Fuel (diesel) 280 l
(74) (gal us)

tive 2003/10/EC

tor's stand


EN 500/ISO 5349 is ≤ 2.5 m/s2.

2.4 Technical data, BW 226 PDH-5

Dimensions
Fig. 14
3355 2500 1500 2339 3078 430 6740 185 35 2130
(132) (98) (59) (92) (121) (16.9) (265) (7.3) (1.4) (84)
Weights
(60627) (lbs)
(56747) (lbs)
(39242) (lbs)
(17505) (lbs)

Travel speed 0-9 km/h
(0 - 5.6) (mph)
Drive
Type TCD 6.1 L6
Cooling Fluid
Electric system
Voltage 12 V
Padfoot drum
Padfeet, quantity 150
Area of one padfoot 137 cm2
21.2 (in2)
Height of padfeet 100 mm
(3.9) (in)
Tyres
Air pressure, nominal value 2 bar
(29) (psi)
Brakes

Steering
(168) (in)
Exciter system
(1560/1560) (vpm)
Amplitude (1/2) 1.70/0.90 mm
(0.067/0.035) (in)
(73737/55528) (lbf)
Filling capacities
Fuel (diesel) 280 l
(74) (gal us)

tive 2003/10/EC

tor's stand



EN 500/ISO 5349 is ≤ 2.5 m/s2.

Technical data – Additional technical data
2.5 Additional technical data

Additional engine data
Combustion principle 4-cycle diesel engine with charge
air cooling
Combustion method Direct fuel injection
Injection system Common Rail
Exhaust gas recirculation externally cooled
Low idle speed rpm 800
High idle speed rpm 2300
ECO rpm 1800
Valve clearance intake ° 75° ±15°
Valve clearance exhaust ° 120° ±15°
Travel pumps
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 bar 400
Reduction gear drum BW 219

Manufacturer Bonfiglioli
Type 711C3
Transmission ratio 93.9
Reduction gear drum BW 226

Manufacturer Bonfiglioli
Type 715C3
Transmission ratio 129.3

Drum drive motor / axle 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 50
Perm. leak oil rate l/min 2
Flushing rate l/min 5
Flushing pressure limitation bar 16
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 400
Charge pressure relief valve 34
Pressure override bar 400
Auxiliary pump cm3/rev 17
Vibration motor, BW 219

Manufacturer Bosch-Rexroth
Type A2FM 63 HDD
System Axial piston/bent axle
Displacement cm3/rev 63
Vibration motor, BW 226

Manufacturer Bosch-Rexroth
Type A2FM 80 HDD

System Axial piston/bent axle

Steering/charge pump
System Gear pump
Max. steering pressure bar 175 + 25
Steering valve
Manufacturer Danfoss
Type OSPC 500 ON
System Rotary spool valve
Rear axle
Manufacturer Dana
Type CHC 193/99
Differential No-Spin
Degree of locking % 100
Reduction ratio 93.74

Overview of machine
3 Overview of machine

Overview of machine
Fig. 15
Fig. 16
1 Central electrics
2 Drum
3 Articulated joint
4 Diesel engine

Overview of machine
Simple servicing due to excellent

accessibility
Fig. 17
Smooth drum: BVC, D and DH

machines
Fig. 18
n Compaction of sand, gravel and crushed rock
n Tapered drum edges
n Optimum surface quality

Overview of machine
Padfoot drum: PD and PDH

machines
Fig. 19
n Use on cohesive soils
n Surface enlargement for faster drying
n Flexing and kneading effect
Padfoot shell optional equipment
Fig. 20
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.

Overview of machine – Electric systems
3.1 Electric systems
Fig. 21
1 Travel control, A34
2 Inclination sensor, B57
3 Power board
4 Diagnostics interface BOMAG, X34
5 Diagnostics interface Deutz, X32
6 Telematic module, A124
7 Engine control unit, A48
8 Connector strip X100 to X109
9 Measurement technology control, A83

Overview of machine – Diesel engine
3.2 Diesel engine

This single drum roller is powered by a Deutz engine series TCD
6.1. This is a water-cooled 6-cylinder diesel engine with a Common
Rail injection system.
The engine is designed with four-valve technology as well as turbo-
charging with intercooler.
Fig. 22
1 Diesel engine
2 Fuel pre-cleaner with sensor for water separator (B124)
3 Main fuses
4 Central electrics, engine control unit (A48)
5 Diagnostics interface, diesel engine (X32)
6 Interface to diesel engine (X41)

Overview of machine – Hydraulic system
3.3 Hydraulic system
Fig. 23
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

Fig. 24
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

Travel pump for drum drive
Forward travel Backward travel

Plugs Y73 Y72
Travel pump for axle drive

Plugs Y16 Y17

Overview of machine – Drum
3.4 Drum
Fig. 25
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

Overview of machine – Signage
3.5 Signage
Keep stickers and decals in good and legible condition and comply
with their meaning.
Replace damaged and illegible stickers or decals immediately.
Fig. 26
1 Warning sticker - Danger of crushing
2 Information sticker - Lifting point
3 Information sticker - Lashing point
4 Information sticker - Engine oil drain
5 Information sticker - Coolant drain
6 Information sticker - Hydraulic oil drain
7 Prohibition sticker - High pressure cleaning
8 Information sticker - Guaranteed sound capacity level

Fig. 27
1 Warning sticker - Danger of crushing
2 Information sticker - Lifting point
3 Information sticker - Lashing point
4 Information sticker - Engine oil drain
5 Information sticker - Coolant drain
6 Information sticker - Hydraulic oil drain
7 Prohibition sticker - High pressure cleaning
8 Information sticker - Guaranteed sound capacity level

Fig. 28
1 Information sticker - Diesel
2 Information sticker - Main battery switch plus side
3 Warning sticker - Vehicle voltage 12 V
4 Operation sticker - Main battery switch
5 Information sticker - Hydraulic oil

Instruction sticker - Always wear your seat belt
Fig. 29

Electric systems
4 Electric systems

Electric systems – Overview of electric system
4.1 Overview of electric system
Fig. 30
3 Power board

Fig. 31
1 Machine with Telematic
2 GPS satellite
3 Mobile communications network
4 External partner
5 Internet (Cloud)
6 User
7 Telematic server
BOMAG TELEMATIC is a Fleet Management System. BOMAG
TELEMATIC enhances the effective use of machines. The
POWER variant enables continuous recording of the fuel consump-
tion.
With BOMAG TELEMATIC the machine operator can localize his
machines and also detect and save operating states. Actual oper-
ating hours are documented. Maintenance planning and documen-
tation is entirely mapped in BOMAG TELEMATIC.
BOMAG TELEMATIC is able to recognize unauthorized use or
theft. Many insurance companies award this with reduced insur-
ance premiums.
The system consists of a machine integrated hardware and an
internet application. All data are saved in a database. Access is
individual for each user and password protected.

BOMAG TERRAMETER
Fig. 32
The optional TERRAMETER, a development by BOMAG, supports
the driver in a special way. It shows the corresponding compaction
value digitally and in form of a bar graph. Moreover, it also informs
about the end of compaction. This helps to avoid unnecessary
passes , saves time and thus enhances the economy.
Optional modules In addition, the system can also be extended with further modules.
The technical requirements for surface covering compaction con-
trol are achieved with BOMAG COMPACTION METER (BCM) and
GPS, the satellite-assisted location system. This means that all
compaction data of a construction project can be recorded, pro-
cessed, managed, graphically displayed and, if required, printed
out.

Continuous Compaction Control
Fig. 33: BCM05, example 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 from of a file on any type of data
storage medium for transfer to third parties (e.g. client, con-
struction supervision, etc.)
The assignment of individual measuring values to the coordinates
is accomplished by manual selection of a track and within the track
by the tachometer signals from the displacement transducer on the
roller.
n Indication of end of compaction
n Office software for analyses
n Interchangeable between machines

Position detection for GPS-fields (A93)
Fig. 34
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.

Electric systems – Table of fuels and lubricants
4.2 Table of fuels and lubricants
This table contains all electrical components used in the machine,

except terminal strips and plugs.
Operating Function text Technical character-

means istics
A02 Flasher encoder
A12 Radio
A15 Monitoring board
A16 Tachograph electronics
A34 Travel control
A48 Engine control unit EMR4 (EDC 17-CV52)
A67 Keyboard
A83 Metrology control
A87 USB-CAN interface BCM
A93 GPS Receiver
A108 Heating/air conditioning unit
A124 Electronics BOMAG Telematik
A138 Aerial for BOMAG Telematic
B03 Air filter service switch
B11.1 Warning horn max. 3.5A
B21 Differential pressure switch for hydraulic oil filter
B51.L Radio speaker
B51.R Radio speaker
B55 Float switch in coolant compensation tank
B57 Inclination sensor speed range selection 0.5-4.5V
B59 Rotary speed sensor for drum speed
B60 Rotary speed sensor for axle speed
B62 Acceleration transducer
B88 EMR engine oil pressure
B93 EMR fuel pressure rail


means istics
B97 Sensor slewing motor
B104 Pressure switch, air conditioning system
B113 EMR coolant temperature sensor
B114 EMR engine speed sensor 1
B124 Water separator sensor, fuel
B130 EMR engine speed sensor 2
B133 EMR sensor charge air pressure / temperature
B145 EMR low pressure fuel
B171 Acceleration transducer
B208 EMR sensor delta p Venturi
B209 EMR sensor temperature EGR after Venturi
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
B238 Pressure sensor exhaust gas counter-pressure DPF before tur-
bocharger
B312 Sensor for height adjustment of plates 4...20mA
B313 Sensor for lateral adjustment of plates 4...20mA
D2.1 Control lamp relay K32
D05 Control lamp relay K13


means istics
Dx Control lamp for fuse test
E08 Direction indicator front left 21W
E09 Flash light, rear left 21W
E10 Flash light, front right 21W
E11 Flash light, rear right 21W
E12 Parking light, left 5W
E13 Tail light left LED
E14 Parking light, right 5W
E15 Tail light, right LED
E16 Head lights, left 55W
E17 Head lights, right 55W
E23 Working head lights, front left 12V 55W
E25 Working head lights, front right 12V 55W
E27 Working head lights, rear left 12V 55W
E28 Working head lights, rear right 12V 55W
E29 Cabin light
E30 Heating unit
E32 Flashing beacon 12V 70W
E72 Illumination of control switch
F00 Main fuse for battery 125A
F05 Fuse for socket 20A
F07 Fuse for hazard light 10A
F08 Fuse for direction indicator 10A
F09 Fuse for parking and tail light, left 10A
F10 Fuse for parking and tail light, right 10A
F11 Fuse for front working head lights, left 15A
F13 Fuse for starter switch 15A
F17 Fuse for radio 5A
F19 Fuse for working head lights, front left 15A


means istics
F22 Fuse for working head lights, rear 15A
F23 Fuse for warning horns 15A
F24 Fuse for monitoring board 10A
F27 Fuse for wiper and washer, front 15A
F28 Fuse for wiper and washer, rear 15A
F29 Fuse, compressor for suspended seat 15A
F39 Main fuse for cabin 80A
F40 Fuse for cabin heating 25A
F48 Fuse for heating flange 150A
F67 Fuse control (potential 30) 15A
F68 Fuse for potential 30 15A
F84 Fuse control (contact 54) 10A
F91 Fuse for sensors 5A
F95 Fuse for engine control 30A
F103 Fuse for potential 15 15A
F122 Fuse for engine control 10A
F124 Fuse for fuel pre-heater 25A
F143 Fuse for rear windscreen heating 20A
F150 Fuse for GPS receiver 5A
F157 Fuse for magnetic switch starter motor 30A
F164 Fuse for B+ charge line 150A
F169 Fuse for starting current 5A
F243 Fuse for Bomag Telematic (potential 30) 7.5A
F244 Fuse for Bomag Telematic (potential 15) 5A
F264 Fuse for BCM05 10A
F266 Fuse for radio / tachograph 10A
F268 Fuse for fuel pump 20A
F271 Fuse for BCM-Net 10A
F272 Fuse, controller for cabin operating console 5A
F279 Spare fuse 15A
F320 Fuse, timer for optional heater (potential 30) 5A


means istics
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 12V / 88/110 Ah
G02 Generator 14V / 150A
G03 Battery 12V / 88 Ah
H06 Hazard light control lamp
H07 Warning buzzer for malfunctions 70mA
H14 Warning buzzer for reverse travel 300mA
K05 Relay for start current 12V/25A
K06 Relay for rear working head lights 12V/25A
K09 Relay for air conditioning 12V/25A
K11 Relay for potential 30 to 15 12V/70A
K13 Relay for warning horn 12V/25A
K14.1 Preheating relay
K16 Relay for front working head lights 12V/25A
K20 Relay for front windscreen wipers 12V/25A
K21 Relay for rear windscreen wipers 12V/25A
K22 Relay, engine shut-down solenoid 12V/25A
K32 Relay cabin 12V/25A
K38 Relay for starter control 12V/40A
K39 Relay for starter motor
K41 Disconnecting relay 12V/25A
K43 Relay for vibration 12V/25A
K48 Relay for travel lever 0-position 12V/25A
K61 Relay for charge control 12V/25A
K141 Relay for rear windscreen heating 12V/25A
K145 Relay for starter solenoid 12V/40A
K209 Relay for fuel pump 12V/25A
M01 Starter
M04 Windscreen wiper motor, front 4.7A
M05 Windscreen wiper motor, rear 4.7A


means istics
M06 Windscreen washer motor front 3.5A
M07 Windscreen washer motor rear 3.5A
M10 Compressor, 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
R06 Heating driver's seat 12V / 6.85A
R10 Parallel resistor 82 Ω
R19 Heating flange 167A
R20 Terminating resistor CAN 120 Ω
R31 Terminating resistor CAN 120Ω
R32 Terminating resistor CAN 120Ω
R79 Fuel pre-heating 200W
R80 Heating for rear windscreen approx. 11 A
S00 Starter switch
S01 Emergency stop switch
S06 Seat contact switch
S09 Switch front vibration


means istics
S14 Hazard light switch
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 250A
S35 Switch, vibration low / high
S36 Switch, vibration of attachment plates
S37 Switch, direction indicator
S42 Travel stage switch 4..20mA / 0-5V
S55 Travel lever
S64 Push button, attachment plates floating position
S107 Switch for amplitude setting 4...20mA
S127 Switch, engine speed
S139 Potentiometer, frequency setting for attachment plates
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
V08 Diode S1M
V09 Diode S1M
V10 Diode S1M
Y04 Brake solenoid valve 2.41A
Y07 Solenoid valve, front vibration high 640...1580mA
Y08 Solenoid valve, front vibration low 640...1580mA
Y15 Magnetic clutch for air conditioning compressor 3.5A
Y16 Solenoid valve, travel direction forward 640...1580mA
Y17 Solenoid valve, travel direction backward 640...1580mA
Y30 Solenoid valve, travel speed range drum 2.41A


means istics
Y30 Solenoid valve, travel speed range drum 1.05A
Y31 Solenoid valve, travel speed range axle 1.05A
Y60 Solenoid valve, floating position
Y72 Solenoid valve, travel direction forward 640...1580mA
Y73 Solenoid valve, travel direction backward 640...1580mA
Y98 Solenoid valve, vibration pump for plates 400-1200mA
Y102 Solenoid valve, floating position
Y122 Solenoid valve, plates up
Y123 Solenoid valve, plates down
Y137 EMR-actuator
Y140 Solenoid valve exciter up 400-1200mA
Y141 Solenoid valve exciter down 400-1200mA
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
Y174 EMR Exhaust gas recirculation
Y261 EMR throttle valve for intake air
Y378 Solenoid valve, dozer blade priority
Y379 Solenoid valve, dozer blade up
Y380 Solenoid valve, dozer blade down

Electric systems – Wiring
4.3 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. 35
1 Wiring loom, instruments
2 Wiring loom, seat console

X78
B55
G02
B124
X72
X73
X67
OPTION
OPTION M35-Winterpaket
M35-Winter package
Kompressor Klimaanlage
1 Compressor air-conditioning
Y15
X12
B218
B03
X68
OPTION
Druckschalter Klimaanlage
Pressure switch air conditioning
GND
180°
-X0.B X1A
2
X101
X108
S-586-0229
Fig. 36
1 Wiring loom, engine
2 Wiring loom, ground

X30
X58 Y07
H14
X56 Y73 Y08
Y16
Y72
1
Y17 X57
X55
X25
X81
2
X11
3 Y04
Y30
X69
X80
B21
nicht benötigt
not required
´B11.1
´B11.2
Y31
X2A
180°
B60
X2B
X103
_
GND
S-586-0230
Fig. 37
1 Wiring loom, double pump
2 Wiring loom, pump installation
3 Wiring loom, adapter warning horn

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. 38
1 Wiring loom, charge line
2 Wiring loom, starter
3 Wiring loom, main battery switch <> main battery fuse
4 Wiring loom, charge system

2 -G03
-G01
+G03
+G01
3
1
- 4
S30:3
S-586-0232
Fig. 39
1 Wiring loom, battery box <> main battery switch
2 Wiring loom, battery (-)
3 Wiring loom, battery (-)
4 Wiring loom, battery (+)
5 Wiring loom ground engine <> ground frame

X104
B59
Y30
S-586-0235
Fig. 40
1 Wiring loom, front frame

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. 41
1 Wiring loom, cabin
2 Wiring loom, cabin internal

AZ 12 Tachograph with connection

A12 Option
1
X205
P09
A16
S-586-0236
Fig. 42
1 Wiring loom radio / tachograph
E21 radio
A12:A
A12:B
X205
S-870-0237
Fig. 43

E66 BOMAG Telematic Power

X6D
1 A124
A138
S-586-0238
Fig. 44
1 Wiring loom, Telematic

FS27 Electric anti-theft protection
X7B
180°
A67
X16
S-586-0239
Fig. 45
1 Wiring loom, immobilizer

K2 Heating
F320
F321
XS28
X207
X76
X76
X7.C
Y14
S-586-0240
Fig. 46
1 Wiring loom, heater
2 Wiring loom, fuel pump

VM31 Bracket and cable BCM/GPS
X95A
1 A87
X91
2 3
X210
X96A
X211
X204
X93
X85
X90
S-586-0243
Fig. 47
1 Interface CAN-USB
2 Wiring loom BCM, Supply + CAN
3 Wiring loom GPS Power

VM33 BOMAG Terrameter

X5.E
GND
180°
X107 A83
X88
2
X21
B171
X20
B62
S-586-0241
Fig. 48
1 Wiring loom, measuring computer
2 Wiring loom, acceleration transducer

Electric systems – CAN BUS overview
4.4 CAN BUS overview
P15
A87
S-586-0270
MESX
CAN3
A67
A177
A83
A144
CAN1
A124
CAN1
A15
X400 A162
A175
X34
CAN2
S55
ESX
X32
A34
CAN1
CAN2
Kubota
Deutz
A48
A48
Fig. 49: CAN-Bus

A34 Machine control, ESX

Electric systems – CAN BUS overview
A48 Control unit engine management, not available in BW177D-5 (Kubota engine, exhaust classification
Tier3a)
A67 Keyboard anti-theft protection
A83 Measurement control, BVC
A87 USB-CAN interface
A124 Telematic module, BOMAG
A144 Control console cabin
A162 Gateway, CAN module
A175 Telematic module, Morey
A177 Telematic module, ECU ZTR
P15 BCM05
S55 Travel lever
X32 Diagnostics interface engine control unit, not available in BW177D-5 (Kubota engine, exhaust classifi-
cation Tier3a)
X34 Diagnostics interface for ESX machine control
X400 Interface for measuring technology
CAN-bus, Controller Area Network created by Bosch at the end of the eighties for automobile applica-
tions.
Development objectives:
Real-time critical, robust and low price communication of control
units, such as transmission and engine control, but also less time
critical applications in the field of convenience electronics, such as
air conditioning.
Why CAN?
n Networking of control units for the realization of complex func-
tions.
n Reduction of the extend of wiring and plug connections.
n Better diagnostic possibilities (central diagnostics socket).
Characteristics of CAN
It is a kind of serial data transmission. The individual bits are trans-
mitted one after the other, only 2 lines are required.
CAN lines are twisted together 30 to 40 times per metre. Electro-
Fig. 50 magnetic interferences therefore always occur simultaneously in
both lines, the software is thus able to filter out interfering signals
more easily.
Wire (+) = cable colour blue
Wire (-) = cable colour yellow
Measuring on 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. Correct connection of lines can only
be checked by means of a continuity test. BOMAG display mod-
ules are connected to the BUS to give engineers and user the pos-
sibility to detect faults or to receive information from the BUS.

Electric systems – Central electrics
4.5 Central electrics
Fig. 51
3 Power board

Multi-point connector strip
X32
X105 X34
X107 X109
X104
X108
X106
X101
X103
X102
X100
S-586-0226
Fig. 52: Multi-point connector strip

X32 Diagnostics interface Deutz
X34 Diagnostics interface BOMAG
Power board for high-current appli-

cations
Power board for high-current appli-
cations
Fig. 53
Power elements implemented in the board by means of pressing
technology, ensure permanent connections, which meet highest
quality demands throughout the entire life cycle of the product and
thus are a major contribution to product reliability.

A powerful electric press fit is made by pressing a press pin

through the contacted hole in a printed circuit board - within the
course of a cold welding process - whereby a gas tight electrical
connection is achieved.
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 100% electric testing
n Increased reliability and prolonged lifetime of the overall
system
n Clear display of switching states by means of LEDs (simple
diagnostics).

Fig. 54: Plug side

X0A Supply potential 30
X0B Supply GND
X0C Supply potential 30 before battery

Fig. 55: 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
The LEDs on the relay bases light when Ubat is applied

to the relay coils.
Example: LED D145 on relay K145

K38
K41
K13
K145
K05
K61
K22
K209
K16
K43
K78 K09
K06
A02
K11
K48
S-538-0055
Fig. 56: Installed relays

A01 Flasher encoder
K05 Relay for start current
K06 Relay front working head lights
K09 Relay for air conditioning
K11 Relay for potential 30 to 15
K13 Relay for warning horn
K16 Relay for front working head lights
K22 Relay for engine solenoid
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
FM2 F19
FM1 F22
F243
F39
F157
F23 F268
F68
F11
F13 F84
F09 F67
F10 F07 F146
F124
F40
F103
F91
F08
F05
F244
F29
F24
F169 F122
F148
S-538-0056
Fig. 57: Installed fuses

1 Fuse test cap

Fuse test cap
The printed circuit board is a equipped with a fuse test

socket (Fuse Test). When plugging in an intact fuse,
the LED "DX" lights up.
Fig. 58: Pictogram

Electric systems – Control console cabin
4.6 Control console cabin
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. 59
K20 Relay for front windscreen wipers
K21 Relay for rear windscreen wipers
K32 Relay 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

F150
F271
F272
F264
F266
F143
F279
F17
F27
F28
S-586-0272
Fig. 60: Installed fuses

Fig. 61
Pos. Designation Note

a Push button for side lights/additional illumina- Optional equipment
tion left
b-g not used
h Push button for side lights/additional illumina- Optional equipment
tion right
i Push button for rear windscreen wiper Interval/on/off
j Push button for rear windscreen washer
k Push button rear windscreen heating The rear windscreen heating is shut down after
three minutes.
l Push button for rear working lights
m Push button for inside cabin light
n Push button for front working lights
o Push button for flashing beacon
p Push button for front windscreen washer
q Push button for front windscreen wiper Interval/on/off

Electric systems – Fuse assignment
4.7 Fuse assignment

4.7.1 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.
4.7.2 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 Headlight, 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 25 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
F124 25 A Fuel pre-heating
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
4.7.3 Main fuses

The main fuse box is located in the engine compartment.
Fig. 62

F164 150 A (B+) charge line
F00 125 A Main fuse (potential 30)
Fig. 63

F48 150 A Preheating system

4.7.4 Fuse, cabin
Fig. 64
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/washer
8 F27 15 A Front windscreen wiper/washer
9 F279 15 A Spare
10 F272 5A Control console cabin

Electric systems – Operator’s stand
4.8 Operator’s stand
Fig. 65
1 [A15] Instrument cluster
2 [S01] Emergency stop switch
3 [S09] Rotary switch for vibration, amplitude pre-selection
4 [S26] Rotary switch for working lights (optional equipment)
5 [S127] Rotary switch for engine speed
6 [S37] Rotary switch for direction indicators (optional equipment)
7 [S154] Rotary switch for hazard light system (optional equipment)
8 [S15] Rotary switch for lighting system (optional equipment)
9 [S42] Rotary switch for travel speed ranges
10 [S00] Starter switch
11 [S55] Travel lever

4.8.1 Instrument cluster

Overview
Fig. 66
1 Control and warning lamps
2 INFO 3 display field
5 RPM-meter
6 not used
7 Fuel level gauge
8 not used
Control and warning lamps
Designation Note
Air filter warning lamp Lights up if the air filter is blocked.
Clean or replace the air filter.
Water in fuel warning lamp Lights up when the water content in the fuel pre-cleaner reaches
the sensor contacts, the warning buzzer sounds.
Clean the water separator.
Pre-heating control lamp Lights up during pre-heating.

Designation Note
Coolant temperature Lights up when the engine overheats. The engine power is
warning lamp reduced after a short while.
Run the engine with idle speed or, if necessary, shut it down and
clean the radiator. If necessary, repair the engine.
Coolant level warning lamp Lights up if the coolant level is too low. The engine is shut down
after a short while.
Check coolant level, check cooling system for leaks, repair if nec-
essary.
Engine oil pressure warning Lights up if the engine oil pressure is too low. The engine is shut
lamp down after a short while.
Check the engine oil level; if necessary, repair the engine.
Central warning lamp Flashes in case of system faults, warnings and for information.
Charge control lamp Lights up if the battery is not being charged.

Check the V-belt drive, if necessary repair the generator.
Hydraulic oil temperature Lights up if the hydraulic oil temperature is too high. The engine
warning lamp power is reduced after a short while.
Run the engine with idle speed or shut it down if necessary and
clean the radiator.
Hydraulic oil filter warning Lights up, if the hydraulic oil filter is blocked. Warning buzzer
lamp sounds. The engine is shut down after 2 minutes.
Check the hydraulic system and replace the hydraulic oil filter.
Driver's seat warning lamp Lights up when the driver's seat is not occupied. If the machine is
travelling, the warning buzzer will sound and the machine is decel-
erated after 3 seconds.
To continue driving, occupy the driver's seat and shift the travel
lever again to the desired travel direction through the parking
brake position.
Parking brake warning lamp Lights up when the parking brake is applied.
Indicator control lamp

INFO 1 display field

Each actuation of the button switches between:
n Operating hours
n Coolant temperature
n Battery voltage
n Vibration frequency (optional equipment)
Fig. 67

Each actuation of the button switches between:
n Travel speed
n Evib-value (optional equipment)
n Travel speed and Evib-value (optional equipment)
Fig. 68
Designation Note
Immobilizer control lamp Lights up when the electronic immobilizer is active.
ECOSTOP control lamp Lights up after the engine has been shut down by the ECOSTOP
function.

Electric systems – Telemecanique switch
4.9 Telemecanique switch

Dismantling
Fig. 69
1. Lift up the interlock (5).
2. Fold down the switch block (4).
3. Loosen the screw (1).
Fig. 70: Folding down the switch

block
4. Lift up the interlock (2) and pull out the front element (3).
Fig. 71: Pulling out the front element

Electric systems – Telemecanique switch
Assembly
Fig. 72: Assembly

1. Insert the front element (3) into the bore in the control panel.
2. Clip the fastening adapter (6) onto the front element (3).
Watch the marks on front element and fastening

flange.
3. Tighten the screw (1) with a tightening torque of 0.6 Nm.
Fig. 73: Observe the marks.
4. Clip on the switch block (4).
Hook in the switch block at the bottom first.
Fig. 74: Install the switch block

Electric systems – Deutsch plug, series DT and DTM
4.10 Deutsch plug, series DT and DTM

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).
When connecting sockets and plugs these must
engage with a noticeable click when both halves inter-
Fig. 75: Crimp connections lock.
The plug connection should not be separable (without
loosening the interlock).
Removing DT contacts
Fig. 76: DT Series

Plug connectors DT and DTM have a wedge to hold the pins and
sockets in their position. This wedge can be removed and
replaced, without having to cut any leads.
Fig. 77
1. Pull the orange wedge out with long nose pliers.
2. Slightly pull the lead and unlock the interlocking hook with a
screw driver.

3. Pull the contact out of the socket.
Use the same method when assembling the

socket.
In this case the interlock disassembly tool serves
as an aid to remove the wedges.
Installing DT contacts
Fig. 78
1. Insert the contacts through the rubber grommet until they
click into place.
2. Insert the orange wedge in direction of arrow.

socket.
Pulling test
This pulling test ensures that the lead is perfectly
crimped and the contact has correctly engaged in the
housing.
1. Perform a pull test on each lead, each of the terminals and

connections must withstand a pulling force of 45 N without
any difficulties.

Removing DTM contacts
Fig. 79: DTM Series

Plug connectors DT and DTM have a wedge to hold the pins and
sockets in their position. This wedge can be removed and
replaced, without having to cut any leads.
Fig. 80
1. Pull the orange wedge (interlock) out with long nose pliers.
2. Slightly pull the lead and unlock the interlocking hook with a
screw driver.
3. Pull the contact out of the socket.

socket.
In this case the interlock disassembly tool serves
as an aid to remove the wedges.

Installing DTM contacts
Fig. 81
1. Insert the contacts through the rubber grommet until they
click into place.
2. Insert the orange wedge, until it clicks into place.

socket.
Pulling test
This pulling test ensures that the lead is perfectly
crimped and the contact has correctly engaged in the
housing.
1. Perform a pull test on each lead, each of the terminals and

connections must withstand a pulling force of 45 N without
any difficulties.

Electric systems – Acceleration transducer, B62 & B171
4.11 Acceleration transducer, B62 & B171
Fig. 82
BVC machines and machines with E-VIB meter are equipped with
two piezo-electric acceleration transducers, which are mounted to
the drum.
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.
Mode of action
1 Seismic mass (m)Seismic mass

2 Piezo electric material
3 Acceleration (a)
The piezo electric acceleration transducer consists of two basic
components:
n Piezo electric material
n Seismic mass
Fig. 83

Electric systems – Acceleration transducer, B62 & B171
Once side of the piezo disc is connected with the so-called 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.
A small wire connects the piezo element with the sensor socket.
The piezo electric effect generates a charge (u) on the electrodes,
which is proportional to the force and thus also to the acceleration
(a).

Electric systems – Checking the main battery switch
4.12 Checking the main battery switch

out.
2. Check by turning the ignition key, whether the battery is dis-
connected from the electric system of the machine.
Fig. 84

Electric systems – Starting the engine with jump leads
4.13 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 consumer is switched on voltage peaks
Fig. 85
may occur when separating the connecting 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.

Electric systems – Differential pressure switch for hydraulic oil filter, B21
4.14 Differential pressure switch for hydraulic oil filter, B21

The differential pressure switch switches to ground at a pressure
differential of Δp 3.6 bar.
Fig. 86
The switching condition is detected by the ESX-control (A34) and

forwarded to the instrument cluster (A15) via the bus connection.
Fig. 87: ESX control
m Hydraulic oil filter warning light
Fig. 88: Instrument cluster

Electric systems – Air filter vacuum switch, B03
4.15 Air filter vacuum switch, B03

The vacuum switch (1) operates at a vacuum of > 50 mbar.
Fig. 89

d Air filter warning light

Electric systems – Sensor, water in fuel filter, B124
4.16 Sensor, water in fuel filter, B124
Fig. 92

e Warning light water in fuel filter

Electric systems – Float switch, coolant compensation tank, B55
4.17 Float switch, coolant compensation tank, B55
B55
S-921-0202
Fig. 95

h Coolant level warning lamp

Electric systems – Level sensor in diesel tank (R03)
4.18 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. 98: R03
Nominal values:
n Tank empty, 64.2 Ω
n Tank full, 0.5 Ω
u Fuel level gauge
If no level switch is connected or the cable is broken, no fuel level

will be displayed
Fig. 99: A15

Electric systems – Charge control lamp
4.19 Charge control lamp
Fig. 100
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.
k Charge control light
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.

Electric systems – Inspection and maintenance work
4.20 Inspection and maintenance work

4.20.1 Maintenance Table
No. Maintenance works Page

Every 500 operating hours
4.20.2.1 Servicing the battery, checking the main battery isolation 133
4.20.2 Every 500 operating hours

4.20.2.1 Servicing the battery, checking the main battery isolation
4.20.2.1.1 Battery service
Maintenance free batteries also need care. Mainte-

nance free only means that the fluid level does not
need to be checked.
Each battery suffers under self-discharge, which may,
in not checked occasionally, even cause damage to
the battery as a result of exhaustive discharge.
Exhausted batteries (batteries with formation of sul-
phate on the plates) are not covered under warranty!
Protective equipment: n Working clothes

n Protective gloves
n Safety goggles
1. Park the machine in secured condition Ä Chapter 1.2.6 ‘Park
the machine in secured condition.’ on page 22.
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. 103

Electric systems – Inspection and maintenance work
4.20.2.1.2 Checking the main battery switch

out.
Fig. 104

Diesel engine
5 Diesel engine

Diesel engine – Overviews
5.1 Overviews
Fig. 105
1 Diesel engine
3 Main fuses
This single drum roller is powered by a Deutz engine series TCD

6.1. This is a water-cooled 4-cylinder diesel engine with a Common
Rail injection system.
The engine is designed with four-valve technology as well as turbo-
charging with intercooler.

The standard BOMAG ECOMODE ensures a clean environmental

balance. Due to the active engine management power is made
available for the driver when it is needed and is reduced again
when permitted by the application. Intelligent sensors in connection
with an ingenious control immediately detect the actual power
requirement and the engine speed of the engine is automatically
adapted.
A nice side effect – the noise sensation inside the cabin is also
very pleasant.
This means that both the exciter shaft speeds and the travel speed
must permanently be adapted, this is enabled by the EP control on
travel and vibration pumps.
ECOSTOP
With the optional ECOSTOP the engine is shut down automatically
after a defined period in idle speed. This additionally reduces fuel
consumption and wear.
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.
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. 106

Flywheel side
Fig. 107
1 Coolant pump
2 Fuel lift pump
3 Throttle valve
4 Exhaust turbo charger
5 Exhaust gas recirculation actuator
6 Starter
7 Exhaust gas recirculation cooler
8 Crankshaft speed sensor
9 Belt drive

Flywheel end
Fig. 108
1 Crankcase ventilation
2 Fuel rail
3 Engine transition plug
4 Oil inlet
5 Generator
6 Lubrication oil cooler
7 Oil level control
8 High pressure fuel pump
9 Oil drain
10 Flywheel

Diesel engine – Lubrication oil circuit TCD 4.1 / 6.1
5.2 Lubrication oil circuit TCD 4.1 / 6.1
Fig. 109: 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

Diesel engine – Lubrication oil circuit TCD 4.1 / 6.1
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.

Diesel engine – Coolant circuit TCD 4.1 / 6.1
5.3 Coolant circuit TCD 4.1 / 6.1
Fig. 110: Coolant circuit

1 Connection possibility for cabin heater
2 Cooler of the exhaust gas recirculation
3 Temperature sensor
4 Thermostat
5 Compensation tank
6 Radiator
7 Coolant pump
9 Coolant flow to engine cooling system
10 Cylinder liner and cylinder head cooling
11 Compressor (optional)
General Depending on the coolant temperature, the coolant will flow in two
circuits.

Diesel engine – Coolant circuit TCD 4.1 / 6.1
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.
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.

Diesel engine – Common Rail System (CRS)
5.4 Common Rail System (CRS)

Sufficient fuel supply to the high pressure pump at any time is a
prerequisite for perfect starting and performance of the diesel
engine.
The fuel pressure in the low pressure system is permanently moni-
tored by a pressure sensor. In case of pressure deviations, the
engine control unit submits an error message to the operator.
Fig. 111: Injection system

1 Engine control unit
2 Injectors
3 Pressure relief valve
4 Rail
5 High pressure pump (2 pieces)
6 Camshaft
7 FCU (fuel control unit)
8 Fuel filter
9 Return line
10 Tank
11 Fuel pre-cleaner
12 Fuel pump
13 Rail pressure sensor

The fuel pump draws fuel through the fuel pre-filter from the tank.
The fuel from the fuel pump is directed through the fuel filter to the
fuel control unit (FCU) with a pressure of 6 bar. The FCU meters
the fuel quantity that flows to the high pressure pumps.
The high pressure pumps are driven by the camshaft of the diesel
engine and increase the fuel pressure to 1600 bar. The fuel is then
directed into the Rail.
The Rail contains the pressure relief valve (PRV) and the rail pres-
sure sensor:
n This PRV protects the engine against damage caused by
excessively high fuel pressure. For this reason the PRV has an
opening pressure of 1750-1950 bar. If this PRV opens, fuel will
flow through the return line back into the tank. The PRV is con-
sidered to be worn after it has opened 50 times. The number of
opening events can be read out with the help of Serdia 2010.
n The rail pressure sensor reports the rail pressure to the
engine control unit. From the rail the fuel flows to the injectors.
The injector is equipped with a solenoid, which is controlled by
he engine control unit. The electro-magnet opens the dis-
charge nozzle in the control chamber, which causes the pre-
vailing pressure to collapse. This unbalance of pressures
moves the valve piston and the nozzle needle up and opens
the path for the fuel flow.

Fuel pump
Fig. 112: Fuel pump

1 Roller for pump drive via flat belt
2 Fuel inlet
3 Fuel outlet
The fuel pump is maintenance free. It draws in fuel with a vacuum
of -0.5 bar and generates a pressure of 6 bar.

Fuel pre-cleaner
Fig. 113: Fuel pre-cleaner

1 Bleeding screw
2 Fuel supply by pump
3 Fuel return flow from FCU (Fuel Control Unit)
4 Fuel lift pump
5 Electrical connection for water level sensor
6 Drain plug
7 Filter element
8 Fuel supply from fuel tank
9 Fuel return flow to fuel tank

Fuel control unit (FCU)
Fig. 114: FCU

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 pressure pumps to the Rail, and from there to the
injectors.

High pressure pump
Fig. 115: High pressure pump

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.

Rail
Fig. 116: Rail

2 Fuel line connections
3 Tube
4 Bores to fasten the Rail
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.

Injector
Fig. 117: Injector

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.

Diesel engine – Wastegate charge pressure controller
5.5 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.
Fig. 118: Exhaust gas turbocharger with Wastegate

1 Control line
2 Pressure control valve
3 Bypass valve closed
The bypass valve is normally closed.

Diesel engine – Exhaust gas recirculation
5.6 Exhaust gas recirculation

Overview
Fig. 119
1 Fresh air intake pipe
2 Exhaust gas recirculation actuator
3 Exhaust gas recirculation cooler
4 Cooling line of the coolant circuit to the EGR cooler
5 Temperature sensor
6 Flap (fresh air inlet)
The exhaust gas recirculation is used to reduce nitrogen oxide
(NOx) emissions. Nitrogen oxides generated in the engine's com-
bustion process must be avoided or at least reduced as early as
possible.
Description Under high combustion temperatures the engine will produce envi-
ronmentally hazardous nitrogen oxides. The higher the combustion
temperature in the cylinder, the higher the proportion of nitrogen
oxide in the exhaust gas.
Feeding in small amounts of exhaust gas reduces the production of
nitrogen oxides. Below the flap (6) and through the fresh air intake
pipe (1) the exhaust gas is returned into the combustion chamber.
The exhaust gas resetter (2) takes over the control of the recircula-
tion. It regulates the exhaust gas quantity to be fed into the com-
bustion process in dependence on the temperature reported by the

Diesel engine – Exhaust gas recirculation
temperature sensor (5). The cooling line (4) supplies the EGR-
cooler (3) to cool the exhaust gas. Temperature peaks and NOx-
emissions are thus reduced. Rapid oxidation of fuel molecules
(which cause the formation of nitrogen oxides) is impeded by the
presence of exhaust gas molecules. This effect is supported by the
higher heat capacity of the main exhaust gas constituents carbon
dioxide and water (in gaseous state).

Diesel engine – Engine electrics
5.7 Engine electrics
Fig. 120
1 Diesel engine
3 Main fuses

5.7.1 CAN BUS overview
P15
A87
S-586-0270
MESX
CAN3
A67
A177
A83
A144
CAN1
A124
CAN1
A15
X400 A162
A175
X34
CAN2
S55
ESX
X32
A34
CAN1
CAN2
Kubota
Deutz
A48
A48
Fig. 121: CAN-Bus

A34 Machine control, ESX

A48 Control unit engine management, not available in BW177D-5 (Kubota engine, exhaust classification
Tier3a)
A67 Keyboard anti-theft protection
A83 Measurement control, BVC
A87 USB-CAN interface
A124 Telematic module, BOMAG
A144 Control console cabin
A162 Gateway, CAN module
A175 Telematic module, Morey
A177 Telematic module, ECU ZTR
P15 BCM05
S55 Travel lever
X32 Diagnostics interface engine control unit, not available in BW177D-5 (Kubota engine, exhaust classifi-
cation Tier3a)
X34 Diagnostics interface for ESX machine control
X400 Interface for measuring technology
CAN-bus, Controller Area Network created by Bosch at the end of the eighties for automobile applica-
tions.
Development objectives:
Real-time critical, robust and low price communication of control
units, such as transmission and engine control, but also less time
critical applications in the field of convenience electronics, such as
air conditioning.
Why CAN?
n Networking of control units for the realization of complex func-
tions.
n Reduction of the extend of wiring and plug connections.
n Better diagnostic possibilities (central diagnostics socket).
Characteristics of CAN
It is a kind of serial data transmission. The individual bits are trans-
mitted one after the other, only 2 lines are required.
CAN lines are twisted together 30 to 40 times per metre. Electro-
Fig. 122 magnetic interferences therefore always occur simultaneously in
both lines, the software is thus able to filter out interfering signals
more easily.
Wire (+) = cable colour blue
Wire (-) = cable colour yellow
Measuring on 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. Correct connection of lines can only
be checked by means of a continuity test. BOMAG display mod-
ules are connected to the BUS to give engineers and user the pos-
sibility to detect faults or to receive information from the BUS.

5.7.2 EMR4 system overview

Engine control unit Together with the introduction of the Deutz Tier IV engines the
engine management system EMR4 with the control unit variant
EDC17 CV52, CV54 or CV56 /(depending on required functionali-
ties) has been introduced.
The management system enables precise controlling of fuel injec-
tion in dependence on engine performance parameters and con-
tains further functions required for achieving high system reliability
and the demanded exhaust gas quality.
The EMR 4 system consists of at least the following elements:
n Control unit
n Rotary speed sensors on timing gear cover for crankshaft and
camshaft
n Rail pressure sensor, rail pressure control valves
n Temperature sensor (coolant)
n Combined charge air pressure and temperature sensor
n Oil pressure sensor
n Ambient pressure sensor (integrated in control unit)
n Control lamp for warning, diagnose, fault messaging, etc.
n Diagnostics button
n Engine wiring loom and vehicle wiring loom
n Monitoring of fuel pre-filter (water in fuel)
n Triggering of exhaust gas aftertreatment system
NOTICE!
It is not permitted to interchange control units from one
manufacturing series or against another engine
number. In this case the warranty will become null and
void.
Sensors and actuators must not be connected to
external power sources for the purpose of testing, but
must only be operated on the EMR4. Otherwise com-
ponents may be permanently damaged.
Pulling off the plug connectors of the control unit while
the control unit is working (i.e. with the power supply to
terminal 15switched on) is not permitted. Correct pro-
cedure: Switch off the electric power supply (normally
with the ignition key), wait until the main relay has
switched off (with a delay of up to 15 seconds, listen
for clicking sound), then pull off the plugs from the con-
trol unit.
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-control

unit is the part number without software specific for the
engine. The correct part number can be found in the
BOMAG spare parts catalogue.
Replacement of DCR (DEUTZ n On TCD-engines with Common Rail technology the system
Common Rail System) components 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
SerDia2010.
n Any other EMR components (sensors etc.) must under no cir-
cumstances be repaired, but must be replaced if they are
defective.
Main relay The internal main relay serves the purpose of releasing the vehicle
energy supply for the EMR4 system. When shutting down the
engine, the ignition switch isolates the electronic system from ter-
minal 15. The injectors are closed immediately, 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..
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.
EDC17 CV52
Fig. 123

Electronic DCR up to 2000 bar
Designation Technical data

Rated voltage 12 and 24 V DC
Operating voltage 9-32 V, engine start possible to 6 V
Main relay integrated
Plug vehicle side 91 pole
engine side 105 pole
EDC17 CV54 and CV56
Fig. 124
Electronic DCR up to 1600 bar
Designation Technical data

Rated voltage 12 and 24 V DC
Operating voltage 9-32 V, engine start possible to 6 V
Main relay integrated
Plug vehicle side 94 pole
engine side 60 pole

Fig. 125: System overview

1 Engine side
2 Vehicle side
3 Service
4 Sensors and actuators
5 EMR 4
6 Diagnostics socket, X32 in central electrics
7 CAN-display
8 SerDia2010
Changes to the control units with respect to settings,

parameterization, deleting the fault log and calibration
are level dependent and only possible with
SerDia2010.

A Ubat electric power supply

B Battery minus (-)
F CAN2 low
G CAN1 low
H CAN1 high
K K-Line
M CAN2 high
Fig. 126: 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
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
Fig. 127
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.

The display is connected to the diagnostic interface by means of a

special cable.
BOMAG Part-No.: 079 900 19
Fig. 128

5.7.3 EMR4 system components

5.7.3.1 Common Rail and electrics
Fig. 129: Injection system

2 Injectors
4 Rail
5 High pressure pump (2 pieces)
6 Camshaft
7 FCU (fuel control unit)
8 Fuel filter
9 Return line
10 Tank
11 Fuel pre-cleaner
12 Fuel pump

Fuel control unit (FCU)
Fig. 130: FCU

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 pressure pumps to the Rail, and from there to the
injectors.

Injector
Fig. 131: Injector

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.

5.7.3.2 Sensors and actuators
Fig. 132: Electronic engine control

1 Fuel pressure sensor (B145)
2 Central plug for engine control unit
3 Coolant temperature sensor (B113)
4 Charge air pressure sensor / charge air temperature sensor (B133)
6 Crankshaft speed sensor (B130)
7 Rail pressure sensor (B93)
8 Lubrication oil level sensor optional equipment
9 Oil pressure sensor (B88)
10 Rotary speed sensor for camshaft (B114)
11 Electric energy supply through battery
12 Multi-function display
13 Signal outputs (configurable)
14 Signal inputs
15 Travel pedal, not used

16 Hand throttle, not used

17 Function selector switch, not used
18 Key switch Start/Stop
19 Diagnostics button, not used
20 Fault lamp with flashing code, not used
21 Diagnostics interface/CAN-Bus
(1) Fuel pressure sensor
The low fuel pressure sensor is located after the fuel filter and the
pressure is normally between 5-7 bar.
Fig. 133
(3) Coolant temperature sensor
The coolant temperature has an effect on the calculated injection

quantity and the preheating behaviour of the glow plugs.
Fig. 134
(4) Charge air pressure sensor /

charge air temperature sensor

This sensor unites two functions in one housing. The one function
measures the charge air pressure and adapts the injection quantity
in dependence on the measured pressure. The temperature of the
air flowing past is additionally measured, it is used for limiting the
development of smoke.
With a faulty sensor the engine continues to run with

charge pressure simulation.
With a defective temperature sensor the engine also
carries on running.
Fig. 135
(6) Crankshaft speed sensor
Determination of the top dead center, emergency function in case

of a camshaft sensor failure.
Fig. 136
1. Check the gap dimension with a feeler gauge.

ð Nominal value: 0.17 - 1.45 mm
The feeler gauge must fit with only little

resistance through the gap between toothed
disc and speed sensor.
Fig. 137: Checking the gap dimen-

sion
(7) Rail pressure sensor This sensor serves the purpose of monitoring the injection pres-
sure.

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.
Disassembling the Rail pressure sensor
1. Unlock and pull out the cable plug.
WARNING!
After shutting down the engine wait 30 seconds, before
starting work in the fuel system.
Fig. 138: Disassembly 2. Unscrew the Rail pressure sensor with a socket spanner.
3. Check thread and sealing edge (arrows) on the Rail pressure

sensor visually.
Fig. 139
Installing the Rail pressure sensor
1.
NOTICE!
Ensure strict cleanliness. Particularly on the
thread and the sealing surface of the rail.
Slightly grease thread and sealing edge on Rail pressure

sensor with assembly grease.
Fig. 140: Assembly

2. Turn in and tighten the Rail pressure sensor (2).
Tightening torque: 40 + 5Nm
3. Plug in the cable plug
(9) Oil pressure sensor This sensor serves the purpose of monitoring the engine oil pres-
sure.
Disassembling the oil pressure sensor
NOTICE!
Ensure absolute cleanliness when working in the lubri-
cation oil system.
Thoroughly clean the area around the affected compo-
nent. Dry off wet locations with compressed air.
Immediately close all connections and openings with
new and clean plugs/caps.
Only remove plugs/caps just before assembling.
1. Unlock and pull out the cable plug.

2. Unscrew oil pressure sensor.
Fig. 141: Disassembling the sensor
Installing the oil pressure sensor

1. Insert the oil pressure sensor with a new seal ring and
tighten.
Tightening torque: 20Nm
Fig. 142: Installing the sensor
(10) Camshaft speed sensor The sensor has the function of determining top dead center, emer-
gency function in case of a crankshaft sensor failure.
Disassembling the speed sensor
1. Unlock and pull out the cable plug (3).

2. Unscrew screw (2).
3. Remove the speed sensor (1).
Fig. 143: Disassembly
4. Clean the sealing surfaces on speed sensor and wheel

housing cover.
5. Install the new O-ring (arrow).
6. Cover the O-ring slightly with oil.
Fig. 144
Installing the speed sensor

1. Insert the speed sensor (1).

2. Tighten the screw (2) with 9 Nm.
3. Plug the cable plugs (3) together.
NOTICE!
Ensure proper routing of cables.
Fig. 145: Assembly
5.7.3.3 Heating flange on engine

Heating flange R19
The heating flange is a component with an electrically operated

heating wire and high energy density used to heat up the intake air
in case of very low ambient temperatures.
The heating power is approx. 2000 Watt.
The heating power improves the cold starting characteristics and
the exhaust emissions (white smoke) of the diesel engine.
A differentiation is made between preheating, to assure the cold
start ability of the engine, and after-heating.
Fig. 146: Heating flange
The heating flange is controlled by the engine control unit via relay
K14.
Fig. 147: K14

5.7.3.4 Fuel pre-heating

Fuel pre-heating (option)
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 D.C-current.
Fig. 148
5.7.3.5 Fault display
The detected faults appear in the INFO1 display field

in the instrument cluster.
Fault codes 5000 - 5499 are diesel engine related.
A detailed reading out of fault codes for the diesel
engine is only possible with Deutz-Serdia
A detailed description of how to read out fault codes
can be found in the Service Training Electrics.

Diesel engine – Inspection and maintenance work


Checks prior to start up
5.8.2.1 Checking the engine oil level 176
5.8.2.2 Checking the coolant level 176
5.8.3.1 Cleaning the radiator module 177
5.8.4.1 Change engine oil and oil filter cartridge 178
5.8.4.2 Replacing the fuel filter, bleeding the fuel system 180
5.8.4.3 Checking the anti-freeze concentration and the condition of the coolant 182
5.8.5.1 Checking the ribbed V-belt 182
5.8.5.2 Check the engine mounts 184
5.8.6.1 Adjusting the valve clearance 184
5.8.6.2 Change the coolant 185
5.8.7.1 Replace ribbed V-belt and idler pulley 188
As required
5.8.8.1 Air filter maintenance 189
5.8.8.2 Checking, cleaning the water separator 192
5.8.8.3 Measures prior to extended shutdown period 192

5.8.2 Checks prior to start up

5.8.2.1 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 immediately.
– Use only oil of the permitted specification
Ä Chapter 1.3.1.1 ‘Engine oil’ on page 27.

n Protective gloves
1. Pull the dipstick out, wipe it off with a lint-free, clean cloth and
reinsert it until it bottoms.
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.
Fig. 149
5.8.2.2 Checking the coolant level

n Protective gloves
n Safety goggles
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 1.3.1.3 ‘Coolant’ on page 29.

A too low coolant level is indicated by the coolant level warning

lamp.
Fig. 150
1. Check the coolant level in the compensation tank.
WARNING!
Danger of scalding by hot fluid!
– Open the compensation tank only when the engine
is cold.
2. To top up, unscrew the filler cap and fill in coolant up to the
Fig. 151 "MAX"-mark.

5.8.3.1 Cleaning the radiator module
NOTICE!
Components may get damaged!
– Dirt on fan blades and oil coolers reduce the
cooling effect. Dirt deposits in these areas are sub-
stantially supported by oil and fuel on these sur-
faces. 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
2. Allow the engine to cool down.

3.
CAUTION!
Danger of eye injuries caused by particles
flying around!
– Wear your personal protective equipment
(safety gloves, protective working clothes,
goggles).
Blow the cooler out with compressed air from the air dis-
charge side.
Fig. 152 4. Blow the cooler out with compressed air from the air supply
side.
Cleaning with cold cleansing agent

The air conditioning condenser is located in front of the
radiator.
WARNING!
Danger of injury caused by exploding component!
– Do not clean the condenser in the air conditioning
system with a hot water jet.
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 cooler 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. Run the engine warm for a while to avoid corrosion.

5.8.4.1 Change engine oil and oil filter cartridge
n Protective gloves
During the regeneration at standstill part of the fuel

may mix with the engine oil.
You should therefore run a possibly necessary regen-
eration at standstill before changing the engine oil.

Perform this maintenance work at the latest after one

year.
NOTICE!
– Change the oil only with the engine at operating
temperature.
Ä Chapter 1.3.1.1 ‘Engine oil’ on page 27.
– Filling quantity: Ä Chapter 1.4 ‘List of fuels and
lubricants’ on page 34

WARNING!
Danger of burning on hot components!
2. Unscrew the oil drain plug and catch any oil running out.
3. Turn the drain plug tightly back in.
Fig. 153
4. Thoroughly clean the outside of the oil filter cartridge.

5. Unscrew the filter cartridge using an appropriate filter
wrench.
6. Clean the sealing face on the filter carrier from any dirt.
7. Slightly oil the rubber seal on the new filter cartridge.
8. Spin the new oil filter cartridge on and tighten it hand-tight.
Fig. 154

9. Fill in 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 oil and oil filter cartridge environmentally.
Fig. 155
5.8.4.2 Replacing the fuel filter, bleeding the fuel system

5.8.4.2.1 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 manda-
tory.

5.8.4.2.2 Replacing the fuel filter

year.


n Protective gloves
1. Loosen and unscrew the fuel filter cartridge using an appro-
priate filter 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. Turn the new filter cartridge on by hand, until the seal con-
tacts.
5. Tighten the filter cartridge by another half turn.
Fig. 156
5.8.4.2.3 Replacing the fuel pre-filter

year.

n Protective gloves
1. Pull the plug off the sensor on the water separator.
2. Place a collecting vessel under the drain bore.
3. Unscrew the drain plug (2) and catch running out fuel.
4. Loosen and unscrew the fuel pre-filter (1) using a suitable
filter wrench.
5. Slightly oil the rubber seal on the new fuel pre-filter element.
6. Spin on the new fuel pre-filter.
7. Turn the oil drain plug back in with a new seal ring.
Fig. 157 8. Push the plug on to the sensor on the water separator.
9. Dispose of fuel and filter environmentally.

5.8.4.2.4 Bleed the fuel system

n Protective gloves
1. Slacken the bleeding screw (1) on the fuel pre-filter for 2 to 3
turns.
2. Unlock the bayonet lock of the manual fuel pump (2) by
pressing it down and turning it anti-clockwise.
3. Operate the hand pump manually, until fuel flows out of the
slackened bleeding screw without air bubbles.
4. Then tighten the bleeding screw while pumping.
5. Lock the bayonet lock of the fuel hand pump by pressing it
down and turning it clockwise.
Fig. 158 6. Start the engine and run it 5 minutes with idle speed.
7. Check the filter cartridges for leaks.
5.8.4.3 Checking the anti-freeze concentration and the condition of the coolant
n Protective gloves
n Safety goggles
3. Unscrew the radiator cap and check the anti-freeze concen-
tration 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 5.8.6.2 ‘Change the coolant’ on page 185.
6. Screw the cap back on again.
Fig. 159

5.8.5.1 Checking the ribbed V-belt
n Protective gloves

3. Remove the air conditioning compressor V-belt Ä Chapter

7.13.4.1 ‘Replacing the air conditioning compressor V-belts’
on page 303.
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. 160
Fig. 161: 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
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 303.
Fig. 162
5.8.5.2 Check 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 lubrication air line
for tight fit and leaks.
5. Check fastening screws on oil sump and engine mounts for
tight fit.
6. Check condition and tight fit of engine pillow blocks.

5.8.6.1 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

n Protective gloves
Special 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. 163
1 Valve adjustment screw
2 Counter nut
3 Rotation angle disc
4 Socket
5 Magnet
5.8.6.2 Change the coolant
Perform this maintenance work at the latest after 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.
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 1.3.1.3 ‘Coolant’ on page 29.
– Do not mix different coolants and additives of any
other kind.
lubricants’ on page 34

n Protective gloves
n Safety goggles
3. Unscrew the lid from the compensation tank.
Fig. 164
4. Unscrew the plug.

5. Drain off and collect all fluid.
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.
10. Fill in clean water.
Fig. 165 11. Start the engine and run to operating temperature.
12. Allow the engine to cool down to approx. 50 °C (122 °F).

13. Drain all water off.

14. When using a cleansing 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 in coolant and tighten the locking cap on the compensa-
tion tank.
Fig. 166
17. Set maximum cabin temperature.
Fig. 167
18. Set maximum blowing range.

20. Run the machine with idle speed until operating temperature
has been reached and the thermostat opens.
21. As soon as the thermostat has opened, run the engine for
approx. 1 minute at high speed.
22. Shut down the engine.
24. Check the coolant level again when the engine has cooled
Fig. 168 down, top up if necessary.
25. Dispose of the coolant in an environmentally friendly way.


5.8.7.1 Replace ribbed V-belt and idler pulley
n Protective gloves
3. Remove the air conditioning compressor V-belt Ä Chapter
on page 303.
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. Unscrew fastening screw and take off the idler pulley.
7. Attach the new idler pulley and tighten the fastening screw,
tightening torque 80 Nm (59 ft·lbs).
Fig. 169
8. Install the new ribbed V-belt.

9. Pull the locking pin out of the fixing bore 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 303.
Fig. 170

5.8.8 As required
5.8.8.1 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 ele-
ment 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 possible
engine damage.

n Protective gloves
n Safety goggles
1. Maintenance of the air filter is due when the air filter warning
lamp lights up, but at the latest after one year.
Fig. 171
4. Loosen both locking hooks on the housing cover and take the
cover off.
5. Clean housing cover and dust discharge valve.
Fig. 172

6. Pull out the main filter element with light turning movements.
CAUTION!
Danger of eye injuries caused by particles flying
around!
– Wear your personal protective equipment (safety
gloves, protective working clothes, goggles).
Fig. 173
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 if free of dust.
Fig. 174
8. Examine the air filter element 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. 175
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 correctly.
11. Reassemble the housing cover.

Fig. 176

5.8.8.1.1 Replace 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 1 year.
– if the air filter warning lamp comes on again after
the air filter has been cleaned.
1. Remove the housing cover and pull the air filter off.
2. Pull the safety element out by turning it lightly.
3. Push in a new safety filter element.
4. Insert the air filter and reassemble the housing cover.
Fig. 177

5.8.8.2 Checking, 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
the filter bowl for signs of water and dirt initially every
day, later as required.
If a too high quantity is drained off, the filter needs to
be bled.
Protective equipment: n Protective gloves
1. If the "water in fuel" warning lamp lights up when starting or

during operation, drain the water from the fuel pre-filter
immediately.
Fig. 178
3. Slacken the drain plug for a few turns and catch running out
fluid.
4. Turn the plug tightly back in. Check for leaks, if necessary
use a new seal ring.
ð Once the water separator is empty the warning lamp for
water in fuel must go out.
Fig. 179
5.8.8.3 Measures prior to extended shutdown period

5.8.8.3.1 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. Clean the water separator.
3. Fill the fuel tank with diesel fuel, to prevent the formation of
condensation water in the tank.
4. 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.
5. After shutting down store the machine under cover in a dry
and well ventilated room.
6. Check the anti-freeze concentration and the coolant level.
7. Disconnect the ground strap from the battery (this avoids
self-discharge caused by closed-circuit consuming devices).

5.8.8.3.2 Battery service during prolonged machine downtimes
WARNING!
Danger of injury caused by exploding gas mixture!
– 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.

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. After each charging process allow the battery to rest for one
hour before taking it into service.
5. 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.
5.8.8.3.3 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 couplings.
7. Check the function of the electric system.

8. Check cables, hoses and lines for cracks and leaks.

9. Start the engine and run it for 15 to 30 minutes with idle
speed.
10. While the engine is running keep an eye on the gauges for oil
pressure and coolant temperature.
11. Check the oil levels.
12. Check the function of electric system, steering and brakes.
13. Clean the machine thoroughly.

Hydraulic system
6 Hydraulic system

Hydraulic system – Overview of hydraulics
6.1 Overview of hydraulics
Fig. 180
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

Fig. 181
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
Vibration pump

Plugs Y07 Y08


Plugs Y73 Y72

Plugs Y16 Y17

Hydraulic system – Open and closed hydraulic circuit
6.2 Open and closed hydraulic circuit

Open circuit
Fig. 182: 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.

Hydraulic system – Open and closed hydraulic circuit
Closed circuit
Fig. 183: 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.

Hydraulic system – Hydraulic units
6.3 Hydraulic units
6.3.1 Travel/vibration pump, H1

6.3.1.1 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.
Fig. 184: 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!
– The aggregate must always be filled with hydraulic
oil and purged before start-up and during opera-
tion.
– This must also be considered for longer periods of
rest, because the aggregate may run empty
through the hydraulic lines.

Schematic
Fig. 185: Block diagram

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

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.

RA - control
Fig. 186: 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 feature.
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 operator.
6.3.2 Swash plate principle, pump
Fig. 187
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. 188
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
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.
6.3.3 Travel motor, H1

6.3.3.1 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.

Fig. 189
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!
tion.

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.
6.3.4 Vibration motor A2FM

6.3.4.1 Axial piston motor A2FE/FM
The plug-in fixed displacement motors A2FE and
A2FM just differ by a different housing.
NOTICE!
tion.

The A2FE/FM is a plug-in fixed displacement axial piston motor

with a tapered axial piston drive in swash plate design for hydro-
static drives in open and closed hydraulic circuits. Due to this bent
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. 190
1 Drive shaft
2 Piston
3 Cylinder
4 Valve plate
5 Connecting plate
6 Flushing valve, optional
In fixed displacement motors in bent axle design the pistons (2)
Ä Fig. 190 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.

Fig. 191: Flushing spool

1 Flushing spool
2 Flushing pressure relief 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
hydraulic oil is flushed out. The oil flows back to the hydraulic oil
6.3.5 Swash plate principle, motor
Fig. 192
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.
Fig. 193
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.
6.3.6 External gear pumps

External gear pumps mainly consist of the friction bearing mounted
gear pair and the housing with front and rear covers. The drive
shaft, which is sealed with a radial seal, protrudes from the front
cover. The bearing forces are absorbed by friction bearings. These
have been designed for high pressures and have excellent antifric-
tion properties - particularly at low speeds. The gears have 12
teeth each. This keeps flow pulses and noise emissions at a low
level.
Fig. 194: 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 rate of effi-
ciency. On the rear side the moveable bearing bushings are pres-
surized and thus tightly pressed against the gears. The pressurized
pressure fields are thereby limited by special seals. Sealing around
the circumference of the gears to the housing is assured by small
gaps, which appears between gears and housing in dependence
on the pressure.

Function
Fig. 195
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. 196
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

Multiple gear pumps Gear pumps are most suitable for multiple pump arrangements,
whereby the drive shaft of pump 1 is extended to drive a second or
3. 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. 197
6.3.7 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 link 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.
The steering unit mainly comprises of a rotary spool valve and a
rating pump (gear set). The steering column connects the steering
unit to the steering wheel of the vehicle. When operating 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 operating direction of the steering wheel.
The gear set measures the oil flow to the steering cylinder propor-
tionally to the turning angle of the steering wheel.
Fig. 198

1 Check valve 8 Outer spool

2 Shock valve 9 Universal shaft
3 Pressure relief valve 10 Distributor plate
4 Housing with anti-cavitation valves 11 Gear
5 Inner spool 12 Ring gear
6 Neutral setting spring 13 Cover
7 Pin
The steering valve is additionally equipped with a pressure relief

valve, it limits the steering pressure.
Suddenly occurring pressure peaks, which may be caused by e.g.
external influences like driving against a curb stone, are compen-
sated by two shock valves, which are integrated in the steering
valve. Each of these shock valves is fitted with an additional anti-
cavitation valve. These anti-cavitation 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 forces are intro-
duced from outside. In such a case the steering cylinders would act
as pumps and press the oil back to the pump.

Hydraulic system – Charge circuit
6.4 Charge circuit
Fig. 199
2 Steering/charge pump + dozer blade (or Vario or attachment plate)
4 Charge circuit filter
5 Vibration pump with integrated charge pump
7 Brake valve
9 Steering valve

Hydraulic system – Charge circuit
B21 Differential pressure switch on charge oil filter

MS Charge circuit pressure test port
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 pressure differential (pressure differ-
ence between filter inlet and filter outlet) of Δp = 3.5 bar. This pres-
sure differential 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.

Hydraulic system – Travel circuit
6.5 Travel circuit

Travel system
The rear axles are equipped with a NoSpin differential with auto-
matic locking up to 100 percent. This means propulsion is avail-
able, even if one wheel comes off the ground. The double pump
system optimally converts the engine power to traction. Even gradi-
ents of more than 60 percent are no problem.
Fig. 200
The travel system of the machine consists of two travel circuits.
n Travel circuit for drum drive
n Travel circuit for axle drive
Each travel circuit is a closed hydraulic circuit, it consists mainly of
travel pump and travel motor.
The two travel pumps and the vibration pump are mounted
together to a triple pump unit, which is driven by the flywheel side
of the engine via an elastic coupling.
The travel pump has the function of supplying the travel circuit with
hydraulic oil.
Drive wheels and drum are driven by fast rotating hydraulic motors.
Both travel motors are equipped with flushing valve and speed
range selector valve.
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
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.
Drum drive The drum drive motor is a Sauer-Danfoss axial piston motor based
on the swash plate principle with variable displacement, the
hydraulic motor drives the travel gear. The reduction gear reduces
the high output speed to the final rotational speed of the drum.
The travel gearbox is fitted with dip-feed oil lubrication. The equip-
ment includes an integrated, hydraulically released multi-disc
parking brake. The integrated wet, but hydraulically releasable
multi-disc brake serves as parking brake, it is permanently closed
by spring pressure is released by feeding in pressure oil.

Fig. 201
1 Vibration motor
2 Exciter unit
3 Clutch
4 Travel gear
5 Travel motor
6 Drum shell
7 Rubber buffer
9 Travel bearings
Functional principle ECOMODE The standard BOMAG ECOMODE ensures a clean environmental
adapted.
very pleasant.


Travel circuit for drum drive
Fig. 202
2 Radiator


5 Vibration pump
6 Brake valve
7 Travel gear with brake discs
8 Drum drive motor with travel speed range selector
9 Return flow manifold with thermostat
B234 Pressure sensor, axle MA
B235 Pressure sensor, axle MB
B236 Pressure sensor, drum MA
B237 Pressure sensor, drum MB
MA/3 Pressure test port, axle drive MA
MB/3 Pressure test port, axle drive MB
MA/4 Pressure test port, drum drive MA
MB/4 Pressure test port, drum drive MB

Plugs Y73 Y72

Travel circuit for axle drive
Fig. 203
2 Radiator


5 Vibration pump
6 Brake valve
7 Drive axle with brake
8 Axle drive motor with travel speed range selector
B234 Pressure sensor, axle MA
B235 Pressure sensor, axle MB
B236 Pressure sensor, drum MA
B237 Pressure sensor, drum MB
MA/3 Pressure test port, axle drive MA
MB/3 Pressure test port, axle drive MB
MA/4 Pressure test port, drum drive MA
MB/4 Pressure test port, drum drive MB

Plugs Y16 Y17

Hydraulic system – Vibration circuit
6.6 Vibration circuit
Fig. 204

2 Radiator
5 Vibration pump
6 Vibration motor
Vibration pump

Plugs Y07 Y08
Vibration circuit The vibration circuit is a closed hydraulic circuit, it consists mainly
of vibration pump and vibration motor.
The two travel pumps and the vibration pump are mounted
together to a triple pump 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.
Fig. 205
The vibration system is designed in such a way, that the high
exciter shaft speed (frequency) is coupled with the low amplitude
and the low exciter shaft speed (frequency) with the high ampli-
tude.

The eccentric weights on the vibrator shaft are fitted with additional
change-over weights. Depending on the sense of rotation of the
exciter shaft these change-over weights add to or subtract from the
basic weights.
n Basic weight plus change-over weight = high amplitude
n Basic weight minus change-over weight = low amplitude
Fig. 206
1 Basic weight
2 Changeover weight
3 Exciter shafts
When switching the vibration on the motor must first start to move
the resting exciter shaft. This resistance causes a hydraulic starting
pressure, which is limited by the pressure override. 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. 207: low amplitude

Use of low amplitude
n thin layers
n gravels, sands, mixed soils
n gravel and road metal bearing courses
n surface compaction
Fig. 208: 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

Fig. 209
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 joined with the exciter shaft in
the drum via a Bowex coupling. The rotation of the exciter shaft
with the bolted on eccentric weights causes the vibration of the
elastically suspended drums.
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.

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.
Functional principle ECOMODE The standard BOMAG ECOMODE ensures a clean environmental
adapted.
very pleasant.

Hydraulic system – Steering circuit
6.7 Steering circuit
Fig. 210
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

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. 211
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
Front and rear frames of the single drum rollers are connected by
an oscillating articulated joint.
The front console of the joint is fastened with screws to the rear
cross-member of the front frame. The rear console is tightly bolted
to the rear frame.

The use of rocker bearings between front and rear frame ensures
that both frames can oscillate to each other for +/- 12°. This ena-
bles good ground contact of drum and wheels, even under severe
soil conditions.
When turning the steering wheel, the steering cylinders will extend
or retract and swivel the front console around the vertical bolt. This
articulates the machine and results in a steering movement.

Hydraulic system – Flushing and bleeding
6.8 Flushing and bleeding

6.8.1 Flushing - general
Flushing - general
NOTICE!
Changing a component
– Always flush the complete oil circuit after you have
replaced a component.
– Solid particles in the circuit will very quickly cause
damage to machine components.
Fig. 212
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 aging of oil, corrosion.

n Water in oil
– Increased wear, accelerated aging 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
Fig. 213
2.
NOTICE!
Clean the hydraulic tank
Change the oil in case of excessive contamina-
tion, oil discoloration 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
Fig. 214 tank.
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.

Bleeding
1. Always bleed closed hydraulic circuits if lines had been
removed or connected.
Fig. 215
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 filtering process.
2. Clean hoses and connections and store the flushing kit in a
clean and protected environment.
Fig. 216

6.8.2 Drum drive

Flushing schematic for drum drive
Fig. 217
1 Elbow union (tool)
2 Connecting union (tool)
3 Drum drive motor
4 High pressure hose A <> B
6 High pressure hose B <> A
7 Flushing hose 25S - 20S (tool)

8 Screw socket R1 - 25S (tool)

9 Flushing filter with filter element 1µ (tool)
6.8.2.1 Flushing the drum drive
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 pressure
side in the return flow to the pump, so that only
cleaned oil will enter the travel pump in forward travel.
With the connection shown in the illustration the travel
pump must therefore be actuated to forward direction.
Disconnect the drum drive motor 1. Disconnect the high pressure hose (6) from the drum drive
motor (port A) and connect it with the flushing hose (7,
flushing filter outlet “OUT”).
2. Take the drum drive motor (3) out of the hydraulic circuit by
joining the hoses (4 & 10) together.
Fig. 218

Bleeding the travel circuit

WARNING!
Danger of severe injuries caused by uncontrolled
machine movements
– Operate the travel lever only after the axle drive
has been disabled.
1.
Bleeding the travel circuit, see chapter "Bleeding
the travel circuit".
Fig. 219
Flushing the hoses

1. Keep circulating the complete tank content with the filling and
filtering unit throughout the entire flushing process.
Fig. 220
2. Block drums and wheels with suitable chocks.
Fig. 221

3.
WARNING!
Danger of severe injuries caused by uncon-
trolled machine movements
– Operate the travel lever only after the axle
drive has been disabled.
NOTICE!
Move the travel lever only to travel direction for-
ward, as otherwise the flushing filter will be sub-
jected to oil flow from the wrong direction.
Fig. 222
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.
Flushing the drum drive motor

1. Reconnect the hoses (4 and 10) to the drum drive motor.
2. Jack up the front of the machine, so that the drum can rotate
freely.
3. Secure the rear wheels with chocks.
4. Pre-select the slow speed range.
Fig. 223
Fig. 224

6.
WARNING!
– Operate the travel lever only after the axle
NOTICE!
Fig. 225
Start the engine, run it with maximum speed and shift the
travel lever to travel direction forward.
7. 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.
Removing the flushing filter 1. Disconnect the flushing filter and reconnect the high pressure
hose (4 & 6) to the drum drive motor.

WARNING!
machine movements
– Operate the travel lever only after the axle drive
has been disabled.
1.
Fig. 226

Circulating the tank content

1. After completing the bleeding process circulate the tank con-
tent with the filtering unit for another 15 minutes.
Fig. 227
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. 228

6.8.3 Axle drive

Flushing diagram for axle drive
Fig. 229
3 Travel motor, axle


6.8.3.1 Flushing the axle drive

NOTICE!
cleaned oil will enter the travel pump in forward travel.
With the connection shown in the illustration the travel
pump must therefore be actuated to forward direction.
Disconnecting the axle motor 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. Take the axle drive motor (3) out of the hydraulic circuit by
Fig. 230


WARNING!
machine movements
– Operate the travel lever only after the drum drive
has been disabled.
1.
Fig. 231
Flushing the hoses

Fig. 232
Fig. 233

3.
WARNING!
– Operate the travel lever only after the drum
NOTICE!
Fig. 234
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.
Flushing the axle motor

WARNING!
Danger of accident!
Both wheels must be off the ground. The wheels must
be able to rotate freely.
1. Reconnect the hoses (4 and 10) to the drum drive motor.

2. Jack up the rear of the machine, so that the wheels can
rotate freely.
3. Secure the drum with wheel chocks.
4. Pre-select the slow speed range.
Fig. 235

Fig. 236
6.
WARNING!
– Operate the travel lever only after the drum
NOTICE!
Fig. 237
Start the engine, run it with maximum speed and shift the
travel lever to travel direction forward.
7. 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.
Removing the flushing filter 1. Disconnect the flushing filter and reconnect the high pressure
hoses (4 & 6) to the axle drive motor.


WARNING!
machine movements
– Operate the travel lever only after the drum drive
has been disabled.
1.
Fig. 238

Fig. 239
Function test
2. Check all connections for leaks with the engine running
3. Perform a test drive, load the travel system in forward and
reverse, e.g. by driving uphill or starting on a gradient.
Fig. 240

6.8.4 Vibration circuit

Flushing schematic for vibration
drive
Fig. 241
1 Vibration pump


6 Vibration motor
6.8.4.1 Flushing the vibration circuit

NOTICE!
cleaned oil will enter the vibration pump in high fre-
quency.
D-5, DH-5 & PDH-5 machines: For the connection
schematic shown here the vibration must always be fil-
tered with "high frequency / low amplitude".
Disconnect the vibration motor

1. Take the vibration motor (6) out of the hydraulic circuit by
Fig. 242

Bleeding the vibration circuit

1.
Bleeding the vibration circuit, see chapter
"Bleeding the vibration circuit".
Fig. 243
Flushing the hoses

Fig. 244
Fig. 245
3.
NOTICE!
D-5, DH-5 & PDH-5 machines: Use only high
frequency, as otherwise the flushing filter will be
subjected to oil flow from the wrong direction.
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. 246 vibration on and off at intervals of approx. 30 seconds.

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. 247
Fig. 248
4.
NOTICE!
D-5, DH-5 & PDH-5 machines: Use only high
frequency, as otherwise the flushing filter will be
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.
Fig. 249 6. Shut down the engine.
Remove the flushing filter and rein- 1. Remove the flushing filter, install the vibration motor and
stall the vibration motor reconnect the high pressure hoses (2 & 3).

Bleeding the vibration circuit

1.
Bleeding the vibration circuit, see chapter
"Bleeding the vibration circuit".
Fig. 250

Fig. 251
Function test
2. Test drive.
Fig. 252

6.8.5 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.
WARNING!
The engine must not start.
3. Actuate the emergency stop switch.
Fig. 253
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
from the pressure test hoses.
6. Remove the pressure test hoses.
Fig. 254
7. Unlock the emergency stop switch.
Fig. 255

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

port and run the engine max. 15 seconds at idle speed.
9. Pause for approx. 30 seconds and keep repeating this proce-
dure, until the gauge shows a constant charge pressure
reading.
Fig. 256
10.
NOTICE!
With the flushing filter installed shift the travel
lever only to travel direction forward, as other-
wise the flushing filter will be subjected to oil flow
from the wrong direction.
WARNING!
Run the engine with idle speed.
Fig. 257
Start the engine.
11. Shift the travel lever approx. 1/3 to forward direction.
12. After approx. 1 to 2 minutes shut down the 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 engine.

6.8.6 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. 258
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. 259
7. Unlock the emergency stop switch.
Fig. 260

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. 261
10.
NOTICE!
With the flushing filter installed use only high fre-
quency, as otherwise the flushing filter will be
For bleeding switch on vibration with high frequency.

12. After running the engine 1 to 2 minutes pause for approx.
Fig. 262 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.

Hydraulic system – Inspection and maintenance work


6.9.2.1 Checking the hydraulic oil level 261
6.9.3.1 Check the hydraulic lines 262
6.9.4.1 Replacing the hydraulic oil filter 263
6.9.5.1 Changing the Hydraulic Oil 264
6.9.2 Checks prior to start up

6.9.2.1 Checking the hydraulic oil level
NOTICE!
– Check the hydraulic oil level at room temperature
(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.
Ä Chapter 1.3.1.4 ‘Hydraulic oil’ on page 32.
– In hydraulic systems filled with Panolin HLP Synth.
46 always use the same oil to top up. With other
ester based oils consult the lubrication oil service
of the respective oil manufacturer.

Protective equipment: n Protective gloves
1. Check the oil level in the inspection glass.

ð Normal level: approx. 3 cm (1.2 in) below the upper edge
of the inspection glass.
Minimum level: Middle of inspection glass
2. If necessary fill in hydraulic oil through the filler neck.
Fig. 263

6.9.3.1 Check the hydraulic lines
This work must only be performed by an expert / qualified
person!
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 deformations 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, squeezed locations, 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 - hose 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.


6.9.4.1 Replacing the hydraulic oil filter

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 bowl again.
– Apart from the normal oil change intervals, the filter
element must also be changed after major repairs
in the hydraulic system.

n Protective gloves
3. Unscrew filter bowl (4) and take it off with filter element (3).
NOTICE!
Negligence may cause destruction to the entire
hydraulic system.
– Visible dirt may be an early sign for the failure of
system components and indicate the possible
failure of components.
– In this case determine the cause and replace or
repair the defective components, if necessary.
Fig. 264 – Do not clean or reuse the filter element.
4. Take out the old filter element and clean the filter bowl.
5. Clean the thread on the filter bowl.
6. Reassemble the filter bowl with a new filter element and new
O-rings (1, 2).
7. After a short test run check the filter for leaks.
8. Dispose of oil and filter in an environmentally friendly way.


6.9.5.1 Changing the Hydraulic Oil

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 the hydraulic oil.
Do not use any detergents to clean the system.
Use only lint-free cleaning cloths.
When changing from mineral oil based hydraulic oil to an ester
based biologically degradable oil, you should consult the lubrica-
tion 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 specification
Ä Chapter 1.3.1.4 ‘Hydraulic oil’ on page 32.
lubricants’ on page 34.

n Protective gloves
2. Clean the area around hydraulic oil tank, filler opening and
filler cap.
3. Remove the cover from the hydraulic oil tank.
Fig. 265

4. Unscrew the plug.

5. Drain off and collect all hydraulic oil.
6. 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 system.
Fig. 266 7. Fill in new hydraulic oil.
8. Check the oil level in the inspection glass.

ð Normal level: approx. 3 cm (1.2 in) below the top edge
of the inspection glass.
Minimum level: Middle of inspection glass
9.
The breather filter for the hydraulic oil tank is
integrated in the filler cap, you must therefore
replace the complete filler cap.
Fig. 267 Close the tank with a new cap.

10. Dispose of oil in an environmentally friendly way.


Air conditioning
7 Air conditioning

Air conditioning – Overview
7.1 Overview
Fig. 268
1 Compressor
2 Condenser
3 Drier / collector
4 HKL module

Air conditioning – Physical principles
7.2 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. 269
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. 270
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.

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. 271: 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 abso-

lute vacuum. The normal ambient pressure (overpres-
sure) 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. 272: 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

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

Air conditioning – Refrigerant R134a
7.3 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.
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:
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.

Air conditioning – Compressor oil / refrigeration oil
7.4 Compressor oil / refrigeration oil

General
The compressor oil lubricates the movable parts in the com-

pressor, seals e.g. the gap between piston and cylinder inside the
compressor 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.
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
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 replace-
ment of other components.
The compressor oil quantity must be 10% of the refrig-
erant 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 compressor
and only fill in the exact quantity that had been
drained out of the old compressor. The com-
pressor oil from the new compressor can be used
for this purpose.

Topping up compressor oil / refrigeration oil is possible

on a pressureless compressor directly into the oil pan,
in a pressureless refrigeration system directly into the
pressure side, but it is also possible to draw it into the
pressure side of the refrigeration system during the
evacuation process.

Air conditioning – Working principle of the air conditioning system
7.5 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.
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. 273: 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.

Air conditioning – Monitoring devices
7.6 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.
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. 274: Monitoring chain

Air conditioning – Description of components
7.7 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!
Fig. 275
The fins must be free of dirt and damage.
NOTICE!
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. 276
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 inter-
vals. We recommend to replace it 1 x per years, before
the start of the season.

NOTICE!
The filter/dryer must generally be replaced whenever
opening the refrigerant circuit, because moisture 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. 277
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. 278 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.
Air in the system is characterized by high pressures

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. 279 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.
+

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. 280 filter condensation water may flow into the inside of the vehicle.
NOTICE!
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. 281
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.

The adjusted temperature must be below the actual

temperature inside the cabin, so that the compressor
will be switched on.
Fig. 282: adjustable temperature con-

troller
Pressure switch
Pressure switch, B104

After a minimum pressure is reached in the low pressure side or a
maximum pressure in the high pressure side, the pressure switch
will switch of the magnetic clutch of the compressor, thus to avoid
destruction of system components by excessive pressure or
drawing in external gases and foreign matter as a result of too low
pressure.
Working pressure:
Low pressure off: 1,5 ±0,5 bar
Low pressure on: 3.5 bar
Overpressure off: 25,0 ±1,5 bar
Fig. 283
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

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

Air conditioning – Compressor
7.8 Compressor
Structure
Fig. 284: Refrigerant compressor
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.

Air conditioning – Compressor
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.
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.

Air conditioning – Emptying in case of repair
7.9 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 environ-
mentally
Releasing refrigerant into the atmosphere is prohibited
(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 permitted
amount of refrigerant in litres and has sufficient gas
space for expansion (filling factor: 0,7).
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.

Air conditioning – Drying and evacuation
7.10 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.

Air conditioning – Filling instructions
7.11 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.
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 compressor
should generally be avoided during filling and opera-
tion 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.

Fig. 285
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
11 Collecting container 23 Pressure gauge bar
12 Capacitor

Filling instructions
1 Connect the service adapter with the blue hand wheel in the
suction side.
2 Connect the service adapter with the red hand wheel in the
pressure side (the hand wheels on the service adapters must
be fully backed out - left hand stop)
3 Connect the blue suction hose below the blue hand wheel on
the pressure gauge bar to the blue service adapter.
4 Connect the red pressure hose below the red hand wheel on
the pressure gauge bar to the red service adapter.
5 Connect the yellow hose below the yellow hand wheel on the
manometer bar to the 2-stage vacuum pump.
6 Connect the last hose below the black hand wheel on the
nitrogen bottle via the pressure reducing valve.
7 Check on the pressure gauge bar that all hand wheels are
closed.
8 Turn the hand wheels on both service adapter clockwise. This
opens the valves (right hand stop).
9 Open the valve on the nitrogen bottle (only via pressure
reducer); pressure approx. 20 bar.
10 Open the black and red hand wheels on the pressure gauge
bar and fill nitrogen into the system, until a pressure of approx.
3.5 to 5.0 bar is indicated on the suction side.
11 Then open the blue hand wheel and raise the pressure in the
suction side (max. 10 bar). Check for leaks with a leak detec-
tion fluid or soapsuds.
12 If the system is leak tight, release the nitrogen from the system.
For this purpose disconnect the hose from the nitrogen bottle
and open the red, blue and black hand wheels on the pressure
gauge bar.
13 Then connect the hose to the refrigerant bottle.
14 Switch on the vacuum pump and open all hand wheels on the
pressure gauge bar. In case of a leak no or only an insufficient
vacuum will be reached. In this case proceed as described
under point 9-12. Once the leak is sealed continue with point
14.
15 Once a sufficient vacuum is reached, both pressure gauges
show -1, close all hand wheels on the pressure gauge bar.
16 Switch off the vacuum pump, watch the pressure gauges to
see whether the vacuum is maintained.
17 Open the valve on the refrigerant bottle and open the black and
red hand wheels on the pressure gauge bar. Fill refrigerant into
the system, until a pressure equilibrium between suction and
pressure side is reached (reading of pressure gauges).
18 Close the red hand wheel.
19 Perform a leak test with the electronic leak detector.
20 Start the engine and switch on the system.
21 Open the blue hand wheel and continue filling in refrigerant
until the inspection glass is free or air bubbles (in fluid con-
tainer/dryer combinations the white pearl should float in the
upper third of the inspection glass). Then close the refrigerant
bottle.
22 Close the blue hand wheel on the pressure gauge bar.
23 Preparing the test run: -Close windows and doors -Fan on full
speed stage -Mount measuring feelers to air discharge and air
intake.
24 Run the system for approx. 20 minutes with medium engine
speed.

25 The temperature difference between air discharge and air

intake should be (depending on type of air condition) 8-10°C.
Ambient temperature in this case approx. 20 °C. (These data
are only reference values, which may be influenced by possible
insolation)
26 Switch off system and engine and check for leaks again.
27 Turn out (left hand stop) and remove the hand wheels on both
service adapters.
28 Fit all valves with dust caps.
29 Perform a leak test.
30 Mark the system with the corresponding type plates and infor-
mation decals, such as type of oil and refrigerant.

Air conditioning – Steam table for R134a
7.12 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
-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


ture tion heat
t p p' p'' v' v'' h' h'' r
-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
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


ture tion heat
t p p' p'' v' v'' h' h'' r
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
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


ture tion heat
t p p' p'' v' v'' h' h'' r
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

Air conditioning – Inspection and maintenance work


7.13.2.1 Checking, tensioning the V-belt for the generator system 299
7.13.3.1 Servicing the air conditioning system 301
7.13.4.1 Replacing the air conditioning compressor V-belts 303
7.13.4.2 Cleaning the circulation air filter for the heating 304
7.13.4.3 Changing the fresh air filter in the cabin 304
As required
7.13.5.1 Checking the compressor oil level / refrigeration oil level 306

7.13.2.1 Checking, tensioning the V-belt for the generator system
7.13.2.1.1 Checking the condition of the V-belt

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 7.13.4.1
‘Replacing the air conditioning compressor V-belts’
on page 303.
Fig. 286

7.13.2.1.2 Checking the V-belt tension

n Protective gloves
Special 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. 287
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. 288
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. 289

7.13.2.1.3 Tightening the V-belt

n Protective gloves
1. Loosen the screws (2, 3, 4) on the air conditioning com-
pressor.
2. Turn the tensioning screw (1) to tighten the V-belt to the
specified value.
3. Tighten screws (2, 3, 4) again.
Fig. 290

7.13.3.1 Servicing the air conditioning system
7.13.3.1.1 Cleaning the condenser
n Protective gloves
n Safety goggles
WARNING!
Heat will cause extreme overpressure, which could cause damage

or explosion of the system.
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.


The air conditioning condenser is located in front of the

radiator.
3.
CAUTION!
Danger of eye injuries caused by particles
flying around!
– Wear your personal protective equipment
(safety gloves, protective working clothes,
goggles).
Clean the condenser fins with compressed air or cold water.
Fig. 291
7.13.3.1.2 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. 292
a Adjust the air distribution
b Regulate the cabin temperature
c Air conditioning on/off
d Fan on/off
7.13.3.1.3 Checking the condition of the drier/collector unit
Have the drier/collector unit replaced by our customer

service once every year before the operating season.

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.
Fig. 293
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.
Fig. 294
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.
Fig. 295

7.13.4.1 Replacing the air conditioning compressor V-belts

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.
6. Turn the tensioning screw (1) to tighten the V-belt to the
specified value Ä Chapter 7.13.2.1.2 ‘Checking the V-belt
tension’ on page 300.
7. Tighten screws (2, 3, 4) again.
Fig. 296
7.13.4.2 Cleaning the circulation air filter for the heating

2. Loosen the locks and disassemble the covering.
3. Remove the filter.
4. Clean the filter, replace if necessary.
5. Insert the filter and reassemble the covering.
Fig. 297
7.13.4.3 Changing the fresh air filter in the cabin

2. Pull the fastening pins out of the left cover and take off the
cover.
Fig. 298

3. Loosen the fastening screw.

4. Remove also the cover from the right hand side and loosen
the fastening screw.
Fig. 299
5. Tilt the console towards the front screen and hold it.
Fig. 300
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 reassemble
the covers.
Fig. 301

7.13.5 As required
7.13.5.1 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 / refrig-
eration 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. 302, 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. 302

Oscillating articulated joint
8 Oscillating articulated joint

Oscillating articulated joint – Overview
8.1 Overview
Fig. 303
1 Oscillating articulated joint
2 Bearing cover
3 Housing
4 Cover
5 Carrier
6 Console

Drum
9 Drum

Drum – Repair overview for drum
9.1 Repair overview for drum
Fig. 304
1 Vibration motor
2 Exciter unit
3 Clutch
4 Travel gear
5 Travel motor
6 Drum shell
7 Rubber buffer
9 Travel bearings

Fig. 305: Repair overview for drum

NOTICE!
Ensure strict cleanliness!
– Thoroughly clean work place and components.
– Dry off wet locations with compressed air.
NOTICE!
Notes on repair
– 1
Install the O-ring with some grease.
– 2
Fitting and contact surface 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 axis of the
shaft.
– 5
The thread must be free of grease, oil, paint and
conserving agents.
– 6
Wet the elastomer part + bore in flanged hub with
spirit (no oil) to ease assembly of the mechanical
seal.
– 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 space to 1/3 filled with grease.
– 8
Ventilation bore in cover pointing down.
– 9
Check the end float of the shaft: Nominal value
0.6 to 1.8 mm.

Drum – Inspection and maintenance work


9.2.2.1 Checking the oil level in the exciter housing 313
9.2.2.2 Checking the oil level in the drum drive reduction gear 314
9.2.3.1 Change the oil in the exciter housing 315
9.2.3.2 Change the oil in the drum drive reduction gear 316
As required
9.2.4.1 Retightening the padfoot shell 317
9.2.4.2 Adjust the scrapers 317

9.2.2.1 Checking the oil level in the exciter housing
NOTICE!
– Use only gear oil of the permitted specification
Ä Chapter 1.3.1.5 ‘Gear oil SAE 75W-90’
on page 32.

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. 306

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. 307
9.2.2.2 Checking the oil level in the drum drive reduction gear
NOTICE!
on page 32.

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. 308 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.


9.2.3.1 Change the oil in the exciter housing
NOTICE!
– Drain gear oil only at operating temperature.
on page 32.

year.

n Protective gloves
1. Before changing the oil level run the machine warm for about
1/2 hour.
2. Move the drum, until the drain plug is in bottom position.
4. Clean the area around the drain plug and unscrew the plug.
5. Drain off and catch old oil.
Fig. 309
7. Clean the area around the oil level inspection plug.

8. Unscrew the oil level inspection plug.
Fig. 310

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 environmentally.
Fig. 311
9.2.3.2 Change the oil in the drum drive reduction gear
NOTICE!
on page 32.

year.

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 so that one inspection plug is in horizontal
position and the two other plugs are facing vertically upwards
and vertically downwards.
3. Clean the area around the level inspection plugs and
unscrew all plugs.
Fig. 312 4. Drain and catch all oil.
5. Turn the bottom level inspection plug tightly back in.
6. Fill in oil through the opening of the upper level inspection
plug, until it starts to run out through the horizontal inspection
plug.
7. Retighten both inspection plugs again.

9.2.4 As required
9.2.4.1 Retightening the padfoot shell
After the installation of the padfoot shell, 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. 313
9.2.4.2 Adjust the scrapers

1. Check adjustment and condition of front and rear scrapers, if
necessary adjust or replace the scraper rubber.
2. In order to adjust the scrapers, slacken the fastening screws
(1) in the slots and push the scraper towards the drum to
contact.
3. Fasten the fastening screws again.
Fig. 314
1. Check adjustment and condition of scrapers, adjust or

replace the teeth if necessary.
2. To adjust the scrapers slacken the clamping screws and
push the scrapers towards the drum, leaving a gap of about
25 mm.
3. Retighten the clamping screws.
Fig. 315


Drive axle
10 Drive axle

Drive axle – Drive axle
10.1 Drive axle

10.2.1 Checking wheels and tyres 321
10.3.1 Checking the oil level in the drive axle 322
10.3.2 Checking the oil level in the drive axle reduction gear 322
10.3.3 Checking the oil level in the wheel hubs 323
10.4.1 Change the oil in the drive axle 324
10.4.2 Change the oil in the drum drive reduction gear 325
10.4.3 Changing the oil in the wheel hubs 326
10.4.4 Retightening the fastening of the axle on the frame 327
10.4.5 Tighten the wheel nuts 327
As required
10.5.1 Adjust the parking brake 328

Drive axle – Checks prior to start up
10.2 Checks prior to start up

10.2.1 Checking wheels and tyres
WARNING!
Danger of being injured by bursting tyres!
– Wear your personal protective equipment (safety
shoes, gloves, goggles, hard hat).
– When checking the tyre pressure stand in the
extension of the tyre tread.
– Use an air hose with a length of min. 6 meters.
– Never exceed the permitted maximum pressure.
The tire pressure can be adapted to the operating con-

ditions within the specified limits.
A reduced tire pressure improves the traction espe-
cially on sandy soils.
Higher tires pressures improve the driving stability of
the machine.
The total height of the machine can also be influenced
by changing the tire pressure.
Protective equipment: n Safety shoes

n Protective gloves
n Safety goggles
n Hard hat
1. Move the machine until the tire inflation valve (1) is in top
position.
3. Check the tyres for cuts, bulges, damaged rims, missing
wheel studs or nuts.
4. Have damaged wheels or tyres replaced immediately.
5. Unscrew the valve caps and check the front and rear tire
pressure, correct if necessary.
Fig. 316 Ensure equal pressure in all tires.
Tire pressure, nominal value Ä Chapter 2 ‘Tech-

nical data’ on page 37
6. Screw the valve caps back on again.

Drive axle – Every 250 operating hours
10.3 Every 250 operating hours

10.3.1 Checking the oil level in the drive axle
NOTICE!
on page 32.

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. 317
5. After filling in oil wait until the oil has evenly distributed inside
the axle.
6. Retighten level inspection and filler plugs.
10.3.2 Checking the oil level in the drive axle reduction gear
NOTICE!
on page 32.


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. 318
10.3.3 Checking the oil level in the wheel hubs
NOTICE!
on page 32.

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. 319 6. Change the oil in both wheel hubs.

10.4 Every 1000 operating hours

10.4.1 Change the oil in the drive axle
NOTICE!
on page 32.

year.

n Protective gloves
2. Clean the area around the drain plug and unscrew the plug.
3. Drain and catch all oil.
Fig. 320
5. Clean the area around the level inspection plug (1) and
unscrew the plug.
A second inspection plug is located on the left

front side of the drive axle.
6. Clean the area around the filler plug (2) and unscrew the filler
plug.
Fig. 321
8. After filling in oil wait until the oil has evenly distributed inside
the axle, if necessary fill in some more oil.
9. Retighten level inspection and filler plugs.

10.4.2 Change the oil in the drum drive reduction gear
NOTICE!
on page 32.

year.

n Protective gloves
2. Clean the area around drain plug and level inspection plug
and unscrew the plugs.
Fig. 322
the plug.
6. Fill in oil through the inspection bore, until it starts to run out
Fig. 323

10.4.3 Changing the oil in the wheel hubs
NOTICE!
on page 32.

year.

n Protective gloves
1. Move the drum, until the oil level inspection plug is in bottom
position.
the plug.
Fig. 324
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. 325

10.4.4 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·lbs).
Fig. 326
10.4.5 Tighten the wheel nuts

1. Tighten the wheel nuts cross-wise, tightening torque: 550 Nm
(405 ft·lbs).
Fig. 327

Drive axle – As required
10.5 As required
10.5.1 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.
1. Disengage the travel lever Ä Fig. 328 to the left, but do not
move to position "I" or "II".
The parking brake is released
Fig. 328
1. Unscrew locking plate 2 Ä Fig. 329.

2. Turn the square (1) in anti-clockwise direction against the
stop.
Fig. 329
1. In order to adjust the brake clearance turn the square 1

Ä Fig. 330 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. 330

Optional heating, AIRTRONIC
11 Optional heating, AIRTRONIC

Optional heating, AIRTRONIC – Overview
11.1 Overview
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. 331
1 Hot air fan wheel
2 Control unit
3 Combustion air fan wheel
4 Glow pin
5 Cover
6 Heat exchanger
7 Combined sensor (overheating / flame sensor)
8 Control elements, 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
F Fresh air
V Combustion air

W Heating air
Description of function n The fan motor (19) Ä Fig. 331 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 s flame is present, the glow pin (4) will be 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.
Switch on
DANGER!
Danger of suffocation caused by exhaust fumes!
– Do not operate inside closed rooms.
When switching on, the operation indicator in the control element

(8) Ä Fig. 331 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 cold air).
Once the residual heat is 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. 331 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°.

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.
Switch off When switching off the AIRTRONIC, the control lamp will go out
and the fuel supply is shut off.
The fan will continue running for approx. 4 minutes for cooling pur-
poses.
While the fan is still running, the glow pin is switched on for 40 sec.
(AIRTRONIC D2) or 30 sec. (AIRTRONIC D4 / D4S) for cleaning.
Exceptional case
If no delivery of fuel (start phase) takes place until the
system is switched off, or if the AIRTRONIC is in con-
trol 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.

Fault log in the control unit The electronic control unit is able to store up to 5 faults, which can
then be read out with the module clock and displayed.
Fig. 332
1 Display field with fault display
2 Rotary switch for temperature pre-selection
3 Push button to set time/week day
4 Push button to activate switch on period
5 Push button auxiliary heating On/Off
6 Push button to reduce the heating period
7 Push button to extend the heating period
In case of malfunctions you should

check the following
If the AIRTRONIC does not start after being switched on:
n Switch the AIRTRONI Off and on again, but not more than 2
times in succession.
If the AIRTRONIC still does not start, please check:
n Fuel in tank?
n Fuses O.K.?
n Electric cables, connections, terminals O.K.?
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 unit for short circuit.
In this case no fault code will be submitted.
Ä Chapter 12.7 ‘Troubleshooting, additional heating’ on page 566.

Optional heating, AIRTRONIC – Inspection and maintenance work


Monthly
11.2.2.1 Notes on maintenance 334
Heating season
11.2.3.1 Notes on maintenance 334
11.2.2 Monthly
11.2.2.1 Notes on maintenance
n Switch the auxiliary heating on every month for about ten
minutes.
After longer periods of rest one check and probably

clean the openings on heating air duct, the combustion
air duct and the exhaust duct.
11.2.3 Heating season

11.2.3.1 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 distinct smell
of fuel can be noticed, or electric / electronic compo-
nents are overheating, the heater must be switched off
and taken out of service by removing the fuse.

Trouble shooting
12 Trouble shooting

Trouble shooting – Preliminary remarks
12.1 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 instruction on correct oper-
ation and maintenance.
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.

Trouble shooting – Emergency procedures
12.2 Emergency procedures

12.2.1 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. 333
12.2.2 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 anti-clockwise and pull it out or
pull the battery terminal off the battery.
Fig. 334

12.2.3 Towing the machine

Tow the machine only in a case of emergency or to avoid 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 unbraked towed load,
n fastening means are able to withstand the load and are fas-
tened to the points provided for this purpose.
If no tow bar is used, towing is only permitted uphill.
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.
2. Open and secure the engine hood.
Fig. 335
Access to the travel pumps

4. Loosen the clamp on the exhaust pipe.
Fig. 336

5. Unscrew four fastening screws (1) from the main fuse box
and lay the main fuse box to the side.
Fig. 337
6. Unscrew the screws (1) from the engine oil filter bracket.
7. Lay the engine oil filter bracket to the side.
Fig. 338
8. Unscrew the two screws (1) from the left side of the cross-
member.
Fig. 339
9. Unscrew the two outer screws (1) from the right side of the
cross-member.
10. Tilt the cross-member to the right.
Fig. 340

Releasing the parking brake

11. Loosen the high pressure relief valves (1) on both travel
pumps for approx. three turns in counter-clockwise direction
to open a bypass.
Leakage!
– Do not back the valves out for more than
three turns!
Fig. 341
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.
Fig. 342
12.2.4 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 opera-

tion button is pushed out by hydraulic pressure.
Fig. 343

2. Retighten the high pressure relief valves (1) on both travel

pumps again, tightening torque: 70 Nm (52 ft·lbs).
3. Return the cross-member to installation position.
Fig. 344
4. Tighten the two outer screws (1) on the right side of the
cross-member.
Fig. 345
5. Tighten the two screws (1) on the left side of the cross-
member.
Fig. 346
6. Attach the engine oil filter bracket in installation position and

tighten both screws (1).
Fig. 347

7. Attach the main fuse box in installation position and tighten

both screws (1).
Fig. 348
8. Attach the exhaust pipe in installation position and tighten the

clamp.
Fig. 349

Trouble shooting – Troubleshooting, electrical systems
12.3 Troubleshooting, electrical systems
12.3.1 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 instruction on correct oper-
ation and maintenance.
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.
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.
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.
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 fastened
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.
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 principle
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
12.3.2 Starting the engine with jump leads
NOTICE!
battery.
NOTICE!
Fig. 350
components.

tive poles after.

12.3.3 Servicing the battery, checking the main battery isolation

12.3.3.1 Battery service
Maintenance free batteries also need care. Mainte-

nance free only means that the fluid level does not
need to be checked.
Each battery suffers under self-discharge, which may,
in not checked occasionally, even cause damage to
the battery as a result of exhaustive discharge.
Exhausted batteries (batteries with formation of sul-
phate on the plates) are not covered under warranty!

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. 351
12.3.3.2 Checking the main battery switch

out.
Fig. 352

12.3.4 Fuse assignment

12.3.4.1 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.
12.3.4.2 Central electrics

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 Headlight, 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 25 A Heating, air conditioning, fan
F84 10 A Control (contact 54)
F91 5A Sensors
F124 25 A Fuel pre-heating
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
12.3.4.3 Main fuses

The main fuse box is located in the engine compartment.
Fig. 353

F164 150 A (B+) charge line
F00 125 A Main fuse (potential 30)
Fig. 354

F48 150 A Preheating system

12.3.4.4 Fuse, cabin
Fig. 355
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/washer
8 F27 15 A Front windscreen wiper/washer
9 F279 15 A Spare
10 F272 5A Control console cabin
12.3.5 Understanding electric circuit diagrams

12.3.5.1 Electric circuit diagrams
Electric circuit diagrams are graphic presentations of control logical
conditions in the electric system. They do not contain any informa-
tion on the type of wiring, their purpose is solely the clarification of
control logics.
The wiring diagram is indispensable for effective and systematic
trouble shooting in the vehicle wiring system. This plan provides
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-and-socket connections.
Structure of electric circuit diagram

n Cover sheet, see section "Cover sheet"
n Table of contents, see section "Table of contents"
n Structuring symbol overview, see section "Structuring symbol
overview"
The structuring symbol overview is NOT present in cir-

cuit diagrams, which are sorted by systems and local
identification!
n Sheets with illustration of function, see section"Sheets with

illustration of function"
n List of fuels and lubricants, see "List of fuels and lubricants"
n Terminal strip overview, see section "Terminal strip overview"
n Plug overview, see section "Plug overview"
n Pin overview, see section "Pin overview"

Cover sheet
Fig. 356: Example: Cover sheet

The cover sheet contains general information.

Table of contents
Fig. 357: Example: Table of contents

The table of contents lists the individual functions and informs
about where to find them in the electric circuit diagram (Blatt/
Page).
Overview of structural symbols

The structuring symbol overview is NOT present in cir-
cuit diagrams, which are sorted by systems and local
identification!
The structural identification overview represents the structure of

the machine with respect to equipment, functions and installation
locations.
Structuring symbols are mainly abbreviations for machine parts/
machines, functions and installation locations, which were derived
from designations in English.

Fig. 358: Example: MPH122-2
Fig. 359: Example: MPH122-2

1 Identification of structure, example EBOX

Sheets with representations of n The main reading direction is sheet by sheet, from top to
functions bottom and from left to right.
n All sheets are successively numbered.
n BOMAG used 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, serve as linkage between
these partial components.
Fig. 360: Example: Sheet with functions

1 Relay cross references serve the tracking of signals, which need to be tracked for components with out-
going contacts. A mimic diagram with information about the contact types of a relay and their positions in
the wiring diagram is additionally attached to the bottom of each contactor coil.
2 Structuring symbols
3 Potential cross references serve the purpose of tracking signals, which are transmitted from one repre-
sentation of a function to another. Potential cross-references may additionally have structuring symbols
assigned to them.
4 Mimic diagram of relay
5 Current paths are successively numbered from 0 to 9.
Example: Potential cross-reference (3) → 15_54 ∼ +SEAT/16.1 is
continued to the right to page 16, current path 1. +SEAT is the
structuring symbol.
Example: The relay cross-reference 8-K61/$.2) indicates that the
relay coil on page 4 is found in current path 2.

List of components
Fig. 361: Example: List of components

The list of components, see example , is the first evaluation list that
follows the representation of function. This list contains all compo-
nents used in the wiring diagram, except terminal strips and plugs.
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 identifies 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 wiring diagram for a single drum
roller, a tandem roller, a paver or a milling machine.
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 wiring 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 elec-

trical and the hydraulic documentation and are iden-
tical.
Overview of terminal strips
Fig. 362: Example: Terminal strip overview X1

The overview of terminal strips, see example, contains all terminal
strips used in the circuit diagram. Each terminal strip starts on a
new page and can be localized via the cross-reference in the
wiring diagram.

Overview of plugs
Fig. 363: Example: Plug overview X0

The overview of plugs contains all plugs used in the circuit dia-
gram.
The following information is listed for each plug:
n Contact numbering
n Structuring symbols
n Function text
n Use in wiring diagram.

Overview of pins
Fig. 364: Example: Overview of pins, control A66

The overview of pins informs about the type of inputs and outputs
of the electronic controls (E-BOX) used in the machine, as well as
their signals and potentials.
12.3.5.2 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. 365: 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
10 Fuse
11 Terminal strip
12 Plugs
Different symbols are used to simplify the differentiation of terminal
strips 11 Ä Fig. 365 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. 366: 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.
Identification of externally supplied
documentation
Fig. 367: 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. 368: PLC 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 needed do not need to be
represented. The PLC-Box representation enables the representa-
tion of further reaching functional descriptions to the individual
component 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 switching symbols
In wiring diagrams you will frequently find the situation that sym-
bols of the same type appear in a line or are arranged just next to
each other. In such cases it is common practice to reduce the iden-
tification on the subsequent symbol to the criteria, which are dif-
ferent to the previous symbol to the left.
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.

12.3.5.3 Identification of switch blocks

Switches of modular design
Fig. 369
F Direction
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.

12.3.6 Measuring method

Test lamp
NOTICE!
This type of tester must not be used for testing on
electronic components. The high power consumption
of the test lamp may destroy electronic components in
the control units.
Fig. 370: Test lamp
Diode test lamp

This instrument is used for simple voltage measurements. The test
lamp consists of two test points. The negative measuring cable is
connected to ground and the positive measuring cable to the corre-
sponding measuring location.
If voltage is present, the corresponding light emitting diode will light
up.
Fig. 371: Diode test lamp

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. 372: 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. 373
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. 374

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. 375: Measuring voltage
n A measurement at the consumer measures the voltage drop at

this component.
Fig. 376: 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. 377: Measuring current

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. 378: Current measurement
Clip-on measuring instrument

The clip-on measuring instrument can be used to measure current,
voltage and resistance.
Fig. 379: Clip-on measuring instru-

ment
n For measuring current the individual conductor must be fully

enclosed by the measuring tongs, the actual measurement
takes place without contact.
Fig. 380

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. 381: 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. 382
12.3.7 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 control
unit (ESX, 68 pole) is connected. The complete repre-
sentation 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 different, but
the procedures for line testing are generally the same.

Fig. 383: 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.

Fig. 384: 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. 385 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.

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 setpoint.
Fig. 385: Pinbox for 68 pole ESX control

General measuring setup to check

a supply line (plus side)
Fig. 386: 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.

General measuring setup to check

a return line (minus side)
Fig. 387: 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.

Connection example to check the

plus line between battery and plug
pin 28
Fig. 388
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. 389
P Multimeter
X Wiring loom plug disconnected from control unit or Pinbox
E Nominal value: E is bright. UV max. 0.5 Volt

Test protocol for ESX
E Lamp 12V / 21W in 12V vehicle network, to load the current

branches
E Lamp 24V / 21W in 24V vehicle network, to load the current
branches.
G01 Battery
P Multimeter, measuring range: DC
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.

12.3.8 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. 390
(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.

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. 391
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

Sequence after the fault is found
Fig. 392
12.3.9 Electrics training machine control

Service Training
Electric Systems
Single Drum Rollers – 5
Version 1.00
Version/Status: V1.00 / 18.02.16 Page 1 of 51

Author: Brand / EE

Service Training WZ -5
Table of contents
1 Confirmation of changes ..............................................................................................4

1.1 Document ..............................................................................................................................4
1.2 Software.................................................................................................................................5
2 Displayed monitoring activities with fault reactions ..................................................6
3 Known faults..................................................................................................................7
4 The diagnostics system ................................................................................................8
4.1 Display functions ..................................................................................................................8
4.2 General facts and operation ................................................................................................8
4.2.1 Calling up service mode .....................................................................................................8
4.2.2 Entering input codes ..........................................................................................................9
4.3 Query firmware version .....................................................................................................10
4.3.1 Meaning of the firmware number ......................................................................................10
5 Fault log – display and delete ....................................................................................11
5.1.1 Showing stored faults .......................................................................................................11
5.1.2 Deleting all stored faults ...................................................................................................11
5.2 Delete engine control fault log ..........................................................................................12
5.2.1 Deleting logged engine faults ...........................................................................................12
5.2.2 Deleting active engine faults ............................................................................................12
6 Settings and queries ...................................................................................................13

6.1 Adjusting the machine type...............................................................................................13
6.1.1 Procedure for initial commissioning of a control ...............................................................16
6.1.2 Procedure for changing a machine type ...........................................................................16
6.2 Driving against the closed brake ......................................................................................17
6.3 Automatic detection of surge currents in travel system ................................................18
6.3.1 Procedure.........................................................................................................................19
6.4 “Trimming” the speed measurement ...............................................................................20
6.4.1 Procedure.........................................................................................................................20
6.4.2 Explanation ......................................................................................................................20
6.5 Calibrating the speed detection (calibration of wheel diameter) ..................................21
6.5.1 Procedure.........................................................................................................................21
6.5.2 Explanation ......................................................................................................................21
6.6 Show pulses per 10 metres ...............................................................................................22
6.6.1 Procedure.........................................................................................................................22
6.7 Showing the speed of the rotary speed sensor ..............................................................22
6.7.1 Procedure.........................................................................................................................22
6.8 Showing the pulses of the rotary speed sensor .............................................................22
6.8.1 Procedure.........................................................................................................................22
6.9 Showing the direction signal of the rotary speed sensor ..............................................23
6.9.1 Procedure.........................................................................................................................23
6.10 Adjusting the vibration frequency ....................................................................................24
6.10.1 Procedure.........................................................................................................................24

Author: Brand / EE

6.11 Activating/deactivating the cabin .....................................................................................25

6.11.1 Procedure.........................................................................................................................25
6.12 Adjusting the serial number ..............................................................................................26
6.12.1 Procedure.........................................................................................................................26
6.13 Activating/deactivating the measuring technology ........................................................27
6.13.1 Procedure.........................................................................................................................27
6.14 Activating/deactivating the printer ...................................................................................27
6.14.1 Procedure.........................................................................................................................27
6.15 Read out counter for “Regeneration suppressed” .........................................................28
6.15.1 Procedure.........................................................................................................................28
6.16 Delete counter for “Regeneration suppressed” ..............................................................28
6.16.1 Procedure.........................................................................................................................28
6.17 Activating/deactivating the dozer blade...........................................................................30
6.17.1 Procedure.........................................................................................................................30
6.18 Activating/deactivating the attachment plates ................................................................31
6.18.1 Procedure.........................................................................................................................31
6.19 Activating/deactivating the reversing lock for lowered attachment plates ..................31
6.19.1 Procedure.........................................................................................................................31
6.20 Adjusting the cross-slope sensor ....................................................................................32
6.20.1 Procedure.........................................................................................................................32
6.21 Flushing the double pumps hydrostatically ....................................................................33
6.21.1 Procedure.........................................................................................................................33
7 Other explanations ......................................................................................................34
7.1 Extended machine functions.............................................................................................34
7.1.1 Hydraulic oil filter monitoring ............................................................................................34
8 Replacement of components .....................................................................................35
8.1 How to proceed when replacing components?...............................................................35
8.2 Replacement of an ESX-control ........................................................................................35
8.3 Replacement of a travel pump / axle drive motor / drum drive motor ..........................35
8.4 Replacement of a vibration pump / vibration motor .......................................................35
8.5 Component replacement without adjustment procedure ..............................................36
9 Description of the signals on the ESX-control ..........................................................37
10 Description of signals on the travel lever ..................................................................43
11 Descriptions of signals in the display .......................................................................45
12 Fault codes of the ESX control ..................................................................................47
13 Input Codes for ESX Control ......................................................................................47
14 History .........................................................................................................................47
15 Terminology in connection with ESX.........................................................................48

Author: Brand / EE

1 Confirmation of changes
1.1 Document
This document is valid for all single drum rollers (BW145-226 D/PD/DH/PDH/BVC/DI/RC) from soft-
ware version 3.00.
No. Date Description of changes resp.

1.00 23/06/2015 Created version 1.00 for small single drum rollers -5 Brand
(BW145-226 from software version 3.00)

Author: Brand / EE

1.2 Software
Ver. Date Description of changes resp.

V 3.00 04/05/2015 ÆFirst software for series. Brand
V 3.01 19/06/2015 Æ BW211 D/PD/DH/PDH released. Brand
Æ BW212 D/PD/DH released.
Æ BW213 D/BVC released.
Æ BW214 D released.
Æ BW216 D/PD released.
Æ BW219 DH/PDH released.
V 3.02 22/07/2015 Æ BW213 DH/PDH released. Brand
Æ BW226 DH/PDH/BVC/DI/RC released.
Æ BW211 D/PD/DH/PDH vibration frequency adapted.
Æ BW212 D/PD/DH vibration frequency adapted.
Æ BW213 D/BVC vibration frequency adapted.
Æ BW213 DH/PDH/BVC min. idle speed adapted.
Æ BW216 D/PD min. idle speed adapted.
V 3.03 06/08/2015 Æ BW216 DH/PDH released. Brand
V 3.05 21/10/2015 Æ BW219 BVC released. Fondel
Æ Fault 9170 corrected.
Æ Fault teach process “Pulses per 10 m” rectified. Brand
V 3.06 11/12/2015 Æ BW219 D/PD released. Brand
Æ BW226 BVC without CE released.
Æ BW226 DI without CE released.
Æ BW177 D (Kubota Tier4f) released.
ÆEOL-test procedure revised.
Æ Driving in reverse with the plate lowered deactivated.
Æ Adjustable coolant level sensor mode implemented.

Author: Brand / EE

2 Displayed monitoring activities with fault reactions
Reaction Symbol in fault Warning Warning Engine stop

message display
Code output Code output Code output
Signal without buzzer with buzzer with buzzer
Fault in exhaust gas

after-treatment
Exhaust gas after-

treatment
5161 5153 5154
5155
5156
High exhaust gas
temperature
5161
Engine oil pressure

(from EMR)
5100 5101
5112 5112
Coolant temperature
(from EMR)
5100 5101
5116 5116
Coolant level
5024 5025
after 5 s after 10 s
Engine air filter
5026 5027
after 5 s after 2 min.
Hydraulic oil filter
5500 5501
(ATTENTION! Delay after 5 s after 2 min.
in acceleration time.
See 7.1.1)
Water separator in
fuel filter
5028 5029
after 5 s after 2 min.
(Standard not
active)
Seat contact
1300
Arm rest
1330

Author: Brand / EE

3 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:
Error code 5100, 5140 and engine does not re- Switch the ignition off and on and restart the ma-
spond to full speed switch or travel lever chine immediately.

Author: Brand / EE

4 The diagnostics system

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

warning
triangle
Fault message
* *
Warning
* *
Note
* *
Display, 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.
4.2 General facts and operation
The following chapter describes the operation of the display via the travel lever buttons.
4.2.1 Calling up service mode

For this purpose the display must be switched over to service mode via input mode. This is accom-
plished via the two yellow Info-buttons “INFO 1” and “INFO 2” on the back of the travel lever. Naviga-
tion in input and service mode takes place via the green and blue buttons on the front of the travel
lever.
Change values
Werte ändern Navigieren
(green) Navigation
INFO 1 Taste (grün) (blau)
(blue)
INFO 1 button
(gelb)
(yellow)
INFO 2 Taste
INFO 2 button Werte ändern
(gelb) Change values
(yellow) (grün)
(green)
Navigieren
Navigation
(blau)
(blue)
Version/Status: V1.00 / 18.02.16 Functions of ESX Control Page 8 of 51

Author: Brand / EE

The travel lever must be in locked braking position in order to activate input mode!
Input mode is switched on by simultaneously pressing both INFO – buttons over a period of approx.
3 seconds.
4.2.2 Entering input codes

Input mode starts with flashing of the left hand digit. Here you have the possibility to change to the
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 operating one of the blue buttons one can jump to the next (left
or right) digit. Once the last right hand digit has been entered the code will be transferred to the control
by pressing the right hand blue button once again.
If the access code has been entered correctly, the “Spanner” symbol is displayed and the first input
digit flashes again. Individual operating states of the machine can now be interrogated by transferring
the input code to the control (as described above).
When operating both INFO buttons again for approx. 3 seconds, another input code can be entered.
The 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 be-
come active, with the exception of the LC-display, which remains in service mode and continues to
display the operating values requested last.

Author: Brand / EE

4.3 Query 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).
4.3.1 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 firmware one must make sure that it “matches” the control to be flashed (part number
of raw part).
Revision number:
Any change in revision number indicates a change of the firmware while the part number remained
unchanged. The firmware is downwards compatible to firmware versions with the same version num-
ber.

Author: Brand / EE

5 Fault log – display and delete

5.1.1 Showing stored faults
Switch on function “Show stored faults”:

• Enter code number “0 7 0 0 ” (!WITHOUT service code 9999). This code number enables the func-
tion “Show stored faults”.
The faults stored in the ESX are displayed in flashing mode. If several faults are stored, these are
successively displayed in cycles of 3 seconds. After the last fault has been displayed, the first fault will
appear again. If no faults are stored in the ESX, the display will show “- - - - - ”
Switch off function “Show stored faults”:

• Enter code number “0 7 0 1 ” (!WITHOUT service code 9999). This code number disables the func-
tion “Show stored faults”.
L
Apart from the stored faults the current faults are also displayed.
Note
L
This function can only be activated / deactivated when the travel lever is
Note locked in the brake gate. (Æ Input mode)
5.1.2 Deleting all stored faults

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

• 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.
L
Stored faults can only be deleted when the engine is not running.
Note
L
Note locked in the brake gate. (Æ Input mode)

Author: Brand / EE

5.2 Delete engine control fault log
5.2.1 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.
5.2.2 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

6 Settings and queries

6.1 Adjusting 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 first time 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 hy-
draulic components (valve spools), or may be equipped with attachment plates or other optional
equipment.
For simple checking of the actually set machine type just enter the code “0 7 2 0 ”.
The following machine types can be adjusted:
D-machines
First Last Available

Machine type serial number serial number Code from version
Standard1 - - 7200 3.00
BW211 D 101 586 08 1001 XXX XXX XX XXXX 7201 3.01

BW211 D without CE 101 586 47 1001 XXX XXX XX XXXX 7202
BW211 PD 101 586 10 1001 XXX XXX XX XXXX 7203 3.01



BW216 PD without CE 101 586 29 1001 XXX XXX XX XXXX 7212

BW219 PD without CE 101 586 36 1001 XXX XXX XX XXXX 7216
BW145 D 101 586 54 1001 XXX XXX XX XXXX 7261

1
The standard machine type does not represent a real machine, but is the initial point for not yet set controls
during initial commissioning or after replacing a control.

Author: Brand / EE

DH machines

BW211 DH 101 586 09 1001 XXX XXX XX XXXX 7220 3.01

BW211 PDH 101 586 11 1001 XXX XXX XX XXXX 7221 3.01

BW213 DH without CE 101 586 17 1001 XXX XXX XX XXXX 7224
BW213 PDH without CE 101 586 19 1001 XXX XXX XX XXXX 7226
BW213 DH with plates 101 586 22 1001 XXX XXX XX XXXX 7227 3.02



BW145 DH 101 586 01 xxxx XXX XXX XX XXXX 7263

BW145 PDH 101 586 02 xxxx XXX XXX XX XXXX 7264

BW177 PDH 101 586 05 xxxx XXX XXX XX XXXX 7268


Author: Brand / EE

DH-BVC machines

BW213 BVC 101 586 20 1001 XXX XXX XX XXXX 7250 3.01
BW213 BVC without CE 101 586 21 1001 XXX XXX XX XXXX 7251
BW213 BVC with plates 101 586 23 1001 XXX XXX XX XXXX 7252 3.01
BW226 BVC without CE 101 586 44 1001 XXX XXX XX XXXX 7255 3.06
BW226 DI 101 586 45 1001 XXX XXX XX XXXX 7256 3.02
BW226 DI without CE 101 586 53 1001 XXX XXX XX XXXX 7257 3.06
BW226 RC 101 586 46 1001 XXX XXX XX XXXX 7258 3.02
BW177 BVC 101 586 06 xxxx XXX XXX XX XXXX 7270
EXAMPLE: Machine code for BW 213 DH: 7223
•
L
Parameter adjustments can only be made when the engine is not run-
Note ning!
• This function can only be activated / deactivated when the travel lever
is locked in the brake gate. (Æ Input mode).

Author: Brand / EE

6.1.1 Procedure for initial commissioning of a control

• The control has been installed into the machine.
• Switch the ignition on. After switching on the letters “C O D E ” are displayed for a period of approx.
3 seconds. After this the display changes and shows code “7 2 0 0 ”.
• Use the Arrow Up or Arrow Down keys to select the correct machine code from the list of codes.
• Confirm the selection with the Arrow Right key.
• After a short while (< 10 seconds) the new parameters, in accordance with the set machine type,
are loaded. 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.
6.1.2 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 “Adjusting machine type”.
The display module now permanently shows the code “7 2 0 0 ”.
• Select the machine code from the table above and confirm it with the Arrow Right key. After operat-
ing the Arrow Right key the control switches automatically off and on again.
• After a short while (< 10 seconds) the new parameters, in accordance with the set machine type,
are loaded. 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.
L
A machine must not be operated with a wrong type setting, because in
Note such a case the correct function of the control cannot be assured!
New controls are delivered with a default machine type setting “7 2 0 0 ”.

This does not enable to drive or steer the machine. It only serves the pur-
pose of commissioning.

Author: Brand / EE

6.2 Driving against the closed brake

After entering code number “0 5 0 0 ” the brake will not be released. If the travel lever is in this condi-
tion shifted out of the brake gate and moved to any travel direction, the travel pumps will be triggered
according to the chosen travel direction. At the same time a warning (fault code “0 5 0 0 ”) appears on
the display and the warning buzzer is triggered, in order to keep the operator informed about the con-
dition. The brake control light in the LC-display remains activated.
In order to terminate this function and to release the brake you must either enter code number
“0 5 0 1 ” or switch the ignition off. After entering code number “0 5 0 1 ” the function is aborted and
“O K ” is displayed as confirmation for 5 seconds. After this the code needs to be entered again.
L
Note locked in the brake gate. (Æ Input mode).

Author: Brand / EE

6.3 Automatic detection of surge currents in travel system
For a sensitive and exact function of the travel system the surge currents in the travel system must be
determined for both travel directions. The surge currents are automatically determined after entering a
code number, so that no electric meter is required.
The surge currents must only be determined during initial commissioning in the factory, after a service
during which the control on a steering valve or the complete steering valve has been replaced and
after the replacement of the ESX-control.
The measurement is identical for both travel directions: after entering the respective code number the
current is increased by the control solenoid of the travel pump in small steps, starting from 580 mA.
After each current increase the system waits for 3 seconds. If a considerable axle o9r 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 measured values are averaged to determine
the final surge current. This surge current is automatically stored and is valid from the next start of the
machine.
Before the measurement you should strictly make sure that the machine is parked on level ground and
has a sufficient distance for movement to front and back, because the machine will move to the re-
spective direction when performing the measurement.
Attention! First set the machine to input mode (code “9 9 9 9 ”). It must be strictly assured that the
speed sensor(s) 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, only on DH/BVC machines)
into the display module. This code can be used to display the number path pulses from the speed
sensor. The displayed value must change when the machine is driven.
If this value does not change even though the machine is moving, the measurement must not
be performed!
The state of the speed sensor must first be corrected, as otherwise the movement of the machine
cannot 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 progressing!
Please take notice of the emergency stop button to be able to quickly shut
down the machine, if this should be required.
During the measurement watch your environment and interrupt the meas-
urement if people come too close to the machine!
The machine can be stopped by returning the travel lever to neutral posi-
tion!

Author: Brand / EE

6.3.1 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 “1 0 9 0 ”. This code number activates the function “Automatic detection of surge cur-
rents in the travel system”; the display now shows the reading “0 0 0 0 ” with the first digit flashing.
This code number must be entered to be able to perform the following steps. From this point the
machine can no longer be operated with the travel lever! The travel lever will only be in
function again after the teach function has been completed or the machine has been re-
started.
• The measurements (forward/reverse) must be started by entering a code number. The code num-
ber 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 for-
ward 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 measuring process in reverse the display will show “O K ” again.
• The travel lever must now be returned to braking position.
• Once both surge currents have been learned correctly and the travel lever is in “braking position”,
the display shows the reading “D O N E ”, the values are saved and the function is completed. Now
the machine can be operated again with the travel lever. The new surge current values for the
travel system are valid from the next start.
• The teach function can at any time be aborted by operation of the emergency stop or the ignition
switch.

Author: Brand / EE

6.4 “Trimming” the speed measurement
6.4.1 Procedure
Input Description
• 9999 Switch on Service Mode.
• 1158 Allow function “Trimming the speed measurement”.
• 1159 Start function “Trimming the speed measurement”.
• The display shows: “F O R W ”: Move the travel lever forward (or back).
• Green button up = raise indicated speed (measuring value too low)
• Green button down = reduce indicated speed (measuring value too high)
• Travel lever in braking position: “D O N E ” = FINISHED! Procedure finished.
6.4.2 Explanation
In order to adjust the speed display e.g. to the BOMAG measuring system or to reference test
benches, the machine integrated travel speed detection may be “trimmed”, i.e. adjusted.
For this purpose the input codes “1 1 5 8 ” (enable function) and “1 1 5 9 ” (start function) are used to
activate the function “Trim speed measurement”.
With the green button on the travel lever an internal calibration value can now be changed to such an
extent, that the displayed speed corresponds with the actual travel speed.
L
Attention! If the speed detection is extremely falsified because of operat-
Note ing errors, this can lead to uncomfortable travel behaviour.

Author: Brand / EE

6.5 Calibrating the speed detection (calibration of wheel diameter)
6.5.1 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 10 m distance
• The display shows: “F O R W ”: Move the travel lever forward (or back).
• 1168 Load original values.
• 1169 Save the values.
6.5.2 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 cri-
terion for the speed detection.
With the input code “1 1 6 8 ” it is also possible to adjust the basic value for series machines
(“1 1 6 0 ” -> “1 1 6 8 ” -> “1 1 6 9 ”).
L
Attention! If the speed detection is extremely falsified because of operat-
Note ing errors, this can lead to uncomfortable travel behaviour.

Author: Brand / EE

6.6 Show pulses per 10 metres
6.6.1 Procedure
• 9999 ^ǁŝƚĐŚŽŶ^ĞƌǀŝĐĞDŽĚĞ͘
• 1110 ^ŚŽǁƉƵůƐĞƐƉĞƌϭϬŵĞƚƌĞƐŽŶƚŚĞĂǆůĞ͘
or
• 1100 ^ŚŽǁƉƵůƐĞƐƉĞƌϭϬŵĞƚƌĞƐŽŶƚŚĞĚƌƵŵ;ŽŶůǇĨŽƌ,ͬW,ͬsͲŵĂĐŚŝŶĞƐͿ͘
• dŚĞĚŝƐƉůĂǇŶŽǁƐŚŽǁƐĂǀĂůƵĞ͕ǁŚŝĐŚƌĞƉƌĞƐĞŶƚƐƚŚĞƉƵůƐĞƐƉĞƌϭϬŵĞƚƌĞƐŽŶƚŚĞĂǆůĞŽƌƚŚĞ
ĚƌƵŵ͘
The pulses per 10 metres is a fixed value that does not change while travelling. (see chapt.6.5 on
page 21)
6.7 Showing the speed of the rotary speed sensor
6.7.1 Procedure
• 1115 ^ŚŽǁƚŚĞƐƉĞĞĚŽĨƚŚĞƐƉĞĞĚƐĞŶƐŽƌŽŶƚŚĞĂǆůĞ͘
or
• 1105 ^ŚŽǁƚŚĞƐƉĞĞĚŽĨƚŚĞƐƉĞĞĚƐĞŶƐŽƌŽŶƚŚĞĚƌƵŵ;ŽŶůǇĨŽƌ,ͬW,ͬsͲŵĂĐŚŝŶĞƐͿ͘
• dŚĞĚŝƐƉůĂǇƐŚŽǁƐƚŚĞĐƵƌƌĞŶƚƐƉĞĞĚŝŶŵͬŵŝŶ͘

tŝƚŚƚŚĞŵĂĐŚŝŶĞĂƚƐƚĂŶĚƐƚŝůůƚŚĞƐƉĞĞĚŝƐϬ͘KŶĐĞƚŚĞŵĂĐŚŝŶĞŝƐƚƌĂǀĞůůŝŶŐ͕ǀĂůƵĞƐƵŶĞƋƵĂůϬǁŝůůďĞ
ĚŝƐƉůĂǇĞĚ͘
6.8 Showing the pulses of the rotary speed sensor
6.8.1 Procedure
• 1116 ^ŚŽǁƚŚĞƉƵůƐĞƐŽĨƚŚĞƐƉĞĞĚƐĞŶƐŽƌŽŶƚŚĞĂǆůĞ͘
or
• 1106 ^ŚŽǁƚŚĞƉƵůƐĞƐŽĨƚŚĞƐƉĞĞĚƐĞŶƐŽƌŽŶƚŚĞĚƌƵŵ;ŽŶůǇĨŽƌ,ͬW,ͬsͲŵĂĐŚŝŶĞƐͿ͘
• dŚĞĚŝƐƉůĂǇŶŽǁƐŚŽǁƐƚŚĞƉƵůƐĞƐŽĨƚŚĞĂǆůĞŽƌĚƌƵŵ͘
tŝƚŚƚŚĞŵĂĐŚŝŶĞĂƚƐƚĂŶĚƐƚŝůůƚŚĞĚŝƐƉůĂǇĞĚǀĂůƵĞǁŝůůŶŽƚĐŚĂŶŐĞ͘tŚĞŶƚŚĞŵĂĐŚŝŶĞŝƐĚƌŝǀŝŶŐ͕ƚŚĞ
ǀĂůƵĞǁŝůůŝŶĐƌĞĂƐĞĐŽŶƚŝŶƵŽƵƐůǇ͘

Author: Brand / EE

6.9 Showing the direction signal of the rotary speed sensor
6.9.1 Procedure
• 1117 ^ŚŽǁƚŚĞƐĞŶƐĞŽĨƌŽƚĂƚŝŽŶŽĨƚŚĞƐƉĞĞĚƐĞŶƐŽƌŽŶƚŚĞĂǆůĞ͘
or
• 1107 ^ŚŽǁƚŚĞƐĞŶƐĞŽĨƌŽƚĂƚŝŽŶŽĨƚŚĞƐƉĞĞĚƐĞŶƐŽƌŽŶƚŚĞĚƌƵŵ;ŽŶůǇĨŽƌ,ͬW,ͬsͲ
ŵĂĐŚŝŶĞƐͿ͘
• dŚĞĚŝƐƉůĂǇŶŽǁƐŚŽǁƐƚŚĞƐĞŶƐĞŽĨƌŽƚĂƚŝŽŶŽĨƚŚĞƐĞŶƐŽƌŽŶƚŚĞĂǆůĞŽƌŽŶƚŚĞĚƌƵŵ;Ϭ͗ƌĞǀĞƌƐĞ͕
ϭ͗ĨŽƌǁĂƌĚͿ͘
&ŽƌƚŚĞƐĞŶƐĞŽĨƌŽƚĂƚŝŽŶƐŝŐŶĂůƚŽďĞĚŝƐƉůĂǇĞĚĐŽƌƌĞĐƚůǇ͕ƚŚĞŵĂĐŚŝŶĞŵƵƐƚďĞŵŽǀĞĚĨŽƌĂĨĞǁŵĞͲ
ƚƌĞƐ͘

Author: Brand / EE

6.10 Adjusting 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 meter and corrected, if necessary.
The drum of the machine must be standing on a rubber mat for adjusting
L 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”!
6.10.1 Procedure
• Start the 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 meter.
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 34 30
Checking the vibration frequency re-
quires the use of an external measuring
instrument. BW216 D/PD/DH/PDH 36 30
• Once the correct frequency is reached,
the value can be saved with the right BW219 D/PD/DH/PDH 26 26
blue button. BW219 BVC 26
• Repeat this procedure for the low or
high amplitude. BW226 DH/PDH 26 26
• Once both frequencies have been set, BW226 BVC/DI/RC 26
vibration can be switched off with the red button on the travel lever.

Author: Brand / EE

6.11 Activating/deactivating the cabin
If the machine is NOT equipped with a cabin, this software should be de-
L Note activated. 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 9109 appears in the display and the cabin needs to be deactivated.
6.11.1 Procedure
Input Description
• 8821 Enable function “Activate or deactivate cabin”.
• 8822 Activate the cabin.
or
• 8823 Deactivate the cabin.

Author: Brand / EE

6.12 Adjusting the serial number
The serial number needs to be adjusted on these machines. The serial number consists of 4 blocks
(101 586 03 1001). The first three blocks have already been set and do not need to be changed. Only
the last block needs to be adapted to the machine.
L Note
Only switch the ignition on, do NOT start the engine!
6.12.1 Procedure
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 for approx. 5 seconds shows the text “O K ”.
• With the help of the input code “4 0 1 9 ” the complete serial number can be shown in the display.
• With codes “4 0 1 2 ”, “4 0 1 3 ” or “4 0 1 4 ” you can also adjust the other blocks of the serial num-
ber. However, this should only be made, if they do not contain the correct value.

Author: Brand / EE

6.13 Activating/deactivating the measuring technology
During the input the diesel engine of the machine should not be running!
L 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.
6.13.1 Procedure
Input Description
• 3011 Enable function “Activate or deactivate measuring technology”.
• 3012 Activate the measuring technology.
or
• 3013 Deactivate the measuring technology.
• The display for approx. 5 seconds shows the text “O K ”.
6.14 Activating/deactivating the printer
L Note Any change to the setting of the printer will only become effective after
switching the ignition off and back on again!
6.14.1 Procedure
Input Description
• 3016 Enable function “Activate or deactivate printer”.
• 3017 Activate the printer.
or
• 3018 Deactivate the printer.

Author: Brand / EE

6.15 Read out counter for “Regeneration suppressed”
The machine is equipped with a counter to display the number of times the regeneration has been
suppressed.
6.15.1 Procedure
Input Description
• 5151 Read out regeneration suppression counter.
• The display now shows the number of times the regeneration had been suppressed.
6.16 Delete counter for “Regeneration suppressed”
6.16.1 Procedure
Input Description
• 5152 Enables function “Delete regeneration suppression counter”.
• 5153 Delete regeneration suppression counter (set to “0”).

Author: Brand / EE


Author: Brand / EE

6.17 Activating/deactivating the dozer blade
L Note Any change to the setting of the dozer blade will only become effective af-
ter switching the ignition off and back on again!
6.17.1 Procedure
Input Description
• 3021 Enable function “Activate or deactivate dozer blade”.
• 3022 Activate the dozer blade.
or
• 3023 Deactivate the dozer blade
• 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

6.18 Activating/deactivating the attachment plates
L Note Any change to the setting of the attachment plates will only become effec-
tive after switching the ignition off and back on again!
6.18.1 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).
6.19 Activating/deactivating the reversing lock for lowered attachment plates

On machines with attachment plates, reversing with lowered plates or locked or deactivated by de-
fault. Reversing can be enabled by using the following input procedure.
6.19.1 Procedure
Input Description
• 3077 Enable function “Activate or deactivate reversing with lowered attachment plates”.
• 3062 Activate reversing with lowered attachment plates.
or
• 3063 Deactivate reversing with lowered attachment plates.
• Reversing with lowered attachment plates is possible or locked after switching the ignition off and
back on again.

Author: Brand / EE

6.20 Adjusting the cross-slope sensor
L Note The machine must stand on level ground to adjust the cross-slope!
6.20.1 Procedure
Input Description
• 1265 Enable the function “Adjust cross-slope sensor”.
• 1266 Adjust the cross-slope sensor (set to “0”).

Author: Brand / EE

6.21 Flushing the double pumps hydrostatically
On machines with double pump drive (DH/PDH/BVC) 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 hydro-
static circuit. This can be accomplished by entering the input code 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!
L Note After switching the ignition off and on again the function will be deacti-
vated again!
This function is only available on machines with double pump system

L Note (DH/PDH/BVC/DI/RC).
6.21.1 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 ma-

L Note chine must be lifted off the ground at the corresponding drive. If the ma-
chine is moved on the ground in this condition, the display will show and
error message and the engine will be shut down!

Author: Brand / EE

7 Other explanations
7.1 Extended machine functions
7.1.1 Hydraulic oil 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 appearance 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).

Author: Brand / EE

8 Replacement of components
8.1 How to proceed when replacing components?
Each machine is adjusted individually during initial commissioning. This adjustment or teaching proc-
ess is necessary to make sure that the travel and vibration functions are almost identical on all ma-
chines. 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 for both mechanical as well
as electrical functions and are unavoidable for manufacturing reasons.
To enable simple and quick adjustment procedures we have decided to do without expensive tools. All
that is needed is this manual and a bit of time. By following the described procedure it is possible to
take a machine back into operation after the replacement of one of the components specified above
and to re-establish the usual functional quality, with almost any previous knowledge. Even an incor-
rectly or incompletely conducted teaching procedure can be repeated without problems as often as
necessary. At the first glance it seems to be at bit awkward to perform this adjustment work on every
machine, but this procedure enables the operation of all machines with the same operating software.
At the end of the day this considerably increases the spare parts availability.
8.2 Replacement of an ESX-control

Since the control stores all teach values of the machine, each teaching procedure must be performed
with the new control after a replacement.
L
ATTENTION: Before performing one of the following steps you must first set
Note the corresponding machine type (see chapt. 6.1 on page 13)!
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 chapt. 18 on page 6.3)
• Adjust the vibration frequencies (see chapt. 6.3 on page 18)
• On BVC
• Adjust the vibration frequency (see chapt. 6.3 on page 18)
8.3 Replacement of a travel pump / axle drive motor / drum drive motor
8.4 Replacement of a vibration pump / vibration motor

• Adjust the vibration frequency(ies) (see chapt. 6.3 on page 18)

Author: Brand / EE

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

Author: Brand / EE

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

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

minal
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. Measurement not possible!
Communication interface for parameter changes
X35:5 Interface RS 232 TxD, not used for normal operation. Measurement not possible!
X35:6 Input hydraulic pressure travel pump circuit axle forward B234 0 bar ) approx. 4 mA
Analogue input (current input 4..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 B234 0 bar ) approx. 4 mA
pump
X35:8 Input sensor height adjustment of plates B312
Analog input (current input 4..20 mA) from height-distance measuring sys-
tem 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
BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 / BW 226 PDH-5

X35:10 Input release of vibration pump for plates
Digital input active low.
Version/Status: V1.00 / 18.02.16 Description of Signals on ESX Control Page 37 of 51

Author: Brand / EE
415
416

minal
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 approx. 12 V, when machine is
Frequency input active low (0....7.5 kHz) driving.
Frequency with travel speed m/min
Machine type:
XX m/min ) approx. XX Hz
Machine type:
Machine type:
X35:13 Input sense 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 on BW145/177/197)
X35:17 Input sense of rotation drum B60 Sense of rotation forward ) approx. 12 V
Digital input active high Rotary direction reverse ) 0V
X35:18 Input pressure switch engine oil B06
Digital input active low
(only BW177 D/DH/PDH with Tier3-engines)

X35:19 Input coolant temperature switch B53

Author: Brand / EE

minal
X35:20 Output travel pump drum forward Y72 Forward travel active ) 600..1800 mA
PWM power output (max. 4 A) Forward travel inactive ) 0 mA
X35:21 Output travel pump drum reverse Y73 Reverse travel active ) 600..1800 mA
PWM power output (max. 4 A) Reverse travel inactive ) 0 mA
X35:22 Output solenoid valve plates vibration pump Y98 Vibration of attachment plates active ) 400..1200 mA
PWM power output (max. 4 A)
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 mode (emergency function). This voltage must be measured against AGND.
X35:24 Output relay engine shut-down solenoid active, i.e. floating position switched on ) 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,
the cabin module and the immobilizer.
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

Author: Brand / EE
417
418

minal
X35:31 Input sensor side adjustment of plates B313
Analog input (current input 4..20 mA) from side distance measuring system
for attachment plates.
X35:32 Input inclination 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 approx. 12 V, when machine is
Frequency input active low (0....7.5 kHz) driving.
(only on DH-machines) Frequency with travel speed m/min
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 high (0....7.5 kHz)

Author: Brand / EE

minal
X35:41 Input pre-heating relay K14 active ) approx. 12 V
Digital input active high inactive ) 0V
X35:42 Output levelling blade up Y379 active, i.e. dozer blade/plates up ) approx. 12 V
or inactive, i.e. dozer blade/plates not lifted ) 0V
Output plates up Y122
X35:43 Output levelling blade down Y380 active, i.e. dozer blade/plates down ) approx. 12 V
or inactive, i.e. dozer blade/plates not lowered ) 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 On BW145/177/197 DH/PDH/BVC
PWM power output (max. 4 A) Vibration active ) 400..1200 mA
Vibration inactive ) 0 mA
On all other machines
Vibration active ) 600..1800 mA
Vibration inactive ) 0 mA

X35:50 Output plates left Y142 active, i.e, shift plates to the left ) approx. 12 V
Digital output (max. 5 A) inactive, i.e, do not shift plates to the left ) approx. 0 V

Author: Brand / EE
419
420

minal
X35:51 Output plates right Y143 active, i.e, shift plates to the right ) approx. 12 V
Digital output (max. 5 A) inactive, i.e, do not shift plates to the right ) approx. 0 V
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 to communicate with the travel lever
and 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 for plates P43 active ) approx. 12 V
Digital output (max. 2.5 A) inactive ) 0V
X35:64 Output brake Y04 Brake opens ) approx. 12 V
PWM power output (max. 4 A) Close brake ) 0V
X35:65 Ground connection approx. 0 V



Author: Brand / EE
Service Training WZ -5 Description of Signals on the Travel Lever
10 Description of signals on the travel lever

Notes:
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 0 V (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 range selector switch. This volt- Permissible range: approx. 4.8..5.2 V
age 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 en- Measurement not possible!
gine EMR.
X23:7 Interface CAN-Bus 2 Wire -, is used to communicate with ESX and en- Measurement not possible!
gine 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 stage selector switch The voltage signal changes with the adjusted travel speed range
Analogue input Travel stage min. ) ?? V
Travel stage 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
Version/Status: V1.00 / 18.02.16 Description of Signals on Travel Lever Page 43 of 51

Author: Brand / EE
421
422
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 re- Voltage supply inactive ) 0V
quired 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.)

Version/Status: V1.00 / 18.02.16 Description of Signals on Travel Lever Page 44 of 51
Author: Brand / EE
Service Training WZ -5 Description of Signals on the Display
11 Descriptions of signals in the display

Notes:

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. Measurement not possible!
X33:7 Interface RS232 TxD, not used for normal operation. Measurement not possible!
X33:8 Input indicator relay Direction 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 Regeneration suppressed active ) approx. 12 V
Digital input active high Regeneration suppression inactive ) 0V
(only on machines with Tier4f engines)
X33:12 Input request regeneration S299 High idle active ) approx. 12 V
Digital input active high High idle inactive ) 0V
(only on machines with Tier4f engines)

X33:13 Not used
X33:14 Not used
X33:15 Not used
Version/Status: V1.00 / 18.02.16 Description of Signals on the Display Page 45 of 51

Author: Brand / EE
423
424
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, Measurement not possible!
ESX, the cabin module and with the immobilizer.
X33:22 Interface CAN-Bus 1 Wire -, is used for communication with MESX, ESX, Measurement not possible!
the cabin module and with the immobilizer.
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

Version/Status: V1.00 / 18.02.16 Description of Signals on the Display Page 46 of 51
Author: Brand / EE
12 Fault codes of the ESX control

See list of fault codes.
13 Input Codes for ESX Control

See list of input codes.
14 History
Version/Status: V1.00 / 18.02.16 Terminology Page 47 of 51

Author: Brand / EE

15 Terminology in connection with ESX

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

• loosened, slipped off
• broken off,
• corroded,
• socket / plug faulty

Author: Brand / EE

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 4 mA to 20 mA; voltage 0 V to 8.5 V; resistance 100 Ω to 300 Ω; valve 0%
to 100% opened (proportional valve)

Author: Brand / EE

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 ...) must be known.
Disturbance variable (z)
Input (w) Cont rol u Output (y)

Distance
system
Closed loop control

Closed loop control is a process during which a value, the closed loop control value (e.g.
pressure), is continually measured and compared with a nominal value (guide value). The
result of this comparison will affect the closed loop control value, thereby adapting the closed
loop control value to the guide value.
This sequence occurs in a closed circuit, the co-called closed loop control circuit.
Disturbance variable (z)
Input (w) + e u Output (y)

Regulator Distance
-
Identification Closed loop control Control system

Operating path: closed open
(control circuit) (control chain)
Measurement and Value to be adjusted is meas- Values to be controlled
comparison of value to ured and compared. are not measured and
be adjusted: compared.
Reaction to faults Counteracts to all faults target- Does not respond to un-
(generally): ing the system to be controlled. known faults
Technical expense: Low expense: High expense if many
Measurement of the value to faults have to be consid-
be controlled, comparison of ered, low expense if not
nominal and actual value, faults occur.
power amplification
Performance in unsta- For unstable systems closed In unstable systems con-
ble systems loop controls must be used. trols cannot be used.

Author: Brand / EE

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 per-
manently 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 ana-
logue ground, which is only to be used for sensors. (see description of the signals on the
ESX-control)
PWM – digital output

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

Author: Brand / EE

430
FaultLocation Output brake valve Y04
FCode FaultDescription Terminal Possible Cause Diag Reac
1001 No or too low current flow out of this X35:64 428Line breakage in current path 5
output
1002 The output to the valve has ground X35:64 549Short 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 630Current path has connection to +Ub (15 or 30) 5
FaultLocation Input BTS brake 5

1005 Plausibility conflict in evaluation of X35:14 5
travel lever X- axis to the brake
contact signal
FaultLocation Output warning horn, K13 5
1015 Although the output is switched off, X35:25 2Line breakage in current path 3
voltage is present
FaultLocation Output backup warning (rear), H14 0

output

FaultLocation Travel lever, S55 5
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
431
432
FaultLocation Input travel stage selector switch, S42 0
1040 Ground Connection faultySignal X23:7, X23:15 927Line breakage in current path 3
outside the valid range
1041 Supply connectionSignal outside X23:7, X23:15 038Current path has connection to +Ub (15 or 30) 2
the valid range
1042 Signal lineSignal outside the valid X23:7, X23:15 3
range
FaultLocation Output valve travel pump (rear) forward, Y16 0
1050 The required control power cannot be X35:46 25Line breakage in current path 2
transmitted to the proportional
solenoid.
1051 Output to proportional valve shorted X35:46 347Short circuit to ground (31) in the current path 2
to ground.
1052 Supply voltage Ub is applied to the X35:46 439Current 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
FaultLocation Output valve travel pump (rear) reverse, Y17 0
solenoid.
to ground.
solenoid.
to ground.
FaultLocation Output valve travel pump (front) forward, Y72 0
solenoid.

to ground.
433
434
solenoid.
to ground.
1180 5
FaultLocation Output valve travel pump (front) reverse, Y73 0
solenoid.
to ground.
solenoid.
to ground.

FaultLocation Teach function travel pump flow controller 0
1090 Informative code - The teach function System 25Informative 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 64Informative code - Follow the adjustment instructions 1
the limiting values 685Software parameter fault, software update may be required.
65Excessive current in current path
FaultLocation Output valve travel speed range selection front, Y30 0


output
435
436
valve output, even though the valve is
not switched.
FaultLocation Input speed sensor travel motor B59 5
1105 No pulses from the speed sensor are X35:35 029Line breakage in current path 3
detected, ven though the travel pump 03Current path has connection to +Ub (15 or 30)
is actuated.
04Short circuit to ground (31) in the current path
02Hardware defect sensors, replacement required
1106 Plausibility of the sense of rotation X35:17 23Line breakage in current path 3
does not match 34Current path has connection to +Ub (15 or 30)
FaultLocation Output valve travel speed range selection rear, Y31 0

output
valve output, even though the valve is
not switched.
FaultLocation Input speed sensor travel motor, B60 5

1115 No pulses from the speed sensor are X35:12 520Line breakage in current path 3
detected, ven though the travel pump

53Current path has connection to +Ub (15 or 30)
is actuated.
1116 Plausibility of the sense of rotation X35:13 624Line breakage in current path 3
does not match 635Current path has connection to +Ub (15 or 30)
FaultLocation Input inclination sensor, B57

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
FaultLocation Input pressure sensor travel pump (rear) forward, B234 0
output
1211 Signal rangeThe current signal is X35:6 3
specification)
1212 Pressure sensor does not measure any X35:6 3
pressure
1255 The sensor is not correctly connected, X35:6 245Sensors not correctly installed or not adjusted 2
it may be mixed up with another 26Sensor mixed up by mistake
sensor.

FaultLocation Input pressure sensor travel pump (rear) reverse, B235 0
437
438
output
specification)
pressure
sensor.
FaultLocation Input pressure sensor travel pump (front) forward, B236 0
output
specification)
pressure
sensor.
FaultLocation Input pressure sensor travel pump (front) reverse, B237 0
output

specification)

pressure
sensor.
FaultLocation Input seat contact switch, S06 0
1300 Informative message, no fault! X35:15 2Line breakage in current path 0
Driver's seat not occupied (driver not

seated!) or cable breakage in signal
line
FaultLocation Input armrest right, B146 0
1330 Information message, no fault! X35:31 0
Right armrest raised Machine does

not pick up throttle and is braked to
stop.
1331 Signal faultSignal outside the valid X35:31 423Line breakage in current path 2
range 4Hardware defect sensors, replacement required
1332 Short circuit X35:31 2
1333 System fault, replace control X35:31 2
FaultLocation Output vibration pump, low amplitude, Y08 0
output
to ground.

3003 No or too low current flow out of this 2
output
439
440
to ground.
3006 Fault current regulator System 2
3008 Hardware initializing error System 2
FaultLocation Vibration frequency controller, low amplitude
3011 Frequency adaptation, saved control 80Software parameter fault, software update may be required. 0
values are outside limiting values
3012 Frequency adaptation, controller has System 98Software parameter fault, software update may be required. 0
reached upper limiting value
3013 Frequency adaptation, controller has System 082Software parameter fault, software update may be required. 0
reached lower limiting value
3014 Frequency/speed to high System 2
3015 Hardware initializing error System 293ESX hardware defect, hardware replacement may be 3
necessary
3016 Hardware initializing error System 394ESX hardware defect, hardware replacement may be 3
necessary
FaultLocation Output vibration pump, high amplitude, Y07 0
output

to ground.
output
to ground.
3028 Hardware initializing error ystem 2
FaultLocation Vibration frequency controller, high amplitude
3031 Frequency adaptation, saved control 682Software parameter fault, software update may be required. 0
values are outside limiting values
3032 Frequency adaptation, controller has 78Software parameter fault, software update may be required. 0
reached upper limiting value
3033 Frequency adaptation, controller has 83Software parameter fault, software update may be required. 0
reached lower limiting value
3034 Frequency/speed to high 2
3035 Hardware initializing error 095ESX hardware defect, hardware replacement may be 3
necessary
3036 Hardware initializing error 94ESX hardware defect, hardware replacement may be 3
necessary
FaultLocation Vibration system 0
3040 Fault in vibration frequencyValue 78Informative code - Follow the adjustment instructions 1

outside the limiting values 789Software parameter fault, software update may be required.
FaultLocation Output vibration pump plates, Y98

441
442
3051 Signal faultSignal outside the valid 1
range
3052 Hardware initializing error 1
range (see signal description)
3054 The required control power cannot be 927Line breakage in current path 1
transmitted to the valve
3055 Hardware initializing error 28Line breakage in current path 1
3056 Fault current regulator 1
FaultLocation Input plates position measuring system height adjustment, B312 0
3060 Cable breakage or sensor defective 429Line breakage in current path 1
FaultLocation Input plates position measuring system side adjustment, B313 3
3063 Cable breakage or sensor defective 1
FaultLocation Attachment plates potentiometer, S139 6


3067 Cable breakage UB 1
FaultLocation Backup alarm 7
3077 Information message, no fault! The 1
machine travels backwards with
lowered attachment plates.
FaultLocation Output amplitude changeover relay, K43 0
output
3091 Output to relay shorted to ground. X35:48 47Short circuit to ground (31) in the current path 3
relay output, even though it is not
switched.
FaultLocation Input exciter position, B97
4001 Cable breakage UB X88:9 92Line breakage in current path 2
4002 Cable breakage GND X88:9 02Line breakage in current path 2
range
4201 ADC initialization 4
4208 Sensor 1 software error 2
4209 Input initialization error 4
FaultLocation Input switch amplitude adjustment, S107 0

4010 Cable breakage UB X88:32 32Line breakage in current path 2
4011 Cable breakage GND X88:32 423Line breakage in current path 2
443
444
4012 Signal lineSignal outside the valid X88:32 2
range
FaultLocation Output valve exciter up, Y140
4023 Cable breakage or sensor defective X88:47 2
FaultLocation Output valve exciter down, Y141 6
FaultLocation Input acceleration transducer, B62
4101 Signal faultSignal outside the valid X88:29, 2
FaultLocation Input acceleration transducer, B171 6

FaultLocation Metrology controller

4150 Software incompatibility metrology 2
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.
match the old one.
4271 Fault: Overvoltage 8.5 V supply 4
4272 Fault: Undervoltage 8.5 V supply 4
4990 Measuring technology not compatible System 1
FaultLocation Input D+ detection 7
5017 Engine running but no D+ signal X35:9 029Line breakage in current path 0

present 07Generator or charge regulator defective
FaultLocation Input engine oil pressure monitoring, B06 0

445
446
5020 Warning: No oil pressure X35:37 0
5021 Fault: No oil pressure X35:37 5
FaultLocation Input coolant level monitoring, B55 4
5024 Warning: Coolant filling level too low X35:39 0
5025 Fault: Coolant filling level too low X35:39 4Informative code - Follow the adjustment instructions 5
452Check the coolant level, top up if necessary
FaultLocation Input air filter sensor, B03 6

5026 Warning: Air filter dirty X35:38 1
5027 Fault: Air filter dirty X35:38 63Informative code - Follow the adjustment instructions 5
654Check filter, if necessary clean or replace as per service
instructions
FaultLocation Input water separator, B124 8
5028 Warning: Water in fuel filter X35:36 0
5029 Fault: Water in fuel filter X35:36 5
FaultLocation Input level switch for fuel filling level, R03 0
5050 Signal faultSignal outside the valid X33:2 725Line breakage in current path 1
range (see signal description) 76Hardware defect sensors, replacement required
FaultLocation Engine speed detection


FaultLocation Engine control unit 0

5100 Info message - Engine control unit System 87Informative code - Follow the adjustment instructions 1
reports a warning
5101 Error message - Engine control unit System 98Informative code - Follow the adjustment instructions 1
reports an error
5102 Error message - Engine control unit System 09Informative 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 20Line breakage in current path 1
5112 Fault: No oil pressure Motor 324Line breakage in current path 0
5113 Turbo charger pressure not correct Motor 428Line breakage in current path 1
5114 Fault: Intake manifold temperature Motor 52Line breakage in current path 1

447
448
5115 Fault: Ambient pressure sensor Motor 62Line breakage in current path 1
5116 Fault: Engine temperature sensor Motor 720Line breakage in current path 0
5117 Fault: Diesel temperature sensor Motor 824Line breakage in current path 1
5118 Fault: Engine speed sensor Motor 928Line breakage in current path 1
5119 Warning: Water in fuel filter Motor 02Line breakage in current path 1
5120 Communication fault with engine System 85CAN communication fault 1
control unit 29Line breakage in current path
5121 Communication fault with engine System 5

control unit
5123 1

Communication fault with engine Motor
control unit
5124 Communication fault with engine Motor 1
control unit
control unit
5126 Communication fault with engine Motor 745CAN communication fault 1
control unit 725Line breakage in current path
5127 Fault: Coolant filling level too low Motor 82Line breakage in current path 1
5128 Fault: Injection pressure in rail system Motor 1
5130 Fault: Oil pressure sensor Motor 02Line breakage in current path 1
5131 Fault: Turbocharger pressure sensor Motor 26Line breakage in current path 1
5133 Fault: Engine temperature sensor Motor 324Line breakage in current path 1

449
450
5134 Fault: Engine speed sensor Motor 428Line breakage in current path 1
5135 Fault: Water in fuel filter Motor 52Line breakage in current path 1
5137 Fault: Coolant level sensor Motor 720Line breakage in current path 1
5138 Fault: Sensor for injection pressure in Motor 824Line breakage in current path 1
rail system 835Current path has connection to +Ub (15 or 30)
5139 Fuel pump Motor 92Line breakage in current path 1

952Excessive current in current path

5140 Error message - Engine control unit Motor 1
reports a fault, which has not been
classified. Engine diagnose required.
5142 Fault pressure limiting valve 3
5143 Fault: Injection pressure in rail system 3
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
control unit
FaultLocation Exhaust gas after-treatment 0
5180 Information message, no fault!The Motor 1
EndOfLine test (EOL test) has not
been performed.
6064 Fault: No DEF system pressure Motor 0
building up!
6068 Fault: DEF system pressure outside of Motor 0
limit values!

6069 Fault: Regeneration requirement Motor 0
ignored too long!
451
452
FaultLocation Input hydraulic oil filter 0
5500 Warning: Hydraulic oil filter dirty X35:37 854Check filter, if necessary clean or replace as per service 1
instructions
5501 Fault: Hydraulic oil filter dirty X35:37 95Check filter, if necessary clean or replace as per service 5
instructions
FaultLocation Exhaust Gas Recirculation (EGR) 0
6000 Fault: Differential pressure below Motor 0
limit value!
FaultLocation DEF quality sensor, B222
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
description).
6016 Fault: DEF quality invalid! Motor 0
description).
6065 Fault: CAN message failed! Motor 0
FaultLocation Diesel particulate filter (DPF) 4
6004 Plausibility error, DPF differential Motor 0
pressure
6005 Fault: Differential pressure below Motor 0
limit value!
6060 Fault: Excessive ash load! Motor 0
6061 Fault: Excessive soot load! Motor 0

FaultLocation DEF metering valve, Y293 6
6006 Short circuit towards Ub Motor 0
453
454
6007 Cable breakage or sensor defective Motor 0
6008 The output to the valve has ground Motor 0
6062 Fault: Valve blocked! Motor 0
FaultLocation DEF supply module 7
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 8
6018 Fault: Temperature has exceeded Motor 0
upper limit value!
6022 Fault: Temperature too low! Motor 0
FaultLocation DEF pump, M41 5

6025 0

Supply voltage Ub is applied to the Motor
output to the pump, even though the
output is not switched.
6026 Output to pump shorted to ground Motor 0
FaultLocation DEF suction valve, Y291 8
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
upper limit value!
FaultLocation Temperature sensor downstream of OXY catalyst, B215 2
upper limit value!

FaultLocation Temperature sensor upstream of SCR catalyst, B224 2
455
456
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 5
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 8
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) 6

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 Motor 0
of 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 0
6199 Warning: Check NOx sensors! Motor 0
FaultLocation Machine type management 2
7012 Machine type conflict After replacing System 2
match the old one.
FaultLocation Setup operating hour meter 3

7013 Operating hour meter not yet System 76Informative code - Follow the adjustment instructions 1
reconstructed
457
458
FaultLocation Software Approval System 0
7020 Software Approval Missing System 4
7021 Software release incomplete System 3
FaultLocation Immobilizer A67 7
FaultLocation Cabin module 9

Functional System 0Output 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 System 4BMESX Module

554 Display of serial number 1
Functional System 5System

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

Functional System Output brake valve Y04

459
460
1001 Display voltage output brake 1 Display in V
Functional System 0Travel lever, S55

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
Functional System 0Input inclination sensor, B57

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

Functional System 0Input travel stage selector switch, S42
1040 Display "Selected travel range" 1
1041 Display input voltage for travel range switch 1
track 1
Functional System 0Output valve travel pump (front) forward, Y72

1050 Display "Actual current value travel pump 1 1 mA/ Digit
forward"
1058 Display start current valve travel pump 1 Display in mA
forward
1059 Display final current valve travel pump 1 Display in mA
forward
Functional System 0Output valve travel pump (front) reverse, Y73

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
Functional System 0Output valve travel pump (rear) forward, Y16

forward"
1078 Display start current valve travel pump 1 Display in mA
forward
1079 Display final current valve travel pump 1 Display in mA
forward

461
462
Functional System 0Output valve travel pump (rear) reverse, Y17
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
Functional System 0Teach function travel pump flow controller

1090 Release teaching surge currents travel pump 1
1091 Start teaching surge currents travel pump 1 [mA / Digit]
Functional System 0Input speed sensor travel motor B59

1100 Display of pulses per 10m 1
1105 Travel speed 1 Display in m/min
1106 Pulses of speed sensor 1
1107 Display "Movement direction of machine" 1
1109 Status display travel motor 1 0: Qmax1: Qmin
Functional System 0Input speed sensor travel motor, B60

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
1119 Status display travel motor 1 0: Qmax1: Qmin
Functional System 0Travel drive, speed adaptation

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
Functional System 0Input pressure sensor travel pump (rear) forward, B234
1270 Display travel pressure 1 [bar]
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

463
464
Functional System 4Input pressure sensor travel pump (rear) reverse, B235
value in mA
1276 Display pressure sensor measuring value 1 0.. 1000
Functional System 0Input pressure sensor travel pump (front) forward, B236
value in mA
1282 Display pressure sensor measuring value 1 0.. 1000
Functional System 4Input pressure sensor travel pump (front) reverse, B237
value in mA
1286 Display pressure sensor measuring value 0.. 1000


Functional System 0Input seat contact switch, S06
1300 Status seat contact switch 1 0 = off, 1 = on
Functional System 0Input armrest right, B146

1330 Status of right armrest 1 1= arm rest up; 2= arm rest down
1331 Status of right armrest 1 Display in V
Functional System 0Metrology controller

3010 Display enable metrology 2 0= Off1 = On
3011 Enable parameter change metrology 2
3012 Activate metrology 2
3013 Deactivate metrology 2
3015 Display enable printer 2 0= Off1 = On
3016 Enable parameter change metrology 2
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
465
466
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
4060 Display vibration operation hour meter 2
4555 Display of the firmware version of the 2
measuring control (ESX)
Functional System 0Dozewr blade parameters


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
Functional System 7Vibration 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 1
3059 1
Functional System 0Attachment plate parameters

3060 Display enable attachment plates 1
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
467
468
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
3089 Display valve attachment plates priority, Y145 1 0= Off1 = On
3090 Display valve attachment plates floating 1 0= Off1 = On
position, Y60/Y144
Functional System 0Engine speed detection

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)
Functional System 4Engine speed default

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)
Functional System 0Input engine oil pressure monitoring, B06

5020 Display status oil pressure switch in diesel Oil pressure present: = 1 = ok No oil pressure = 0 = not ok
engine when engine is running
Functional System Input coolant level monitoring, B55

5021 Display "Engine status - coolant level" 1 0= Coolant level OK1= Coolant level too low

Functional System 4Input D+ detection
469
470
5024 Display D+ status of engine 1 0 = not Ok1 = ok
Functional System 5Input air filter sensor, B03

5025 Display "Engine status - air filter" 1 0= Air filter OK1= Air filter soiled
Functional System 6Input water separator, B124

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
Functional System 0Input coolant level monitoring B55

5040 1
Functional System 0Input level switch for fuel filling level, R03
5050 Display input level sensor in fuel tank 1 0..255 (raw values)
Functional System 0Exhaust gas after-treatment


5060 Display DPF: Ash load 1 0..100%

5150 1
5151 1
5152 1
5153 1
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
Functional System 0EndOfLine test (EOL test)

5180 Enable start EOL test 2
5181 Start EOL test 2
Functional System 0Auto-Stop 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

5609 Change to time Auto-Stop.System 2
471
472
Functional System 0Immobilizer A67
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
Functional System 0Setup display

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
Functional System 0Cabin module

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

travel lever
lever



473
474
travel lever
lever




Trouble shooting – Trouble shooting, diesel engine
12.4 Trouble shooting, diesel engine
12.4.1 Starting the engine with jump leads
NOTICE!
battery.
NOTICE!
Fig. 393
components.

tive poles after.

12.4.2 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


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


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

480
Revision: 10.02.2015
12.4.3
DTC-List-EMR4
Diagnosis- and Errorcodes
KWP-Code SPN FMI Blink code Fehlerbescheibung Error identification

1 132 11 2-2-6 Luftmengen Sensor Last Korrekturfaktor maximales Drift Air flow sensor load correction factor exceeding the
Limit überschritten; Signal unplausibel maximum drift limit; plausibility error
9 172 2 2-2-6 Ansauglufttemperatursensor unplausibles Signal Air inlet filter temperature, plausibility error
37 523924 3 1-6-7 UB2; Batteriekurzschluss Aktuator Relais 2 UB2; Short circuit to battery error of actuator relay 2
38 523925 3 731 UB3; Batteriekurzschluss Aktuator Relais 3 UB3: Short circuit to battery error of actuator relay 3.
40 523927 3 733 UB5; Batteriekurzschluss Aktuator Relais 5 UB5; Short circuit to battery error of actuator relay 5 (UB6)
SCR-Heater/Rev.Valve
42 523924 4 167 UB2; Kurzschluss gegen Masse Aktuatorrelais 2 UB2; Short circuit to ground actuator relais 2
43 523925 4 731 UB3; Kurzschluss gegen Masse Aktuatorrelais 3 UB3; Short circuit to ground actuator relais 3
DTC error code list, EMR4
44 523926 4 732 UB4; Kurzschluss gegen Masse Aktuatorrelais 4 UB4; Short circuit to ground aktuator relais 4.
45 168 3 318 Sensorwert des Batteriespannungssensors über Grenzwert Sensor error battery voltage; signal range check high.
Sensorfehler Batteriespannung; Signalbereich überschritten
46 168 4 318 Sensorwert des Batteriespannungssensors unter Grenzwert Sensor error battery voltage; signal range check low
47 168 2 318 Batteriespannunug zu hoch; Warnschwelle erreicht High battery voltage; warning threshold exceeded
Batteriespannung Grenzwert überschritten; Warnmeldung
wird generiert
48 168 2 3-1-8 Batteriespannung, unterer Grenzwert unterschritten High battery voltage; shot off threshold exceeded
55 523910 14 6-9-5 Brenner Luftpumpe - genereller Fehler Air pump doesn´t achieve air mass flow setpoint
Luftpumpe erreicht Luftmassen-Sollwertvorgabe nicht Burner Control - burner air pump
56 524013 7 8-5-6 Brenner kontrolle Burner Control; burner Flame;

Brenner startet nicht nach X Versuchen Burner does not start after x trials (burner flame lost
Brennerflamme unbeabsichtigt gelöscht detection)
Burner flame unintentional deleted

Revision 1.0 Page 1 / 59
DTC-List-EMR4 Revision: 10.02.2015

57 524020 14 8-6-3 Brenner Konrolle: Leistungsreduktion wegen Burner Control: power reduction due to low lambda
Sauerstoffmangel Engine power; Not enough oxygen for regeneration
Leistungsreduzierung Motor; Zu wenig Sauerstoff für

Regeneration
58 523911 0 7-2-3 Brennerdosierventil (DV2); Überstrom am Ende der Burner dosing valve (DV2); overcurrent at the end of the
Einspritzphase injection phase
59 523911 12 7-2-3 Brennerdosierventil (DV2); Leistungsstufe Übertemperatur Burner dosing valve (DV2); powerstage over temperature
60 523911 3 7-2-3 Batteriekurzschluss Leistungsstufe Brennerdosierventil (DV2) Burner dosing valve (DV2); short circuit to battery
62 523911 4 7-2-3 Massekurzschluss einer Leistungsstufe des Burner dosing valve (DV2); short circuit to ground
Brennerdosierventil (DV2); Massekurzschluss
63 523911 11 7-2-3 Brennerdosierventil (DV2); Kurzschluss Leistungsstufe Burner dosing valve (DV2); short circuit high side powerstage
plusseitig
64 523912 2 7-2-2 Kraftstoffdruck; Drucksensor nach Brennerdosierventil (DV2); Burner dosing valve (DV2) downstream pressure sensor;
Drucksignal nicht plausibel plausibility error
66 523912 0 7-2-2 Brenne-Kraftstoffdruck; Druck nach Brennerdosierventil Physical range check high for burner dosing valve (DV2)
(DV2); Druck über Grenzwert downstream pressure; shut off regeneration
Maximalwert überschritten; Abschaltung Regeneration
69 523912 1 7-2-2 Kraftstoffdruck; Drucksensor nach DV2; Druck unter Physical range check low for burner dosing valve (DV2)
Grenzwert downstream pressure; shut off regeneration. When burner
injector is actuated, the measured pressure does not rise
above ca. 1250mbar abs (expected: ca. 2400mbar).
72 523912 3 7-2-2 Sensorfehler Drucksensor nach Brennerdosierventil (DV2); Sensor error burner dosing valve (DV2) downstream
Signalbereich überschritten pressure sensor; signal range check high

481
482

73 523912 4 7-2-2 @ Motoren kleiner 4l: @ engines < 4l:
Sammelfehler für Drosselklappe, Wackelkontakt oder Throttle valve error, Open Load or Short cut to Battery,
Kurzschluss nach Masse oder Batterie, blockierte Klappe blocked valve or wrong control signal for valve.
oder falsches Ansteuersignal.
@ Brenner Motoren T4i: @ engines with Burner T4i:
Sensorfehler Drucksensor nach Brennerdosierventil (DV2), Pressure Sensor error after valve (DV2), lower limit reached
unterer Grenzwert unterschritten)
74 523913 3 7-2-1 Diagnoseleitung Glühkerzenkontrolle Spannung zu hoch Sensor error glow plug control diagnostic line voltage; signal
range check high
75 523913 4 7-2-1 Sensorfehler Spannung Diagnoseleitung Sensor error glow plug control diagnostic line voltage; signal
Glühkerzenkontrolle; Signalbereich unterschritten range check low
Diagnoseleitung Glühkerzenkontrolle Spannung zu niedrig
76 523914 5 7-2-1 Glühkerzenkontrolle; Kabelbruch Glow plug control; open load

water pump control (PWM)
77 523914 12 7-2-1 Glühkerzenkontrolle; Leistungsstufe Übertemperatur Glow plug control; powerstage over temperature
78 523914 3 7-2-1 Batteriekurzschluss an der Ansteuerung der Wasserpumpe Glow plug control; short circuit to battery
79 523914 4 7-2-1 Glühkerzenkontrolle; Massekurzschluss Glow plug control; short circuit to ground
82 1235 14 2-7-1 CAN-Bus 2 = CAN_C hat Bus-Fehler {Bei <8L und CV52 CAN-Bus 2 = CAN_C reports Bus-error
handelt es sich um den engine-CAN@250kbaud} (for engines <8L and CV52 it is the engine-CAN@250kbaud)
CAN Bus passiv Fehler; Warnung CAN C - engine CAN CAN Bus error passive; warning CAN C - engine CAN
84 639 14 271 CAN-Bus 0 "BusOff-Status" CAN-Bus 0 "BusOff-Status"

CAN-Bus 0 (CAN_A; Customer-CAN) hat "BusOff"-Message
{I.d.R.: 250kbaud}
85 1231 14 271 CAN-Bus 1 "BusOff-Status" CAN-Bus 1 "BusOff-Status"
86 1235 14 271 CAN-Bus 2 (CAN_C = engine bus) hat "BusOff"-Message CAN-Bus 2 = engine bus "BusOff-Status"

{Bei <8L und CV52 : Engine-CAN; 250kbaud}


88 102 2 223 Ladeluftdruck Grenzwert überschritten; Warnmeldung wird Charged air pressure above shut off threshold.
generiert
89 102 2 223 Ladedruck zu hoch (Abschaltschwelle überschritten) - Charged air pressure above warning threshold;
Wastegate prüfen
92 110 0 2-2-5 Kühlmitteltemperatur zu hoch, physikalischer oberer Physical Range Check high for Coolant temperature
Grenzwert überschritten
93 110 1 225 Kühlmitteltemperatur zu niedrig, physikalischer unterer Physical Range Check low for Coolant temperature.
Grenzwert unterschritten
96 110 3 225 Sensorfehler Kühlmitteltemperatur, oberer Grenzwert Sensor error coolant temperature; signal range check high
überschritten
97 110 4 225 Sensorfehler Kühlmitteltemperatur, unterer Grenzwert Sensor error coolant temperature; signal range check low
unterschritten
98 110 0 232 Kühlmitteltemperatur zu hoch; Warnschwelle erreicht High coolant temperature; warning threshold exceeded
99 110 0 232 Kühlmitteltemperatur Grenzwert überschritten; Abschaltung Coolant temperature; system reaction initiated
wird generiert
101 111 1 235 Kühlmittelstand zu niedrig Coolant level too low
121 1109 2 341 Motor Abschaltanforderung wurde vom Fahrer ignoriert Engine shut off demand ignored
122 523698 11 591 Abschaltanforderung durch übergeordnete Überwachung Shut off request from supervisory monitoring function
125 523717 12 5-9-5 Timeout der CAN-Sendebotschaft AmbCon; Wetter Timeout Error of CAN-Transmit-Frame AmbCon; Weather
Umgebungsbedingungen environments
126 523603 9 3-3-8 Timeout der CAN-Empfangsbotschaft AMB; Timeout Error of CAN-Receive-Frame AMB; Ambient
Umgebungstemperatur Sensor Temperature Sensor

483
484

127 3224 2 5-9-6 DLC Fehler der CAN-Empfangsbotschaft AT1IG1 NOX DLC Error of CAN-Receive-Frame AT1IG1 NOX Sensor
Sensor (SCR-System vor Katalysator; DPF-System nach (SCR-system upstream cat; DPF-system downstream cat);
Katalysator); Botschaftslänge nicht korrekt length of frame incorrect
128 3224 9 5-9-7 Timeout der CAN-Empfangsbotschaft AT1IG1; NOX Sensor Timeout Error of CAN-Receive-Frame AT1IG1; NOX sensor
vor Katalysator upstream
129 3224 2 596 Botschaftlänge des Vor-Kat Nox-Sensors stimmt nicht mit der DLC Error of CAN-Receive-Frame AT1IG1Vol NOX sensor.
Spezifikation überein
DLC Fehler der CAN-Empfangsbotschaft AT1IG1Vol NOX
Sensor (SCR-System vor Katalysator; DPF-System nach
Katalysator); Botschaftslänge nicht korrekt
130 3224 9 597 Timeout der CAN-Empfangsbotschaft AT1IG1Vol; NOX Timeout Error of CAN-Receive-Frame AT1IG1Vol; NOX
Sensor vor Katalysator sensor.
133 523938 9 766 Kalibrierbotschaft 1 vom Vor-Kat Nox-Sensor ist ausgefallen Timeout Error (BAM to packet) for CAN-Receive-Frame
Timeout (BAM to packet) der CAN-Empfangsbotschaft AT1IGCVol1.
AT1IGCVol1 information; Faktoren & Sensorkalibrierung für
NOX Sensor (SCR-System vor Katalysator; DPF-System
nach Katalysator)
134 523939 9 766 Broadcast Announce Message der Kalibrierbotschaft vom Broadcast Announce Message of the calibration message
Vor-Kat Nox-Sensor ist ausgefallen. of the upstream catalytic NOx sensor has failed.
135 523940 9 766 Kalibrierbotschaft 2 vom Vor-Kat Nox-Sensor ist ausgefallen Timeout Error (PCK2PCK) for CAN-Receive-Frame
AT1IGCVol1
137 3234 9 1-1-7 Timeout der CAN-Empfangsbotschaft AT1OG1; NOX Sensor Timeout Error of CAN-Receive-Frame AT1OG1; NOX sensor
(SCR-System nach Katalysator; DPF-System nach (SCR-system downstream cat; DPF-system downstream cat)
Katalysator)
138 3234 2 114 Botschaftlänge des Nach-Kat Nox-Sensors stimmt nicht mit DLC Error of CAN-Receive-Frame AT1O1Vol NOX
der Spezifikation überein
DLC Fehler der CAN-Empfangsbotschaft AT1OG1Vol NOX

Sensor (SCR-System nach Katalysator; DPF-System nach
Katalysator); Botschaftslänge nicht korrekt


139 3234 9 117 Timeout der CAN-Empfangsbotschaft AT1OG1Vol; NOX Timeout Error of CAN-Receive-Frame AT1OG1Vol.
Sensor (SCR-System nach Katalysator; DPF-System nach
Katalysator)
140 523941 9 767 Ausfall der Nach-Kat Nox-Sensor Botschaft Timeout Error (BAM to packet) for CAN-Receive-Frame
Timeout (BAM to packet) der CAN-Empfangsbotschaft AT1OGCVol2.
AT1OGCVol2 information; Faktoren & Sensorkalibrierung für
NOX Sensor (SCR-System nach Katalysator; DPF-System
nach Katalysator)
141 523942 9 767 Kalibrierbotschaft 1 vom Nach-Kat Nox-Sensor ist Calibration message 1 of the after catalyst NOx sensor has
ausgefallen. failed.
142 523943 9 767 Broadcast Announce Message der Kalibrierbotschaft vom Timeout Error (PCK2PCK) for CAN-Receive-Frame
Nach-Kat Nox-Sensor ist ausgefallen AT1OGCVol2.
Timeout (PCK2PCK) der CAN-Empfangsbotschaft
AT1OGCVol2 information; Faktoren & Sensorkalibrierung für
NOX Sensor (SCR-System nach Katalysator; DPF-System
nach Katalysator)
167 523704 12 6-1-5 Timeout Error of CAN-Transmit-Frame EEC3 Timeout Error of CAN-Transmit-Frame EEC3
168 523935 12 763 Timeout der CAN-Sendebotschaft EEC3VOL1; Motor Timeout Error of CAN-Transmit-Frame EEC3VOL1; Engine
Sendebotschaften send messages
169 523936 12 764 Timeout der CAN-Sendebotschaft EEC3VOL2; Motor Timeout Error of CAN-Transmit-Frame EEC3VOL2; Engine
Sendebotschaften send messages
171 523212 9 3-3-3 Timeout der CAN-Empfangsbotschaft ComEngPrt; Engine Timeout Error of CAN-Receive-Frame ComEngPrt; Engine
Protection Protection
179 523240 9 527 Timeout der CAN-Empfangsbotschaft FunModCtl; Function Timeout CAN-message FunModCtl; Function Mode Control
Mode Control

198 523216 9 3-3-7 Timeout der CAN-Empfangsbotschaft PrHtEnCmd; Timeout Error of CAN-Receive-Frame PrHtEnCmd; pre-heat
Vorheiz-Anforderung, Motor Anforderung command, engine command

485
486

202 523793 9 6-7-8 Timeout der CAN-Empfangsbotschaft UAA10; AGS Sensor Timeout Error of CAN-Receive-Frame UAA10; AGS sensor
Service Botschaft service message
203 523794 9 6-7-8 Timeout der CAN-Empfangsbotschaft UAA11; AGS Sensor Timeout Error of CAN-Receive-Frame UAA11; AGS sensor
Daten data
212 523803 9 6-7-8 Timeout der CAN-Empfangsbotschaft RxEngPres; Status Timeout error of CAN Receive Message RxEngPres; Status
Brenner Luftpumpe Burner Air Pump
291 523776 9 119 Timeout der CAN-Empfangsbotschaft TSC1TE - aktiv Timeout Error of CAN-Receive-Frame TSC1TE - active
292 523777 9 119 Passiver Timeout der CAN-Empfangsboschaft TSC1TE; Passive Timeout Error of CAN-Receive-Frame TSC1TE;
Sollwertvorgabe Setpoint
299 523788 12 6-5-5 Timeout der CAN-Sendebotschaft TrbCH; Status Wastegate Timeout Error of CAN-Transmit-Frame TrbCH; Status
Wastegate
305 898 9 118 Timeout der CAN-Empfangsboschaft TSC1TE; Timeout Error of CAN-Receive-Frame TSC1TE; Setpoint
Sollwertvorgabe
306 520 9 1-1-9 Timeout der CAN-Empfangsbotschaft TSC1TR; Timeout Error of CAN-Receive-Frame TSC1TR; control
Sollwertvorgabe signal
313 523858 12 6-7-9 Timeout CAN-Botschaft "UAA11" wurde nicht gesendet Timeout Error of CAN-Transmit-Frame UAA11
No detail informationen!
322 523867 12 6-7-9 Timeout der CAN-Sendebotschaft UAA1 auf CAN 2; Ansteuerung Brenner Luftpumpe;_Timeout Error of
Ansteuerung Brenner Luftpumpe CAN-Transmit-Frame UAA1 on CAN A
360 523982 0 737 Leistungsstufen Diagnose abgeschaltet; Batteriespannung zu Powerstage diagnosis disabled; high battery voltage
hoch
361 523982 1 737 Leistungsstufen Diagnose abgeschaltet; Batteriespannung zu Powerstage diagnosis disabled; low battery voltage
niedrig

362 523090 2 329 Motorbremse Vorauswahlschalter; Plausibilitätsfehler Engine Brake Pre-Selection switch; Plausibility Error
376 630 12 281 Zugriffsfehler EEPROM-Speicher (Löschen) Access error EEPROM memory (delete)


377 630 12 281 Zugriffsfehler EEPROM-Speicher (Lesen) Access error EEPROM memory (read)
378 630 12 281 Zugriffsfehler EEPROM-Speicher (Schreiben) Access error EEPROM memory (write)
381 411 4 693 AGR Differenzdruck; Minimalwert unterschritten Physical range check low for EGR differential pressure
384 2791 12 4-1-5 Leistungsstufe Aktuator AGR Ventil; Übertemperatur Actuator EGR Valve; powerstage over temperature
387 523612 12 555 Interner Softwarefehler EMR; Injektion abgeschnitten Internal software error ECU; injection cut off
Drehmoment plaus. Fehler / ADC Monitoring Level 2, Notlauf
aktiviert
388 190 0 214 Überdrehzahl Detektion in der Komponente Engine Engine speed above warning threshold
Protection Overspeed detection in component engine protection
389 190 0 214 Motordrehzahl über Warnschwelle (FOC-Level 1) Engine speed above warning threshold (FOC-Level 1)
390 190 11 214 Motordrehzahl über Warnschwelle (FOC-Level 2) Engine speed above warning threshold (FOC-Level 2)
391 190 14 214 Motordrehzahl über Warnschwelle (Schubbetrieb) Engine speed above warning threshold (Overrun Mode)
411 108 11 2-9-2 Umgebungsluftdruck empfangen von einem CAN-Bus ist als DFC for CAN message
defekt gemeldet No detail informationen!
Detailinformationen fehlen!
412 108 3 2-9-2 Sensorfehler Umgebungsluftdruck; Signalbereich Sensor error ambient air pressure; signal range check high
überschritten
413 108 4 2-9-2 Sensorfehler Umgebungsluftdruck; Signalbereich Sensor error ambient air pressure; signal range check low
unterschritten
415 171 0 3-1-2 Umgebungstemperatursensor, Temperatur hat mnaximalen Environment temperature sensor, temperature above upper

physikalischen Grenzwert überschritten physical threshold
416 171 1 3-1-2 Umgebungstemperatursensor, Temperatur hat minimalen Physical Range Check low for Environment Temperature
Grenzwert unterschritten No detail informationen!

487
488

417 171 3 312 Sensorfehler SCR-System Umgebungslufttemperatur; Sensor error SCR-System environment temperature;
DPF-System Lufteintrittstemperatur; Signalbereich DPF-System air inlet temperature; signal range check high
überschritten
418 171 4 312 Sensorfehler SCR-System Umgebungslufttemperatur; Sensor error SCR-System environment temperature;
DPF-System Lufteintrittstemperatur; Signalbereich DPF-System air inlet temperature; signal range check low
unterschritten
419 190 8 212 Sensor Nockenwellendrehzahl; Signal gestört Sensor camshaft speed; disturbed signal
420 190 12 212 Sensor Nockenwellendrehzahl; kein Signal Sensor camshaft detection; out of range, signal disrupted; no
signal
421 190 2 213 Offsetfehler zwischen Kurbelwelle und Nockenwelle Offset angle between crank- and camshaft sensor is too
large.
422 190 8 212 Fehlerhaftes Kurbelwellensensorsignal Sensor crankshaft detection; out of range, signal disrupted;
Sensor Kurbelwellendrehzahl; Signal gestört disturbed signal
423 190 12 212 Fehlendes Kurbelwellensensorsignal Speed detection; out of range, signal disrupted
Sensor Kurbelwellendrehzahl; kein Signal Sensor crankshaft speed; no signal
455 975 5 2-3-8 Lüfter Aktuator (PWM Ausgang); Kabelbruch Fan actuator (PWM output); open load
457 975 3 2-3-8 Lüfter Aktuator(PWM Ausgang); Batteriekurzschluss Fan actuator (PWM output); short circuit to battery
458 975 4 2-3-8 Lüfter Aktuator (PWM Ausgang); Massekurzschluss Fan actuator (PWM output); short circuit to ground
459 1639 12 2-3-8 Lüfterdrehzahlsensor; elektrischer Fehler oder Signal gestört Fan speed sensor; electrical error or signal disturbed
460 1639 0 2-3-8 Sensorfehler Lüfterdrehzahl; Signalbereich überschritten Sensor error fan speed; signal range check high
461 1639 1 2-3-8 Sensorfehler Lüfterdrehzahl; Signalbereich unterschritten Sensor error fan speed; signal range check low
462 523602 0 2-3-8 Lüfterdrehzahl zu hoch; Warnschwelle erreicht High fan speed; warning threshold exceeded

463 523602 0 2-3-8 Lüfterdrehzahl zu hoch; Abschaltschwelle erreicht High fan speed; shut off threshold exceeded
464 97 3 228 Sensorfehler Wasser in Kraftstoff; Signalbereich Sensor error water in fuel; signal range check high
überschritten


465 97 4 228 Sensorfehler Wasser in Kraftstoff; Signalbereich Sensor error water in fuel; signal range check low.
unterschritten
472 94 3 216 Sensorfehler Kraftstoffvordruck; Signalbereich überschritten Sensor error low fuel pressure; signal range check high
473 94 4 216 Sensorfehler Kraftstoffvordrucksensor; Signalbereich Sensor error low fuel pressure; signal range check low
unterschritten
474 94 1 216 Kraftstoffvordruck zu niedrig; Warnschwelle erreicht Low fuel pressure; warning threshold exceeded
475 94 1 2-1-6 Kraftstoffvordruck zu niedrig; Abschaltschwelle erreicht Low fuel pressure; shut off threshold exceeded
486 523618 3 1-3-3 Getriebeöltemperatur; Kurzschluss gegen Batterie oder Gearbox oil temperature; Short circuit to battery or broken
Kabelbruch harness
487 523618 4 1-3-3 Getriebeöltemperatur; Kurzschluss gegen Masse Gearbox oil temperature; Short circuit to ground
488 523619 2 1-3-3 Abgastemperatur vor (SCR-CAT); Maximalwert überschritten Physical range check high for exhaust gas temperature
upstrem (SCR-CAT)
500 523915 0 1-6-5 HCI Dosierventil (DV1); Überstrom am Ende der HCI dosing valve (DV1); overcurrent at the end of the
Einspritzphase injection phase
501 523915 12 1-6-6 HCI Dosierventil (DV1); Leistungsstufe Übertemperature HCI dosing valve (DV1); powerstage over temperature
502 523915 3 1-5-9 Batteriekurzschluss Leistungsstufe HCI Dosierventil (DV1) HCI dosing valve (DV1); short circuit to battery
503 523915 3 1-6-4 Batteriekurzschluss Leistungsstufe plusseitig HCI HCI dosing valve (DV1); short circuit to battery high side
Dosierventil (DV1)
504 523915 4 1-5-9 HCI Dosierventil (DV1); Massekurzschluss HCI dosing valve (DV1); short circuit to ground
505 523915 11 1-6-4 Kurzschluss Leistungsstufe plusseitig Dosierventil (DV1) HCI dosing valve (DV1); short circuit high side powerstage
506 523916 2 7-1-9 Sensor Kraftstoffdruck nach HCI Dosierventil (DV1); Signal Sensor HCI dosing valve (DV1) downstream pressure;
unplausibel plausibility error
508 523916 0 7-1-9 Druck nach HCI Dosierventil (DV1) Maximalwert Physical range check high for HCI dosing valve (DV1)

überschritten; Abschaltung Regeneration downstream pressure; shut off regeneration
511 523916 1 7-1-9 Druck nach HCI Dosierventil (DV1) Minimalwert Physical range check low for HCI dosing valve (DV1)
unterschritten; Abschaltung Regeneration downstream pressure; shut off regeneration

489
490

514 523916 3 7-1-9 Sensorfehler Druck nach HCI Dosierventil (DV1); Sensor error HCI dosing valve (DV1) downstream pressure;
Signalbereich überschritten signal range check high
515 523916 4 7-1-9 Sensorfehler Drucksensor nach HCI Dosierventil (DV1), Sensor error HCI dosing valve (DV1) downstream pressure;
unterer Grenzwert unterschritten signal range check low
524 523917 3 7-1-8 Sensorfehler Druck vor DV1 & DV2; Signalbereich Sensor error DV1 & DV2 upstream pressure; signal range
überschritten check high
525 523917 4 7-1-8 Sensorfehler Druck vor DV1 & DV2; Signalbereich Sensor error DV1 & DV2 upstream pressure; signal range
unterschritten check low
534 523918 3 7-1-7 Sensorfehler Temperatur vor DV1 & DV2; Signalbereich Sensor error DV1 & DV2 upstream temperature; signal range
überschritten check high
535 523918 4 7-1-7 Sensorfehler Temperatur vor DV1 & DV2; Signalbereich Sensor error DV1 & DV2 upstream temperature; signal range
unterschritten check low
543 676 11 263 Relais Kaltstarthilfe: Heizflansch defekt (<4L alle Glühstifte Cold start aid relay error.
defekt)
Relais Kaltstarthilfe defekt
544 676 11 263 Relais Kaltstarthilfe Kabelbruch, (,Vorheiz-Sicherung),... Cold start aid relay open load
Relais Kaltstarthilfe Kabelbruch
545 729 5 263 Relais Kaltstarthilfe Kabelbruch Cold start aid relay open load
547 729 12 263 Relais Kaltstarthilfe; Leistungsstufe Übertemperatur Cold start aid relay; over temperature error
549 729 3 263 Vorheizer Ansaugluft; Kurzschluss gegen Batterie Intake Air Heater Device; Short circuit to battery
551 729 4 263 Ansaugluftvorwärmer; Kurzschluss gegen Masse auf CJ945. Air intake heater; Short circuit to ground error for powerstage
on CJ945.
559 523895 13 1-5-8 Fehlender Injektor Korrekturwert (IMA) Injektor 1 (nach Check of missing injector adjustment value programming

Zündfolge) (IMA) injector 1 (in firing order).
560 523896 13 1-5-8 Fehlender Injektor Korrekturwert (IMA) Injektor 2 (nach check of missing injector adjustment value programming


565 523350 4 151 Injector Zylinder-Bank 1; Kurzschluss Injector cylinder-bank 1; short circuit
566 523352 4 152 Injector Zylinder-Bank 2; Kurzschluss Injector cylinder-bank 2; short circuit
567 523354 12 153 Injektoransteuerung defekt Injector powerstage output defect

568 651 5 154 Injektor 1 (nach Zündfolge); Stromunterbrechung Injector 1 (in firing order); interruption of electric connection
580 651 3 154 Injektor 1 (nach Zündfolge); Kurzschluss Injector 1 (in firing order); short circuit

592 523615 5 135 Zumesseinheit (Kraftstoffsystem); Kabelbruch Metering unit (Fuel-System); open load

491
492

593 523615 12 135 Zumesseinheit (Kraftstoffsystem); Leistungsstufe Metering unit (Fuel-System); powerstage over temperature
Übertemperatur
594 523615 3 135 Zumesseinheit (Kraftstoff-System); Batteriekurzschluss Metering unit (Fuel-System); short circuit to battery highside
plusseitig
595 523615 4 135 Zumesseinheit (Kraftstoffsystem); Massekurzschluss Metering unit (Fuel-System); short circuit to ground high side
plusseitig
596 523615 3 135 Zumesseinheit (Kraftstoffsystem); Batteriekurzschluss Metering unit (Fuel-System); short circuit to battery low side
minusseitig
597 523615 4 135 Zumesseinheit (Kraftstoffsystem); Massekurzschluss Metering Unit (Fuel-System); short circuit to ground low side
minusseitig
598 523615 3 1-3-5 Kraftstoffzumesseinheit; Rücklesespannung über Grenzwert; Metering unit, short circuit to battery
Kurzschluss gegen Batterie
599 523615 4 1-3-5 Kraftstoffzumesseinheit; Rücklesespannung unter Grenzwert; Metering unit, short circuit to ground
Kurzschluss gegen Masse
604 1323 12 2-4-1 Zu viele Fehlzündungen in Zylinder 1 (nach Zündfolge) Too many recognized misfires in cylinder 1 (in firing order)
erkannt
erkannt
erkannt
erkannt
erkannt

erkannt
610 1322 12 2-4-1 Zu viele Fehlzündungen in mehreren Zylindern erkannt Too many recognized misfires in more than one cylinder


612 523612 12 555 Steuergeräte interner Software Fehler Internal ECU monitoring detection reported error
613 523612 12 555 Steuergeräte interner Software Fehler ECU reported internal software error
Internal ECU monitoring detection reported error
615 523612 12 555 Steuergeräte interner Software Fehler ECU reported internal software error.
619 523612 12 555 Einspritzsystem, elektrischer Fehler im Bereich der Injektoren Injection system,electrical error injectors
629 523612 12 555 Plaubilisierungsfehler Fahrpedal Spannung Diagnostic fault check to report the accelerator pedal position
error
630 523612 12 555 Synchronisationsfehler der Motordrehzahl Diagnostic fault check to report the engine speed error
631 523612 12 555 Plausibilisierungsfehler bei der Bestromung der Injektoren Error in the plausibility of the injection energizing time
632 523612 12 555 Plausibilisierungsfehler des Starts der Bestromungswinkel Error in the plausibility of the start of energising angles
633 523612 12 555 Plausibiltätsfehler ZFC Diagnostic fault check to report the error due to non
plausibility in ZFC
634 523612 12 555 Diagnosis fault check to report the demand for normal mode Diagnosis fault check to report the demand for normal mode

due to an error in the PoI2 quantity due to an error in the PoI2 quantity
635 523612 12 555 Diagnosis fault check to report the error to demand for an Diagnosis fault check to report the error to demand for an
ICO due to an error in the PoI2 shut-off ICO due to an error in the PoI2 shut-off

493
494

636 523612 12 555 Diagnosis fault check to report the error to demand for an Diagnosis fault check to report the error to demand for an
ICO due to an error in the PoI3 efficiency factor ICO due to an error in the PoI3 efficiency factor
637 523612 12 555 Steuergeräte interner Software Fehler Internal ECU monitoring detection reported error
638 523612 12 555 Überwachung der Einspritzmengenkorrektur Monitoring of Fuel Quantity Correction
639 523612 12 555 Diagnostic fault check to report the plausibility error in rail Diagnostic fault check to report the plausibility error in rail
pressure monitoring pressure monitoring
640 523612 12 555 Diagnostic fault check to report the error due to torque Diagnostic fault check to report the error due to torque
comparison comparison
641 523612 12 555 Diagnosis of curr path limitation forced by ECU monitoring Diagnosis of curr path limitation forced by ECU monitoring
level 2 level 2
642 523612 12 555 Diagnosis of lead path limitation forced by ECU monitoring Diagnosis of lead path limitation forced by ECU monitoring
level 2 level 2
643 523612 12 555 Diagnosis of set path limitation forced by ECU monitoring Diagnosis of set path limitation forced by ECU monitoring
level 2 level 2.
644 523612 3 555 Überwachung; Versorgungsspannung zu hoch Reported Over Voltage of Supply
646 523612 4 555 Überwachung; Versorgungsspannung zu niedrig Reported UnderVoltage of Supply

648 523008 1 4-2-4 Manipulationskontrolle wurde ausgelöst Manipulation control was triggered
649 523008 2 4-2-4 Manipulationskontrolle meldet Timeout Fehler Timeout error in Manipulation control
714 523612 12 555 Diagnostic fault check to report WDA active due to errors in Diagnostic fault check to report WDA active due to errors in
query-/response communication query-/response communication

715 523612 12 555 Diagnostic fault check to report ABE active due to Diagnostic fault check to report ABE active due to
undervoltage detection undervoltage detection


716 523612 12 555 Diagnostic fault check to report ABE active due to Diagnostic fault check to report ABE active due to
overvoltage detection overvoltage detection
717 523612 12 555 Diagnostic fault check to report WDA/ABE active due to Diagnostic fault check to report WDA/ABE active due to
unknown reason unknown reason
732 100 3 224 Sensorfehler Öldruck; Signalbereich überschritten Sensor error oil pressure; signal range check high
733 100 4 224 Sensorfehler Öldruck, Signalbereich unterschritten Sensor error oil pressure sensor; signal range check low
734 100 0 2-3-1 Öldruck zu hoch; Warnschwelle erreicht. High oil pressure; warning threshold exceeded.
735 100 0 2-3-1 Öldruck zu hoch; Abschaltschwelle erreicht High oil pressure; shut off threshold exceeded
736 100 1 231 Öldruck zu niedrig; Warnschwelle erreicht Low oil pressure; warning threshold exceeded
737 100 1 231 Öldruck zu niedrig; Abschaltschwelle erreicht Low oil pressure; shut off threshold exceeded
743 175 3 1-4-4 Sensorfehler Öltemperatur; Signalbereich überschritten Sensor error oil temperature; signal range check high
744 175 4 1-4-4 Sensorfehler Öltemperatur; Signalbereich unterschritten Sensor error oil temperature; signal range check low
745 175 0 1-4-4 Öltemperatur zu hoch; Warnschwelle erreicht High oil temperature; warning threshold exceeded
746 175 0 1-4-4 Öltemperatur zu hoch; Abschaltschwelle erreicht High oil temperature; shut off threshold exceeded
747 1237 2 145 Überbrückungsschalter; Signal unplausibel Override switch; plausibility error.
750 107 3 1-3-6 Sensorfehler Luftfilter Differenzdruck; Batteriekurzschluss Sensor error airfilter differential pressure; short circuit to
battery
751 107 0 1-3-6 Sensorfehler Luftfilter Differenzdruck; Massekurzschluss Sensor error airfilter differential pressure; short circuit to
ground
752 107 0 136 Luftfilter Differenzdrucksensor; Kurzschluss gegen Masse Air filter differential pressure; short circuit to ground
753 523919 2 6-9-4 DPF Brenner Luftpumpe Drucksensor, Signal unplausibel DPF burner air pump pressure sensor, plausibility error

755 523919 0 6-9-4 DPF Brenner Luftpumpe Drucksensor, Druck über oberer DPF burner air pump pressure sensor, pressure above upper
Abschaltschwelle shutoff threshold

495
496

758 523919 1 6-9-4 DPF Brenner Luftpumpe Drucksensor, Druck unter unterer DPF burner air pump pressure sensor, pressure below lower
761 523919 3 6-9-4 DPF Brenner Luftpumpe Drucksensor, Kurzschluss gegen DPF burner air pump pressure sensor, short circuit to battery
Batterie oder Kabelbruch or open load
762 523919 4 6-9-4 DPF Brenner Luftpumpe Drucksensor, Kurzschluss gegen DPF burner air pump pressure sensor, short circuit to ground
Masse
763 523920 2 7-1-6 Abgasdrucksensor vor Brenner, Signal unplausibel Exhaustgaspressure upstream burner, plausibility error
765 523920 0 7-1-6 Abgasdrucksensor vor Brenner, Druck über oberer Exhaustgaspressure upstream burner, pressure above upper
770 523920 3 7-1-6 Abgasdrucksensor vor Brenner, Kurzschluss gegen Batterie Exhaustgaspressure upstream burner, short circuit to battery
oder Kabelbruch or open load
771 523920 4 7-1-6 Abgasdrucksensor vor Brenner, Kurzschluss gegen Masse Exhaustgaspressure upstream burner, short circuit to ground
772 102 2 223 Ladeluftdruck nach Ladeluftkühler, Signal unplausibel Pressure downstream charge air cooler, plausibility error
774 102 1 223 Ladeluftdruck nach Ladeluftkühler, Druck unter unterem Pressure downstream charge air cooler, pressure below
physikalischem Grenzwert lower physical threshold
776 102 3 223 Ladeluftdruck nach Ladeluftkühler, Kurzschluss gegen Pressure downstream charge air cooler, short circuit to
Batterie oder Kabelbruch battery or open load
777 102 4 223 Ladeluftdruck nach Ladeluftkühler, Kurzschluss gegen Masse Pressure downstream charge air cooler, short circuit to
ground
791 411 0 693 Differenzdrucksensorwert AGR Venturiventil über Grenzwert, delta pressure across venturi in EGR line above physical high
zu hoch limit
signal range check low error of pressure control valve
AD-channel



792 411 1 693 Differenzdruck Venturieinheit (AGR); Maximalwert delta pressure across venturi in EGR line below physical low
überschritten limit
Differenzdrucksensorwert AGR Venturiventil über Grenzwert,
zu niedrig
793 411 11 693 Plausibilitätsprüfung Fehler für AGR-Delta-Drucksensor. Plausibility Check fault for deviation of desired and actual
EGR-mass flow, where the latter is calculated out of
EGR Delta Pressure Sensor.
795 411 3 693 Sensor Differenzdruck Venturieinheit (AGR), CAN Signal Sensor error differential pressure Venturiunit (EGR), signal
ungültig. range check low.
Sensorfehler Differenzdruck Venturieinheit (AGR),
Signalbereich überschritten.
796 411 4 693 Sensorfehler Differenzdruck Venturieinheit (AGR), Sensor error differential pressure Venturiunit (EGR), signal
Signalbereich übererschritten. range check high.
Sensorfehler Differenzdruck Venturieinheit (AGR),
Signalbereich unterschritten.
805 524025 14 8-4-5 Partikelfilter Regeneration. Particulate filter regeneration.

Regeneration nach Zeit X nicht erfolgreich (Der Fehler tritt Regeneration after time X is not successful (The error occurs
auf, wenn die Regeneration mehrmals when the regeneration times
(3x) über die max. erlaubte Regenerationszeit abgebrochen (3x) over the max. has been aborted allowed recovery time).
worden ist).
807 3253 2 692 Differenzdrucksensor DPF, Plausibilisierungsfehler Differential pressure DPF, plausibility error
809 3251 0 692 Differenzdruck DPF Maximalwert überschritten. Differential pressure DPF maximum value is exceeded
Abschaltung Regeneration.
810 3251 0 692 Differenzdrucksensor DPF Differential pressure sensor across DPF exceeds warning
Physikalischer Wert über oberem Grenzwert high limit
812 3251 1 692 Differenzdruck DPF Minimalwert unterschritten. Differential pressure DPF, pressure below lower shutoff

Abschaltung Regeneration. threshold.
813 3251 1 692 Differenzdrucksensor DPF. Differential pressure DPF, pressure below lower warning
Physikalischer Wert unter unterem Grenzwert. threshold.

497
498

814 3253 3 692 Sensorfehler Differenzdruck (DPF); Signalbereich Electrical error differential pressure (DPF).
überschritten (signal range check high)
815 3253 4 692 Sensorfehler Differenzdruck (DPF). Electrical error differential pressure (DPF).
Signalbereich überschritten signal range check low.
825 523009 9 253 Druckbegrenzungsventil (DBV) hat seine maximale Anzahl The pressure relief valve (PRV) has reached the number of
an Schaltvorgängen erreicht. allowed activations.
826 523470 2 146 Druckbegrenzungsventil (DBV) ist durch Druckanstieg zum Pressure relief valve is forced to open, perform pressure
Öffnen gezwungen worden. increase.
827 523470 2 146 Druckbegrenzungsventil (DBV) hat wegen Druckstoß Pressure Relief Valve (PRV) forced to open. Performed by
zwangsgeöffnet. pressure increase.
828 523470 12 146 Druckbegrenzungsventil (DBV) geöffnet. Pressure Relief Valve (PRV) forced to open.
Abschaltung Shutoff conditions.
829 523470 12 146 Druckbegrenzungsventil (DBV) geöffnet. Pressure Relief Valve (PRV) forced to open.
Warnung Warning conditions.
830 523470 14 146 Druckbegrenzungsventil (DBV) geöffnet Open Pressure Relief Valve (PRV)
831 523470 11 146 Druckbegrenzungsventil (DBV) ist geöffnet Pressure Relief Valve (PRV) error; Rail pressure out of
tolerance range.
Pressure Relief Valve (PRV) is open.
832 523470 11 146 Raildruck außerhalb Toleranzbereich Rail pressure out of tolerance range.
Das DBV kann in diesem Betriebspunkt nicht von einem The PRV can not be opened at this operating point with a
Druckstoß geöffnet werden pressure shock.
833 523009 10 2-5-3 Druckbegrenzungsventil Rail (PRV) hat seine Maximalzeit im Open time of Pressure Relief Valve (PRV) for wear out
geöffneten Zustand erreicht. monitoring had exceeded

834 523906 5 7-6-1 Elektrische Kraftstoff Vorförderpumpe nicht angeschlossen Electrical fuel pre - supply pump; open load
oder Kabelbruch.


835 523906 12 7-6-1 Elektrische Kraftstoff Vorförderpumpe Übertemperaturfehler Electrical fuel pre - supply pump.
ECU Treiberstufe. ECU powerstage over temperature.
836 523906 3 7-6-1 Elektrische Kraftstoff - Vorförderpumpe. Electrical fuel pre - supply pump; short circuit to battery
Kurzschluss gegen Batterie.
837 523906 4 7-6-1 Elektrische Kraftstoff - Vorförderpumpe. Electrical fuel pre - supply pump.
Kurzschluss gegen Masse. Short circuit to ground.
839 523450 4 1-4-3 Mehrstufenschalter feste Motordrehzahl; Batteriekurzschluss Multiple Stage Switch constant speed; short circuit to battery
847 1176 0 139 Drucksensor vor Turbine,bei Überprüfung Physikalischer Pressure sensor upstream turbine, Physical Range Check
Messbereich nach oben überschritten . high.
848 1176 1 139 Drucksensor vor Turbine; Maximalwert überschritten Pressure sensor upstream turbine, Physical Range Check
low.
849 1176 3 141 Drucksensor vor Turbine. Bei Signalcheck (SRC) Pressure sensor upstream turbine, signal range check (SRC)
Spannungssignal über oberer Grenze. high.
850 1176 4 141 Drucksensor vor Turbine. Bei Signalcheck (SRC) Pressure sensor upstream turbine, signal range check (SRC)
Spannungssignal unter unterer Grenze. low.
856 523613 0 134 Maximale positive Abweichung Raildruck überschritten. Rail pressure metering unit, Positive governor deviation.
857 523613 0 134 Positive Raildruckabweichung in Zumesseinheit Warngrenze Rail pressure metering unit, Rail pressure disrupted.
überschritten (RailMeUn1) Maximum positive deviation of rail pressure exceeded.
Maximale positive Abweichung Raildruck überschritten
(RailMeUn0)
858 523613 0 134 Leckagedetektion Railsystem (RailMeUn10) Rail pressure metering unit, Rail pressure disrupted.
Maximale positive Raildruckabweichung in Zumesseinheit Maximum positive deviation of rail pressure in metering unit
überschritten (RailMeUn1) exceeded (RailMeUn1).

859 523613 0 134 Negative Raildruckabweichung in Zumesseinheit Rail pressure metering unit, Rail pressure disrupted.
Warngrenze unterschritten (RailMeUn2 Railsystem leakage detected.
Leckage Railsystem (RailMeUn10)

499
500

861 523613 1 134 Minimaler Raildruck unterschritten (RailMeUn3) Rail pressure metering unit, Minimum rail pressure exceeded
Negative Raildruckabweichung in Zumesseinheit Stufe 2 (RailMeUn3)
unterschritten (RailMeUn22) Negative deviation of rail pressure second stage
(RailMeUn22)
862 523613 0 134 Maximaler Raildruck überschritten (RailMeUn4) Rail pressure metering unit, Maximum rail pressure
exceeded.
864 523613 2 134 Sollwert Zumesseinheit im Schubbetrieb unplausibel. Rail pressure metering unit, Setpoint of metering unit in
overrun mode not plausible.
876 523470 7 146 Maximaler Raildruck überschritten (DBV). Maximum rail pressure exceeded (PRV).
877 157 3 147 Sensorfehler Raildrucksensor, Sensor error rail pressure.

obere Spannungsgrenze überschritten. Sensor voltage above upper limit.
878 157 4 147 Sensorfehler Raildrucksensor, Sensor error rail pressure.

untere Spannungsgrenze überschritten. Sensor voltage below lower limit.
881 523633 11 1-4-9 Wirkungsgradüberwachung; cat efficiency error Lonterm adaption factor below threshold
882 523633 11 1-4-9 Wirkungsgradüberwachung; cat efficiency error within the Nox conversion rate insufficient (SCR-Cat defect, bad AdBule
range 1 (Nox-Umsatzrate zu gering, SCR-Kat defect, quality)
mangelhafte AdBlue qualität)
Nox Konvertierungsrate ungenügend (SCR-Kat defekt,
mangelhafte AdBlue Qualität)
883 523633 11 1-4-9 Wirkungsgradüberwachung; cat efficiency error within the Nox conversion rate insufficient (SCR-Cat defect, bad AdBule
range 2 (Nox-Umsatzrate zu gering, SCR-Kat defect, quality); temperature range 1
mangelhafte AdBlue qualität)

Nox Konvertierungsrate ungenügend (SCR-Kat defekt,
mangelhafte AdBlue Qualität); Temperaturbereich 1
887 3234 11 1-8-4 Nox-Sensor nach SCR-Kat; NOx Sensor defekt bzw. hängt DFC for plausibility error Min for NOx sensor downstream of
und liefert keine plausibelen Messwerte. SCR Cat.

889 3224 1 1-8-5 Nox-Sensor vor SCR-Kat; NOx Sensor liefert keine DFC for plausibility error Max for NOx sensor upstream of
plausibelen Messwerte. SCR Cat


892 4345 11 2-3-6 Sensor Druck Rücklaufleitung (SCR); Signal unplausibel Sensor backflow line pressure (SCR); plausibility error
893 4343 11 8-7-1 Druckaufbau durch Förderpumpe fehlerhaft (SCR) SCR Monitoring; Pressure stabilisation error, general
pressure check error (SCR)
894 4374 13 8-7-2 Vorhaltedruck AdBlue Dosierventil schwankt (SCR) Pressure stabilisation error dosing valve (SCR)
897 523632 16 8-7-5 Pumpendruck SCR Dosiereinheit zu hoch. Pump pressure SCR metering unit too high.
898 523632 18 8-7-6 Pumpendruck SCR Dosiereinheit zu niedrig Pump pressure SCR metering unit too low
899 523632 0 8-7-7 Druck Überlastung des SCR-System. Pressure overload of SCR-System.
900 523632 1 8-7-8 Druckaufbau im SCR-System fehlerhaft. Pressure build-up error SCR-System.
903 4365 0 8-8-1 DEF Tank Temperatur zu hoch. DEF tank temperature too high.
905 3241 0 8-8-3 Sensor Abgastemperatur vor SCR Katalysator; Signal Sensor SCR catalyst upstream temperature too high;
unplausibel hoch. plausibility error.
908 3361 7 8-8-6 AdBlue Dosiermodul blockiert (SCR) AdBlue dosing valve blocked (SCR)
914 523720 2 1-4-8 AdBlue Supplymodul Heizertemperatur; Signal unplausibel Urea supply module heater temperature; plausibility error
(Normalbetrieb). (normal condition).
915 523720 2 1-4-8 Sensor Heizertemperatur AdBlue Supplymodul; Signal Sensor urea supply module heater temperature; plausibility
unplausibel (Kaltstart) error (cold start condition)
916 523721 2 6-8-9 Sensor AdBlue Supplymodul Temperatur; Signal unplausibel Sensor urea supply module temperature; plausibility error
(Normalbetrieb) (normal condition)
917 523721 2 6-8-9 Sensor AdBlue Supplymodul Temperatur; Signal unplausibel Sensor urea supply module temperature; plausibility error
(Kaltstart) (cold start condition)

918 523981 11 2-4-3 Heizung AdBlue-Tank ohne Funktion (Aufheizphase). SCR plausibility, OBD and diagnosis; Stuck in range check of
Urea tank temperature sensor
Urea-tank without heating function (heating phase)

501
502

919 523330 14 1-3-1 Wegfahrsperrenschlüssel ungültig. Immobilizer status; fuel blocked
Status Wegfahrsperre; Kraftstoffzufuhr gesperrt.
925 523720 8 148 SCR: Dutycycle Temperatur Heizer des Supplymoduls ist Urea supply module heater temperature; duty cycle in failure
ausserhalb der Grenzen range.
AdBlue Supplymodul Heizertemperatur; Duty Cycle fehlerhaft
926 523720 8 148 SCR: Dutycycle Temperatur des Heizers Supplymodul nicht Urea supply module heater temperature; duty cycle in invalid
gültig range.
AdBlue Supplymodul Heizertemperatur; Duty Cycle im
ungültigen Bereich
927 523721 11 689 SCR: Temperaturmessung trotz Anfrage durch ECU nicht Urea supply module temperature measurement not available.
erfolgreich.
AdBlue Supplymodul Temperaturmessung nicht verfügbar.
928 523722 8 691 SCR: Periode des PWM vom Supplymodul ist nicht in den Urea supply module PWM signal; period outside valid range.
Grenzen
AdBlue Supplymodul PWM Signal; Periode außerhalb des
gültigen Bereichs
929 523722 8 691 SCR. Kein gültiges PWM Signal vom Supplymodul Detect faulty PWM signal from Supply Modul.
empfangen.
930 523721 8 689 Kein gültiges PWM Signal vom DEF Supplymodul Urea supply module temperature; duty cycle in failure range.
empfangen.
931 523721 8 689 AdBlue Supplymodul Temperatur; Duty Cycle im ungültigen Urea supply module temperature; duty cycle in invalid range.
Bereich.
932 29 3 1-2-6 Handgasschalter; Batteriekurzschluss Handthrottle idle validation switch; short circuit to battery
935 91 3 2-2-6 Sensorfehler Fahrpedal. Sensor error accelerator pedal.

Signalbereich überschritten. signal range check high.
937 29 4 1-2-6 Handgasschalter; Massekurzschluss Handthrottle idle validation switch; short circuit to ground


940 91 4 2-2-6 Sensorfehler Fahrpedal. Sensor error accelerator pedal.
Signalbereich unterschritten. Signal is below the range.
942 523921 3 7-1-4 Sensorfehler Brennertemperatur; Signalbereich überschritten Sensor error burner temperature; signal range check high
943 3532 3 1-2-7 Sensorfehler AdBlue Tanklevelsensor; Signalbereich Sensor error urea tank level; signal range check high
überschritten.
Sensorfehler AdBlue Tanklevel; Signalbereich überschritten.
944 523921 4 7-1-4 Sensorfehler Brennkammertemperatur; Signalbereich Sensor error burner temperature; signal range check low
unterschritten
945 3532 4 1-2-7 Sensorfehler AdBlue Tanklevel; Signalbereich unterschritten. Sensor error urea tank level; signal range check low
946 1079 13 282 Ausfall der Sensorversorgungsspannung 1 Failure of sensor supply voltage 1.
956 677 3 512 Starterrelais plusseitig; Batteriekurzschluss Starter relay high side.
Short circuit to battery.
957 677 4 512 Starterrelais plusseitig; Massekurzschluss. Starter relay; short circuit.
958 677 5 512 Starterrelais; Kabelbruch. Starter relay; no load error.
959 677 12 512 Starter Relais; Leistungsstufe Übertemperatur Starter relay: Powerstage over temperature.
960 677 3 512 Starterrelais minusseitig: Batteriekurzschluss Starter relay: short circuit to battery.
961 677 4 512 Starterrelais minusseitig: Massekurzschluss. Starter relay: short circuit to ground.
965 523922 3 7-1-5 Shut Off Valve; Batteriekurzschluß Burner shut of valve; short circuit to battery
969 624 5 5-1-3 Diagnoselampe; Kabelbruch SVS lamp; open load

970 624 12 5-1-3 Diagnoselampe: Leistungsstufe Übertemperatur SVS lamp: powerstage over temperature

503
504

971 624 3 5-1-3 Diagnoselampe; Batteriekurzschluß SVS lamp; short circuit to battery
972 624 4 5-1-3 Diagnoselampe; Massekurzschluss SVS lamp; short circuit to ground
973 523612 14 555 Softwarereset CPU SWReset_0 Softwarereset CPU SWReset_0

976 91 11 2-2-6 Plausibilitätfehler zwischen APP1 und APP2 oder APP1 und Plausibility error between APP1 and APP2 or APP1 and idle
Leergasschalter. switch.
978 29 2 1-2-6 Plausibilitätsfehler zwischen Sensor und Leergasschalter bei Plausibility error between sensor and idle switch, Acceleration
Fahrpedalerkennung. Pedal Detection.
Im Falle von Handgas mit Leergasschalter, ist dies die In case of Hand Throttle with Low Idle Switch,
Plausibilitätsprüfung it is the plausibility check between hand throttle and idle
zwischen Handgas und Leergasschalter. switch.
980 523550 12 515 T50 Starterschalter zu lange aktiv. Terminal 50 was operated too long
981 172 3 2-2-6 Sensorfehler Ansauglufttemperatursensor, oberer Grenzwert Air flow temperature sensor; short circuit to battery or open
überschritten. load.
Sensor Luftmengentemperatur; Batteriekurzschluss oder
Kabelbruch
982 172 4 2-2-6 Sensorfehler Ansauglufttemperatursensor, unterer Grenzwert Air flow temperature sensor; short circuit to ground
unterschritten
Sensor Luftmengentemperatur; Massekurzschluss
986 523921 0 7-1-4 Brennertemperatur; Temperatur über oberer Burner temperature, temperature above upper shutoff
Abschaltschwelle threshold
989 523921 1 7-1-4 Brennertemperatur; Temperatur unter unterer Burner temperature, temperature below lower shutoff

Abschaltschwelle threshold


992 105 1 128 Temperatur nach Ladeluftkühler; Temperatur unter unterer Charged Air cooler down stream temperature.
physikalischer Grenze Temperature below lower physical threshold.
994 105 3 128 Sensorfehler Ladelufttemperatur; Signalbereich überschritten Electrical error charged air temperature.
Signal range check high.(SRC)
995 105 4 128 Sensorfehler Ladelufttemperatur; Signalbereich Electrical error charged air temperature.
unterschritten Signal range check low.
996 105 0 233 Ladelufttemperatur Grenzwert überschritten; Warnmeldung Charged air cooler temperature. System reaction initiated.
wird generiert High charged air cooler temperature. Warning threshold
Ladelufttemperatur zu hoch; Warnschwelle erreicht exceeded.
997 105 0 233 Ladelufttemperatur zu hoch; Abschaltschwelle erreicht Low charged air cooler temperature.
Shut off threshold exceeded.
998 105 11 1-2-8 Diagnostic fault check for charged air cooler downstream Diagnostic fault check for charged air cooler downstream
temperature sensor temperature sensor
Detailinformationen fehlen! No detail informationen!
1007 412 3 682 Sensorfehler Temperatur nach AGR Kühler; Signalbereich Electrical error EGR cooler downstream temperature.
überschritten Signal range check high.
1008 412 4 682 Sensorfehler Temperatur nach AGR Kühler; Signalbereich electrical error EGR cooler downstream temperature.
unterschritten Signal range check low.
1011 523960 0 771 Abgastemperatur nach AGR Kühler; Maximalwert Physical range check high for EGR cooler downstream
überschritten temperature.
1012 523960 1 771 Abgastemperatur nach AGR Kühler; Minimalwert Physical range check low for EGR cooler downstream
unterschritten temperature.
1014 5763 6 594 Aktuatorfehler AGR Ventil (2.9;3.6) Drosselklappe Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve
(4.1;6.1;7.8); Signalbereich überschritten (4.1;6.1;7.8).
Signal range check high.

1015 520521 5 594 Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve
(4.1;6.1;7.8); signal range check low.

505
506

1016 5763 7 594 Position AGR Ventil (2.9;3.6) Drosselklappe (4.1;6.1;7.8) Actuator position for EGR-Valve (2.9;3.6) or Throttle-Valve
unplausibel (4.1;6.1;7.8) not plausible.
1022 5763 6 5-9-4 Aktuatorfehler AGR Ventil (2.9;3.6) Drosselklappe Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve
(4.1;6.1;7.8), Signalbereich überschritten (4.1;6.1;7.8); signal range check high
1023 5763 5 5-9-4 Aktuatorfehler AGR Ventil (2.9;3.6) Drosselklappe Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve
(4.1;6.1;7.8); Signalbereich unterschritten (4.1;6.1;7.8); signal range check low
1024 5763 3 594 Lagesensorfehler Aktuator AGR Ventil (2.9;3.6) Position sensor error of actuator EGR-Valve (2.9;3.6) or
Drosselklappe (4.1;6.1;7.8), Signalbereich überschritten Throttle-Valve (4.1;6.1;7.8).
Signal range check high.
1025 5763 4 594 Lagesensorfehler Aktuator AGR Ventil (2.9;3.6) Position sensor error actuator EGR-Valve (2.9;3.6) or
Drosselklappe (4.1;6.1;7.8), Signalbereich unterschritten Throttle-Valve (4.1;6.1;7.8).
Signal range check low.
1026 4769 2 684 Abgastemperatur nach DOC; Signal unplausibel Temperature downstream DOC, plausibility error
1029 4766 0 684 Abgastemperatur nach DOC; Temperatur über Temperature downstream DOC, temperature above upper
Abschaltgrenze shutoff threshold
1030 4766 0 684 Abgastemperatur nach DOC; Temperatur über Warngrenze Temperature downstream DOC, temperature above upper
warning threshold
1034 4769 3 684 Sensorfehler Abgastemperatursensor nach (DOC), oberer Sensor error exhaust gas temperature downstream (DOC);
Grenzwert überschritten signal range check high
1035 4769 4 684 Sensorfehler Abgastemperatur nach (DOC); Signalbereich Sensor error exhaust gas temperature downstream (DOC);
unterschritten signal range check low
1036 4768 2 683 Sensor Abgastemperatur vor DOC; Signal unplausibel Temperature upstream DOC, plausibility error
1039 4765 0 683 Abgastemperatur vor (DOC); Maximalwert überschritten Temperature upstream DOC, temperature above upper
shutoff threshold
1040 4765 0 683 Abgastemperatursensor vor DOC über oberen Temperature upstream DOC, temperature above upper

Warngrenzwert warning threshold


1044 4768 3 683 Abgastemperatursensor vor (DOC) Spannung zu hoch Electrical error exhaust gas temperature upstream (DOC);
Sensorfehler Abgastemperatur vor (DOC); Signalbereich signal range check high
überschritten
1045 4768 4 683 Abgastemperatursensor vor (DOC) Spannung zu niedrig Electrical error exhaust gas temperature upstream (DOC);
Sensorfehler Abgastemperatur vor (DOC); Signalbereich signal range check low
unterschritten
1047 3248 4 6-8-5 Sensorfehler Abgastemperatur nach Partikel Filter; Sensor error particle filter downstream temperature; signal
Signalbereich unterschritten range check low
1067 1180 3 5-5-6 Sensorfehler Abgastemperatursensor, oberer Grenzwert Sensor error exhaust gas temperature upstream turbine;
überschritten signal range check high
Sensorfehler Abgastemperatur vor Turbine; Signalbereich
überschritten
1068 1180 4 5-5-6 Sensorfehler Abgastemperatursensor, unterer Grenzwert Sensor error exhaust gas temperature upstream turbine;
unterschritten signal range check low
Sensorfehler Abgastemperatur vor Turbine; Signalbereich
unterschritten
1069 4360 0 668 Abgastemperatur vor SCR Katalysator; Physikalischer Wert Exhaust temperature upstream SCR-Cat, temperature above
hat obere Grenze überschritten upper physical threshold
1070 4360 1 668 Abgastemperatur vor SCR Katalysator; Minimalwert Sensed exhaust temperature before SCR-Cat is < physical
unterschritten low limit
1072 4361 3 668 SCR: Signalrange Check Kattemperatur Ubatt Sensor error urea catalyst exhaust gas temperature
Sensorfehler Abgastemperatur vor SCR Katalysator; upstream; signal range check high
Signalbereich überschritten
1073 4361 4 668 SCR: Signalrange Check Kattemperatur Masse Sensor error urea catalyst exhaust gas temperature
Sensorfehler Abgastemperatur vor SCR Katalysator; upstream; signal range check low

Signalbereich unterschritten

507
508

1074 1761 14 1-2-7 Urea Tanklevelsensor; AdBlue Tanklevel unter Grenzwert Urea tank level; warning threshold exceeded
(Verbleibender Tankfüllstand < 5%)
AdBlue Tanklevel; Warnschwelle erreicht
1075 3361 6 677 SCR: Strom des Dosierventils am Ende einer Einspritzung zu Urea dosing valve; power at the end of injection too high
hoch
AdBlue Dosierventil; Strom am Ende der Einspritzphase zu
hoch
1077 3361 3 677 SCR: Kurzschluß gegen Ubatt an Lowside Schalter des Urea dosing valve; short circuit to battery on low side
Dosierventils
AdBlue Dosieventil; Batteriekurzschluss plusseitig
1078 3361 3 677 AdBlue Dosierventil; Batteriekurzschluss oder Kabelbruch Urea dosing valve; short circuit to battery or open load on
plusseitig high side
1079 3361 4 677 SCR: Kurzschluß gegen Masse oder Openload an lowside Urea dosing valve; short circuit to ground or open load on low
des Dosierventils side
AdBlue Dosierventil; Massekurzschluss oder Kabelbruch
minusseitig
1080 3361 4 677 SCR: Kurzschluß an Highside Schalter vom Dosierventil Urea dosing valve; short circuit on high side
AdBlue Dosierventil; Kurzschluss plusseitig
1081 4345 5 6-7-4 Heizerrelais SCR; Rückleitung; Kabelbruch SCR heater relay urea returnline sekondary side; open load
SCR Heizer Relais AdBlue Rücklaufleitung sekundär Seite;
Kabelbruch
1082 4366 5 7-6-2 Heizerrelais SCR; Hauptrelais; Kabelbruch (sekundär Seite) SCR main relay (secondary side): open load
SCR Hauptrelais (Sekundärseite); Kabelbruch
1083 4343 5 6-7-3 Heizerrelais SCR; AdBlue Druckleitung; Kabelbruch SCR heater relay urea pressureline secondary side; open
SCR Heizer Relais AdBlue Druckleitung sekundär Seite; load

Kabelbruch
1084 4366 5 7-6-2 SCR Hauptrelais (Sekundärseite); Batteriekurzschluss SCR main relay (secondary side); Shortcut to battery


1085 4366 5 7-6-2 SCR Hauptrelais (Sekundärseite), Heizrelais SCR main relay (secondary side), heat relay (secondary
(Sekundärseite), Heizelemente side), heating elements
oder Heizventil Kurzschluss gegen Masse. or heating valve short to ground.
1086 4341 5 6-7-5 SCR Heizer Relais AdBlue Versorgungsleitung sekundär SCR heater relay urea supplyline secondary side; open load
Seite; Kabelbruch
1087 523719 5 6-7-2 Heizer SCR; Supply Modul; Kabelbruch SCR heater relay urea supply modul secondary side; open
load
1088 4366 5 6-7-1 SCR Tankheizventil sekundär Seite; Kabelbruch SCR Tank heating valve secundary side: open load
1089 4243 11 7-8-3 SCR System Heizerdiagnose meldet Fehler; Abschaltung Heizer SCR; Pressure line heater error and temperature
SCR-System condition to perform an afterrun (Sammelfehler
Heizerdiagnose)
SCR system heater diagnostic reports error; shut off
SCR-system
1090 4345 5 674 SCR: Openload Heizerrelais Rücklaufleitung SCR heater relay urea returnline primary side; open load
SCR Heizer Relais AdBlue Rücklaufleitung primär Seite;
Kabelbruch
1092 4345 3 674 SCR: Kurzschluß Heizerrelais Rücklaufleitung gegen Ubatt SCR heater urea returnline; short circuit to battery
SCR Heizer AdBlue Rücklaufleitung; Batteriekurzschluss
1093 4345 4 674 SCR: Kurzschluß Heizerrelais Rücklaufleitung gegen Masse SCR heater urea returnline; short circuit to ground
SCR Heizer AdBlue Rücklaufleitung; Massekurzschluß
1094 4343 5 673 SCR: Openload Heizerrelais Druckleitung SCR heater relay urea pressureline primary side; open load
SCR Heizer Relais AdBlue Druckleitung primär Seite;
Kabelbruch
1096 4343 3 673 SCR Heizer AdBlue Druckleitung; Batteriekurzschluss SCR heater urea pressureline; short circuit to battery
1097 4343 4 673 SCR Heizer AdBlue Druckleitung; Massekurzschluss SCR heater urea pressureline; short circuit to ground

1098 523718 5 676 SCR: Openload Heizerrelais SCR main relay (primary side); open load
SCR Hauptrelais (Primärseite); Kabelbruch

509
510

1099 523718 12 6-7-6 SCR: Die Leistungsstufe des Heizrelays meldet SCR main relay (primary side); powerstage over temperature
Übertemperatur
SCR Hauptrelais (Primärseite); Leistungstufe
Übertemperatur
1100 523718 3 676 SCR Hauptrelais (Primärseite); Batteriekurzschluss SCR main relay (primary side); short circuit to battery
1101 523718 4 676 SCR Hauptrelais (Primärseite); Massekurzschluß SCR main relay (primary side); short circuit to ground
1102 4341 5 675 SCR: Openload Heizerrelais Saugleitung SCR heater relay urea supply line primary side; open load
SCR Heizer Relais AdBlue Versorgungsleitung primär Seite;
Kabelbruch
1104 4341 3 675 SCR: Kurzschluß Heizerrelais Saugleitung gegen Ubatt SCR-heater urea supplyline; short circuit to battery
SCR-Heizer AdBlue Versorgungsleitung; Batteriekurzschluss
1105 4341 4 675 SCR-Heizer AdBlue Versorgungsleitung; Massekurzschluss SCR-heater urea supply line; short circuit to ground
1106 523719 5 672 SCR: Openload Heizerrelais Supplymodul SCR heater relay urea supplymodule primary side; open load
SCR Heizer Relais AdBlue Supply Modul primär Seite;
Kabelbruch
1108 523719 3 672 SCR: Kurzschluß Heizerrelais Supplymodul gegen Ubatt SCR heater urea supplymodule; short circuit to battery
SCR Heizer AdBlue Supply Modul; Batteriekurzschluss
1109 523719 4 672 SCR Heizer AdBlue Supply Modul; Massekurzschluss SCR heater urea supplymodule; short circuit to ground
1110 4366 5 671 SCR: Openload Heizerrelais Tankheizung SCR tank heating valve primary side; open load
SCR Tankheizventil primär Seite; Kabelbruch
1112 4366 3 671 SCR Tankheizventil; Batteriekurzschluss SCR Tank heating valve; short circuit to battery
1113 4366 4 671 SCR Tankheizventil; Massekurzschluss SCR Tank heating valve; short circuit to ground

1114 0 0


1117 523632 11 666 SCR: Pumpenmotor wird nach Temperaturmessung nicht Pump motor not available for actuation
aktiv
Pump motor not available for actuation
1118 4375 5 666 AdBlue Pumpenmotor; Kabelbruch Urea pump motor; open load
1120 4375 3 666 SCR: Kurzschluß Motor Supplymodul gegen Ubatt Urea pump motor; short circuit to battery
AdBlue Pumpenmotor; Batteriekurzschluss
1121 4375 4 666 SCR: Kurzschluß Motor Supplymodul gegen Masse Urea pump motor; short circuit to ground
AdBlue Pumpenmotor; Massekurzschluss
1122 4334 0 665 SCR: Physikalische Grenze des Pumpendrucks Max Supply module DEF, DEF pressure above upper physical
AdBlue Supplymodul Drucksensor; Signal über oberen threshold
Grenzwert (Defekt am Drucksensor)
1123 4334 1 665 SCR: Physikalische Grenze des Pumpendrucks Min Urea supply module pressure sensor; physical range check
AdBlue Supplymodul Drucksensor; Signal unter unterem low (defect pressure sensor)
Grenwert (Defekt am Drucksensor)
1124 4334 0 6-6-5 Supply Modul Drucksensor SCR; Druckwert über Urea pump pressure sensor; high signal not plusible
vorgegebenen Grenzwert
Sensor AdBlue Pumpendruck; Signal unplausibel hoch
1125 4334 1 6-6-5 Supply Modul Drucksensor SCR; Druckwert unter Urea pump pressure sensor; low signal not plausible
vorgegebenen Grenzwert
Sensor AdBlue Pumpendruck; Signal unplausibel niedrig
1127 523632 3 665 Sensorfehler AdBlue Pumpendruck; Signalbereich Sensor error urea pump pressure; signal range check high
überschritten
1128 523632 4 665 SCR: Kurzschluß Drucksensor gegen Masse Sensor error urea pump pressure; signal range check low

Sensorfehler AdBlue Pumpendruck; Signalbereich
unterschritten

511
512

1129 4376 5 667 SCR: Openload Umkehrventil Tankheizung SCR reversal valve; open load
SCR Umkehrventil; Kabelbruch
1131 4376 3 667 SCR: Kurzschluß Umkehrventil Tankheizung gegen Ubatt SCR reversal valve; short circuit to battery
SCR Umkehrventil; Batteriekurzschluss
1132 4376 4 667 SCR: Kurzschluß Umkehrventil Tankheizung gegen Masse SCR reversing valve; short circuit to ground
SCR Umkehrventil; Massekurzschluss
1135 3031 0 669 AdBlue-Tank Temperatur; Maximalwert überschritten DEF tank, DEF temperature above upper physical threshold
1136 3031 1 669 SCR: Überwachung physikalische Grenzen Tanktemperatur DEF tank, DEF temperature below lower physical threshold
low
AdBlue-Tank Temperatur; Minimalwert unterschritten
1137 4365 2 6-6-9 SCR: Überwachung Signalwert wenn Temperatur über CAN Signal error for CAN message
Signal error for CAN message
1138 4365 3 6-6-9 SCR: Signalrange Check Tanktempsensor Sensor error urea tank temperature: short circuit to battery
Sensorfehler AdBlue-Tank Temperatur; Batteriekurzschluss
1139 4365 4 6-6-9 SCR: Signalrange Check Tanktempsensor Sensor error urea tank temperature; short circuit to ground.
Sensorfehler AdBlue-Tank Temperatur; Massekurzschluss
1157 97 12 228 Wasserabscheider Kraftstoffvorfilter; Maximalwert Water in fuel level prefilter; maximum value exceeded
überschritten
1158 523946 0 7-7-2 Nullmengenkalibrierung Injektor 1 (nach Zündfolge); Zerofuel calibration injector 1 (in firing order); maximum value
Maximalwert überschritten exceeded
1159 523947 0 7-7-2 ZFL-Adaption max-Grenze überschitten 1 Zerofuel calibration injector 2 (in firing order); maximum value
Nullmengenkalibrierung Injektor 2 (nach Zündfolge); exceeded
Maximalwert überschritten


1164 523946 1 7-7-2 ZFL-Adaption Min-Grenze überschitten 0 Zerofuel calibration injector 1 (in firing order); minimum value
Minimalwert unterschritten


513
514

1170 523612 12 555 Steuergeräte interner Software Fehler Internal software error ECU
Interner Softwarefehler EMR
1171 175 2 1-4-4 Kundenseitiger Wert für Öltemperatur unplausibel Customer oiltemperature: signal unplausible
Öltemperatur kundenseitig; Signal unplausibel
1173 523973 14 7-7-9 Nox-Sensor vor SCR-Kat bzw. Abgastemperatursensor; SCR Tamper detection; derating timer below limit 1
Timer 1 nach Manipulationserkennung
(SCRChkNOxUsPlausMin oder
SCRPODPlausUCatUsTMax) abgelaufen
SCR Manipulationserkennung; Leistungsreduktions-Timer
Grenzwert 1 unterschritten
1174 523974 14 7-7-9 Nox-Sensor vor SCR-Kat bzw. Abgastemperatursensor; SCR Tamper detection; derating timer below limit 2
Timer 2 nach Manipulationserkennung
(SCRChkNOxUsPlausMin oder
SCRPODPlausUCatUsTMax) abgelaufen
SCR Manipulationserkennung; Leistungsreduktions-Timer
1175 523975 14 1-7-5 Urea quality Sensor; Timer 1 nach erkennung des Fehlers Urea quality; derating timer below limit 1
abgelaufen
Unzureichende AdBlue Qualität; Leistungsreduktions-Timer
1176 523976 14 1-7-5 Urea quality Sensor; Timer 2 nach erkennung des Fehlers Urea qulaity; derating timer below limit 2
abgelaufen
Unzureichende AdBlue Qualität; Leistungsreduktions-Timer

1177 523977 14 7-8-1 Urea Tank Level Sensor; Timer 1 nach erkennung des leeren Urea tank level; derating timer below limit 1
Tanks (UDCRdcAgRmn) abgelaufen
AdBlue Tanklevel; Leistungreduktions-Timer Grenzwert 1

unterschritten


1178 523978 14 7-8-1 Urea Tank Level Sensor; Timer 2 nach erkennung des leeren Urea tank level; derating timer below limit 2
Tanks (UDCRdcAgRmn) abgelaufen
AdBlue Tanklevel; Leistungreduktions-Timer Grenzwert 2
unterschritten
1180 168 0 318 Sensorwert des Batteriespannungssensors über Grenzwert Physical range check high for battery voltage
Batteriespannung; Maximalwert überschritten
1181 168 1 318 Sensorwert des Batteriespannungssensors unter Grenzwert Physical range check low for battery voltage
Batteriespannung; Minimalwert unterschritten
1183 172 1 226 Temperatur Luft Menge; Minimalwert unterschritten Air inlet filter sensor out of physical range check
1193 1180 0 5-5-6 Temperatursensor vor Turbine; Temperatur über oberen Physical range check high for exhaust gas temperature
physikalischen Grenzwert upstream turbine
Abgastemperatur vor Turbine; Maximalwert überschritten
1194 1180 1 5-5-6 Temperatursensor vor Turbine; Temperatur unter unteren Physical range check low for exhaust gas temperature
physikalischen Grenzwert upstream turbine
Abgastemperatur vor Turbine; Minimalwert unterschritten
1219 524018 14 7-8-6 DPF wurde nicht regeneriert, Leistungsreduktion Phase 1 HMI engine derate service state
(Manuelle Regenerationsanforderung) DPF wasn´t regenerated, power reduction phase 1 (manuell
regeneration request)
1220 524022 14 7-8-6 HMI engine derate stop state HMI engine derate stop state
DPF wasn´t regenerated, power reduction phase 2 (manuell
regeneration request)
1222 190 14 2-1-2 Nockenwellen- und Kurbelwellensensor Signal nicht Camshaft- and Crankshaft speed sensor signal not available
verfügbar auf CAN-Bus on CAN
1223 5763 5 594 H-Brücken Steller; Kabelbruch Actuator EGR-Valve (2.9;3.6) or Throttle-Valve (4.1;6.1;7.8);
Aktuator AGR Ventil (2.9;3.6) Drosselklappe (4.1;6.1;7.8); open load
Kabelbruch

515
516

1224 5763 6 594 H-Brücken Steller; elektrisch überlastet Actuator EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); over
Aktuator AGR Ventil (2.9;3.6) Drosselklappe (6.1;7.8); current
elektrisch überlastet
1226 5763 3 594 AGR Ventil (2.9;3.6) Drosselklappe (4.1;6.1;7.8); EGR-Valve (2.9;3.6) or Throttle-Valve (4.1;6.1;7.8); short
Batteriekurzschluss (A02) circuit to battery
Batteriekurzschluss (A67) circuit to battery
Massekurzschluss (A02) circuit to ground
Massekurzschluss (A67) circuit to ground
1230 5763 6 5-9-4 Aktuator AGR Ventil (2.9;3.6) Drosselklappe (4.1;6.1;7.8); Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve
Überlast durch Kurzschluß (4.1;6.1;7.8); Overload by short-circuit
1231 5763 11 5-9-4 Aktuator AGR Ventil (2.9;3.6) Drosselklappe (4.1;6.1;7.8); Power stage overtemperature due to high current.
Leistungsstufe Übertemperatur durch zu hohen Storm
1232 5763 4 5-9-4 Aktuator AGR Ventil (2.9;3.6) Drosselklappe (4.1;6.1;7.8); Voltage below threshold.
Spannung unter Grenzwert
1239 523984 3 788 UB6; Batteriekurzschluss Aktuator Relais 6 UB6; Short circuit to battery error of actuator relay 5
1241 523986 4 176 Relais SCR-Heizer, Masse-Kurzschluß (Highside Relais SCR-Heater, Short Circuit to Ground (Highside Control
Steuerseite) side)
1242 523987 4 791 UB6; Kurzschluss gegen Masse Aktuatorrelais 6 UB6; Short circuit to ground actuator relay 5
1247 524019 11 8-6-2 Luftpumpe; Luftleitung blockiert Burner Control; Air Line - Blocked us pAir

Air Pump; air lines blocked
1248 523910 9 6-9-5 Luftpumpe; CAN-Kommunikation unterbrochen Burner Control; Air Pump - CAN Lost
Air Pump; CAN communication lost


1249 523910 7 6-9-5 Burner Control; Air Pump - Elecktronik & Spannung Air pump; CAN communication interrupted no purge function
available
1250 523910 12 6-9-5 Luftpumpe; Interner Fehler Air Pump; internal error
1252 523910 0 6-9-5 Burner Control; Air Pump - falsche Spannung (FMI war früher Air Pump; operating voltage error
auf 0 )
Luftpumpe; Betriebsspannungsfehler
1254 524014 1 8-5-8 Luftdruck Glühkerzenspülleitung; Minimalwert unterschritten Air inlet EPV - pressure too low
Air pressure glow plug flush line; below limit
1255 524013 7 8-5-7 Brennerbetrieb zu oft unterbrochen Burner Control; Flame lost max
Burner operation is interrupted too often
1257 523915 7 8-5-3 HCI Dosierventil (DV1); offen blockiert HCI dosing valve (DV1); blocked open
1258 524016 11 8-5-9 HFM Sensor; elektrischer Fehler Burner Control; HFM - Electrical Fault
HFM sensor; electrical fault
1259 524016 2 8-5-9 Geförderte Luftmenge nicht plausibel zur Pumpendrehzahl Burner Control; HFM - Plausibilitätsfehler 1
Amount of air is not plausible to pump speed
1261 523910 6 6-9-5 Burner Control; Air Pump; Strom über Grenzwert Air Pump; over current
Luftpumpe; elektrisch überlastet
1262 523922 7 8-5-4 Brenner Shut Off Valve; geschlossen blockiert Burner Control; Shut-off Valve - Blocked closed
Burner Shut Off Valve; blocked closed
1263 524021 11 8-6-4 Brenner Kraftstoffleitung nach Shut Off Valve undicht Burner Control; Fuel line ShutOff downstream - broken
Burner fuel line pipe leak behind Shut Off Valve
1264 523922 7 8-5-5 Brenner Shut Off Valve; offen blockiert Burner Shut Off Valve; blocked open
1285 524038 9 8-2-4 Timeout der CAN-Empfangsbotschaft ComMS_Sys1TO Timeout error of CAN-Receive-Frame ComMS_Sys1TO
(Fehlerspeicher Slave); Master Slave interne CAN Botschaft (error memory Slave); Master-Slave internal CAN message


517
518

1291 524045 9 8-3-1 Master-Slave CAN; Nachrichtenzähler-Fehler der Master Slave, Error of message counter CAN receive
CAN-Empfangsbotschaft ComMSMoFOvR; message ComMSMoFOvR; ComMSMoFOvR1CNT
ComMSMoFOvR1CNT
1292 524046 9 8-3-2 Master-Slave CAN; Checksummen-Fehler der Master-Slave CAN; Error Checksum of CAN-Receive
CAN-Empfangsbotschaft ComMSMoFOvR Message
1293 524047 9 8-3-3 Master-Slave CAN; Nachrichten-Längen-Fehler der CAN Master-Slave CAN; Error of message length of CAN receive
Empfangsbotschaft ComMSMoFOvR message ComMSMoFOvR;_ComMSMoFOvR1DLC
1294 524048 9 8-3-4 CAN Botschaft ComMSMoFOvR1TO Timeout Fehlerspeicher Timeout error CAN message ComMSMoFOvR1TO error
Slave memory Slave
1299 523788 0 6-5-5 CAN-Sendebotschaft ComTrbChActr Plausibilitäts-Fehler; Wastegate;_ComTrbChActrPlaus

Wastegate
1300 523788 0 6-5-5 Timeout der CAN-Empfangsbotschaft ComTrbChActr; Timeout Error of CAN-Receive-Frame ComTrbChActr;
Wastegate Wastegate
1302 524024 11 8-6-6 Abweichung der Abgastemperatur Sollert zu Istwert nach Deviation of the exhaust gas temperature setpoint to actual
(DOC) zu groß value downstream (DOC) too high
1324 523995 13 7-9-5 Fehlender Injektor Korrekturwert (IMA) Injektor 7 (nach Check of missing injector adjustment value programming
Zündfolge) (IMA) injector 7 (in firing order)

Zündfolge) (IMA) injector 8 (in firing order)


1326 523997 4 7-9-7 Injektor Zylinder Bank 1 Slave; Kurzschluss Injector cylinder bank 1 slave; short circuit
1327 523998 4 7-9-8 Injektor Zylinder Bank 2 Slave; Kurzschluss Injector cylinder bank 2 slave; short circuit
1328 523999 12 7-9-9 Injektoransteuerung Slave defekt Injector powerstage output Slave defect
1329 524000 5 1-7-7 Injektor 7 (nach Zündfolge); Stromunterbrechung Injector 7 (in firing order); interruption of electric connection
1330 524001 5 1-7-8 Injektor 8 (nach Zündfolge); Stromunterbrechung Injector 8 (in firing order); interruption of electric connection
1333 524000 3 1-7-7 Injektor 7 (nach Zündfolge); Kurzschluss Injector 7 (in firing order); short circuit
1334 524001 3 1-7-8 Injektor 8 (nach Zündfolge); Kurzschluss Injector 8 (in firing order); short circuit
1337 2797 4 565 Injektor Diagnose; Timeout der Massekurzschluss Timeout of Short-Circuit Ground Diagnosis Cyl. Bank
Überwachung Zyl. Bank 0 0;_IVDiaShCirGndToutBnk_0
1338 2798 4 566 Injektor Diagnose; Timeout der Massekurzschluss Timeout of Short-Circuit Ground Diagnosis Cyl. Bank
Überwachung Zyl. Bank 1 1;_IVDiaShCirGndToutBnk_1
1339 2797 4 565 Injektor Diagnose; Test Massekurzschluss Überwachung Zyl. Injector diagnostic; Short circuit to ground cylinder bank 0
Bank 0
1340 2798 4 566 Injektor Diagnose; Test Massekurzschluss Überwachung Zyl. Injector diagnostic; Short circuit to ground cylinder bank 1
Bank 1
1342 524036 12 5-5-5 Injektor Diagnose Slave; Timeout der SPI Kommunikation Injector diagnostics Slave; time out error in the SPI
communication
1345 524069 9 8-9-6 Timeout der CAN-Empfangsbotschaft MSMon_FidFCCTO; Timeout Error of CAN-Receive-Frame MSMon_FidFCCTO;
Master-Slave CAN Kommunikation fehlerhaft Master-Slave CAN communication faulty
1357 524052 11 8-3-6 Sammelfehler im Mastersteuergerät verweist auf Error memory Slave reports FID MSMonFC2 (collective error)

Fehlerspeichereintrag im Salve Steuergerät.
1368 524052 11 8-3-6 Fehlerspeicher Slave meldet FID MSMonFC3 Error memory Slave reports FID MSMonFC3 (collective error)
(Sammelfehler)

519
520

1378 523919 2 6-9-4 Luftpresser für die DPF Brennerkomponente; Druck Sensor air pump airpressure; plausibility error
unplausibel
Sensor Luftdruck Luftpumpe; Signal unplausibel
1379 523920 2 7-1-6 Brennerdrucksensor; Druck unplausibel Sensor exhaust gas back pressure burner; plausibility error
Sensor Abgasgegendruck Brenner; Signal unplausibel
1380 3253 2 6-9-2 Partikelfilter Differenzdrucksensor; Druck unplausibel Sensor differential pressure (DPF); plausibility error
Sensor Differenzdruck (DPF); Signal unplausibel
1381 164 2 839 Raildrucksicherheitsfunktion nicht korrekt ausgeführt Rail pressure safety function is not executed correctly
1389 523922 5 7-1-5 Brenner Shut Off Valve; Kabelbruch Burner Shut Off Valve; open load
1390 523922 12 7-1-5 Brenner Shut Off Valve; Übertemperatur Burner Shut Off Valve; powerstage over temperature
1392 523922 4 7-1-5 Brenner Shut Off Valve; Massekurzschluss Burner Shut Off Valve; short circuit to ground
1395 523921 2 7-1-4 Sensor Brennertemperatur; Signal unplausibel Burner temperature sensor; Plausibility Check for burner
temperature sensor
Sensor burner temperature; plausibility error
1398 1136 0 681 ECU Temperatur; Maximalwert überschritten Physical range check high for ECU temperature
1402 4769 2 6-8-4 Temperatursensor nach Oxi-Kat; Temperatur nicht Plausibel Sensor exhaust gas temperature OxiCat downstream
Sensor Abgastemperatur nach OxiCat (Normalbetrieb); (normal operation); plausibility error
Signal unplausibel
1403 4769 2 6-8-4 Temperatursensor nach Oxi-Kat; Temperatur nicht Plausibel Sensor exhaust gas temperature OxiCat downstream
Sensor Abgastemperatur nach OxiCat (Regeneration); Signal (regeneration); plausibility error
unplausibel
1411 1188 11 8-1-4 Wastegate Steller; Interner Fehler Wastegate actuator; internal error

1412 1188 11 8-1-4 Wastegate Steller; EOL Kalibrierung nicht korrekt Wastegate actuator; EOL calibration not performed correctly
durchgeführt


1413 1188 13 8-1-4 Wastegate Steller Abweichung zu Kalibrierwert zu groß, Wastegate actuator calibration deviation too large,
Neukalibrierung erforderlich recalibration required
1414 1188 2 8-1-4 Wastegate; Statusbotschaft von Steuergerät fehlt Wastegate; status message from ECU missing
1415 1188 7 8-1-4 Wastegate Steller; blockiert Wastegate actuator; blocked
1416 1188 11 8-1-4 Wastegate Steller; Übertemperatur (> 145°C) Wastegate actuator; over temperature (> 145°C)
1417 1188 11 8-1-4 Wastegate Steller; Übertemperatur (> 135°C) Wastegate actuator; over temperature (> 135°C)
1418 1188 11 8-1-4 Wastegate Steller; Betriebsspannungsfehler Wastegate actuator; operating voltage error
1423 5763 0 5-9-4 Warnschwelle für einen internen Aktuator Fehler Warning threshold for an internal actuator error exceeded, <
überschritten, < 4L AGR-Steller und >4L Drosselklappe 4L EGR.actuator und >4L Air Intake Flap
1424 5763 1 5-9-4 Abschaltschwelle für einen internen Aktuator Fehler Shut off threshold for an internal actuator error exceeded, <
überschritten, < 4L AGR-Steller und >4L Drosselklappe 4L EGR.actuator und >4L Air Intake Flap
1425 172 0 226 Umgebungstemperatur über Warnschwelle air temperature within air filter box above maximum physical
value
1426 172 1 2-2-6 Umgebungstemperatur unter Warnschwelle Environment temperature below minimum level
1431 524028 2 8-1-5 CAN Botschaft PROEGRActr unplausibel CAN message PROEGRActr; plausibility error
1432 524029 2 8-1-5 Timeout CAN Empfangsbotschaft ComEGRActr - Timeout Error of CAN-Receive-Frame ComEGRActr -
Abgasrückführsteller exhaust gas recirculation positioner
1434 524050 11 8-3-6 CAN; not used
1435 524051 11 8-3-7 ComRxCustSysReacMin CAN; not used

1436 524034 5 8-1-6 Tellerseparator; Kabelbruch _Disc Separator; open load
1437 524034 12 8-1-6 Tellerseparator; Leistungsstufe Übertemperatur _Disc Separator; powerstage over temperature

521
522

1438 524034 3 8-1-6 Tellerseparator; Batteriekurzschluss Separador en disco; cortocircuito en la masa
1439 524034 4 8-1-6 Tellerseparator; Massekurzschluss _Disc separator; short circuit to ground
1440 524030 7 8-1-5 AGR Steller; interner Fehler _EGR actuator; internal error
1441 524031 13 8-1-5 AGR Steller, Kalibrierfehler EGR actuator, calibration error
1442 524032 2 8-1-5 AGR Steller; Statusbotschaft "EGRCust" fehlt _EGR actuator; status message "EGRCust" is missing
1443 524033 7 8-1-5 AGR Steller; wegen Überlastung im Sicherheitsmodus _EGR actuator; due to overload in Save Mode
1455 3711 12 711 SCR Wirkungsgrad Verzögerung Leistungsreduktion 2 Temperature during stand-still main phase too low or too high
abgelaufen
Regenerationstemperatur (PfltRgn LightOff) wird nicht
erreicht; Abbruch der Regeneration
1458 523960 0 7-7-1 EGR Cooler Downstream Temperature Sensor; Temperatur _High exhaust gas temperature EGR cooler downstream;
über Warnschwelle warning threshold exceeded
Abgastemperatur nach AGR Kühler zu hoch; Warnschwelle
erreicht
1481 524025 5 8-4-5 DPF System; Betriebsspannungsfehler _DPF system; operating voltage error
1482 524044 9 1-8-8 CAN-Botschaft ComMS_Sys7 nicht von Slave empfangen CAN message ComMS_Sys7 not received from slave
1484 524068 2 8-9-5 Master ECU und Slave ECU haben sich als identische Typen Master ECU and Slave ECU have been identified as the
identifiziert same types
1485 524052 11 8-3-6 Master ECU und Slave ECU Datenstände oder Software Master ECU and Slave ECU data sets or software are not
nicht identisch identical
1486 523718 5 6-7-6 Heizerendstufe SCR; Hauptrelais Kabelbruch (Fehlerpfad nur SCR mainrelay; open load (only CV56B)

bei CV56b vorhanden)
SCR Hauptrelais; Kabelbruch (nur CV56B)
1488 523718 3 6-7-6 SCR Hauptrelais; Batteriekurzschluss (nur CV56B) SCR mainrelay; short circuit to battery (only CV56B)


1489 523718 4 6-7-6 SCR Hauptrelais; Massekurzschluss (nur CV56B) SCR mainrelay; short circuit to ground (only CV56B)
1490 4376 5 6-6-7 Supply Modul Umkehrventil SCR; Kabelbruch oder SCR reverting valve; open load
Kurzschluß gegen Batterie
SCR Umkehrventil; Kabelbruch
1491 4376 12 6-6-7 Supply Modul Umkehrventil SCR; Temperatur über SCR reverting valve; over temperature
Grenzwert
SCR Umkehrventil; Übertemperatur
1493 4376 4 6-6-7 Supply Modul Umkehrventil SCR; Kurzschluss gegen Batterie SCR reverting valve; short circuit to ground
SCR Umkehrventil; Massekurzschluss
1505 524057 2 8-4-3 Kraftstoffniederdruck Pumpe; Fehler Druckaufbau Fuel low pressure pump; error pressure build up
1523 2659 2 8-2-2 Abgasrückführung AGS Sensor; Signal unplausibel Exhaust Gas Recirculation AGS Sensor; signal not plausible
1524 2659 0 8-2-2 Abgasrückführung AGS Sensor; Messwert des Exhaust Gas Recirculation AGS Sensor; Sensed exhaust
Abgasmassenstroms über maximaler physikalischer Grenze mass value above maximum physical value
1525 2659 1 8-2-2 Abgasrückführung AGS Sensor; Messwert des Exhaust Gas Recirculation AGS Sensor; Sensed exhaust
Abgasmassenstroms unter minimaler physikalischer Grenze mass value below miniimum physical value
1526 2659 12 8-2-2 Abgasrückführung AGS Sensor; Plausibilitätsfehler, AGS Exhaust Gas Recirculation AGS Sensor; plausibility error,
Sensor hat "Freibrennen" nicht durchgeführt AGS sensor has not passed the burn off process
1527 2659 2 8-2-2 Abgasrückführung AGS Sensor; Temperatur des Exhaust Gas Recirculation AGS Sensor; Temperature of
Abgasmassenstroms unplausbibel EGR mass not plausible
1528 1176 2 1-3-9 Drucksensor vor Turbine; Druck nicht plausibel Pressure sensor upstream turbine, plausibility error
1529 524070 2 8-9-7 NOx-Sensor vor SCR-Cat: ungültige Wert (Upstream NOx-Sensor) Diagnostic Fault Check for invalid
upstream NOx value (Sensor self diagnostic DFC set by

Deutz-SW)
NOx-Sensor before SCR-Cat: Invalid upstream NOx value

523
524

1530 524071 2 8-9-8 NOx-Sensor nach SCR-Kat - Lambda Wert ungültig (Downstream NOx-Sensor) Diagnostic Fault Check for invalid
downstream lambda value (Sensor self diagnostic DFC set
by Deutz-SW)
1531 524072 2 8-9-9 NOx-Sensor vor SCR-Cat: ungültige lambda Wert (Upstream NOx-Sensor) Diagnostic Fault Check for invalid
upstream lambda value (Sensor self diagnostic DFC set by
Deutz-SW)
1532 524073 2 2-4-5 NOx-Sensor nach SCR-Kat - NOx Wert ungültig (Downstream NOx-Sensor) Diagnostic Fault Check for invalid
downstream NOx value (Sensor self diagnostic DFC set by
Deutz-SW)
1533 524074 9 246 Kabelbruch Nox-Sensor nach SCR Kat NOx sensor downstream SCR-CAT, sensor internally open
load
1534 524075 11 247 Kurzschluss im Nox-Sensor nach SCR Kat NOx sensor downstream SCR-CAT, sensor internally short
circuit
1535 524076 9 248 Kabelbruch im Nox-Sensor vor SCR Kat NOx sensor upstream SCR-CAT, sensor internally open line
1536 524077 11 249 Kurzschluss Nox-Sensor vor SCR-Kat NOx sensor upstream SCR-CAT, sensor internally short
circuit
1537 524078 9 255 NOx-Sensor nach SCR-Kat, Lambda Wert über oberen NOx sensor downstream SCR-CAT, lambda value above
Grenzwert upper physical threshold
1538 524079 9 256 NOx-Sensor nach SCR-Kat, Lambda Wert unter unterem NOx sensor downstream SCR-CAT, lambda value below
Grenzwert lower physical threshold
1539 524080 9 257 NOx-Sensor vor SCR-Kat, Lambda Wert über oberen NOx sensor upstream SCR-CAT, lambda value above upper
Grenzwert physical threshold
1540 524081 9 258 NOx-Sensor vor SCR-Kat, Lambda Wert unter unterem NOx sensor upstream SCR-CAT, lambda value below lower
1541 524082 9 2-5-9 Nox Sensorwert nach Kat über oberen Grenzwert (Downstream NOx-Sensor) Diagnostic Fault Check for
downstream NOx value over maximum limit (DFC set by

Deutz-SW)


1542 524083 9 261 NOx-Sensor nach SCR-Kat, NOx Wert unter unterem NOx-Sensor downstream SCR-CAT, NOx value below
Grenzwert minimum value.
1543 524084 9 9-1-1 NOx-Sensor vor SCR-Kat, NOx Wert über oberem Grenzwert NOx-Sensor upstream SCR-CAT, NOx value above
maximum value.
1544 524085 9 912 Nox Sensorwert vor SCR Kat, NOx Wert unter unterem NOx sensor upstream SCR-CAT, NOx value below lower
1545 524149 2 9-6-8 Plausibilitätsfehler zwischen Druck nach Turbine (PTrbnDs) Plausibility error between pressure downstream turbine
und Umgebungsdruck (EnvP) (PTrbnDs) and ambient air pressure (EnvP)
1555 524063 5 869 Heizerrelais für die SCR-Rückflußleistung ist nicht SCR heater return line; open load
angeschlossen
SCR Heizer Rücklauf; Kabelbruch
1556 524063 5 869 Hauptrelais SCR-Heizer, nicht angeschlossen SCR main relay not connected
1557 524063 5 869 Heizerrelais für die SCR-Druckleitung ist nicht angeschlossen SCR heater pressureline; open load
SCR Heizer Druckleitung; Kabelbruch
1558 524063 3 869 Kurzschluß nach Battriespannung des SCR-Heizer SCR heater mainrelay; short circuit to battery
Hauptrelais
SCR Heizer Hauptrelais; Kurzschluss gegen Batterie
1559 524063 4 869 SCR Heizer Hauptrelais Lastseite(K31) über Heizventil (Y31), SCR heater main relay load side (K31) on heating valve
Kurzschluss gegen Masse. (Y31),
Short cut to ground.
1560 524063 5 869 Heizerrelais SCR-Ansaugleitung,nicht angeschlossen SCR relay for suction line not connected
1561 524063 5 869 Heizerrelais für das SCR-Modul ist nicht angeschlossen SCR heater supply module; open load

SCR Heizer Supply Modul; Kabelbruch

525
526

1562 524063 5 869 Heizerrelais für den Urea Tank ist nicht angeschlossen SCR heater tank; open load
SCR Heizer Tank; Kabelbruch
1565 524065 0 892 Drucksensor vor SCR Kat; Druck über oberen physikalischen Pressure sensor upstream SCR-CAT, pressure above upper
1566 524065 1 892 Drucksensor vor SCR Kat; Druck unter unteren Pressure sensor upstream SCR-CAT, pressure below lower
physikalischen Grenzwert physical threshold
1569 524065 3 892 Drucksensor vor SCR Kat; Kurzschluss gegen Batterie oder Pressure sensor upstream SCR-CAT; short circuit battery or
Kabelbruch open load
1570 524065 4 892 Drucksensor vor SCR Kat; Kurzschluss gegen Masse Pressure sensor upstream SCR-CAT; short circuit ground
1581 524067 0 894 Temperatur Heizer SCR Pumpenmodul, oberer DEF supply module, heater temperature above upper
physikalischer Grenzwert überschritten physical threshold
1582 524067 1 894 Temperatur Heizer SCR Pumpenmodul, unterer DEF supply module, heater temperature below lower physical
physikalischer Grenzwert unterschritten threshold
1585 524067 0 894 Supplymodul Temperatursensor SCR; Temperatur über DEF supply module, temperature above upper physical
oberen Grenzwert threshold
1586 524067 1 894 Supplymodul Temperatursensor SCR; Temperatur unter DEF supply module, temperature below lower physical
unteren Grenzwert threshold
1593 1761 0 129 Urea Tank Level; maximaler oberer Grenzwert überschritten DEF tank, DEF level above upper physical threshold
1594 1761 1 129 DEF Tank Level; minimaler unterer Grenzwert unterschritten DEF tank, DEF level below lower physical threshold
1597 524149 2 9-6-8 Plausibilitätsfehler zwischen Druck nach Turbine (PTrbnDs) Pressure downstream turbine, plausibility error
und modeliertem Druck aus ASMod Modul

1598 524065 2 892 Drucksensor vor SCR-CAT nicht plausibel. Pressure sensor upstream SCR-CAT, plausibility error


1616 3699 2 8-1-8 Differenzdruck Sensor DPF und ein weiterer Sensor oder Passive regeneration of DPF; Plausibilitätsfehler
Aktuator CRT System defekt DPF differential pressure sensor and a further sensor or
actuator CRT system defective
1617 3699 2 8-1-8 Temperatur Sensor vor und nach DOC gleichzeitig defekt Passive regeneration of DPF; DOC Fehler
Temperature sensor us. and ds. DOC simultaneously defect
1619 524087 5 8-8-4 AdBlue Fehlerlampe; Kabelbruch Urea Error Lamp; open load
1620 524087 12 8-8-4 AdBlue Fehlerlampe; Temperatur über Grenzwert Urea Error Lamp; temperatur over limit
1621 524087 3 8-8-4 AdBlue Fehlerlampe; Kurzschluss gegen Batterie Urea Error Lamp; short circuit battery
1622 524087 4 8-8-4 AdBlue Fehlerlampe; Kurzschluss gegen Masse Urea Error Lamp; short circuit ground
1630 524132 2 9-5-5 Kraftstoffniederdruck vor Kraftstoffpumpe: Signal unplausibel Fuel low pressure upstream fuel low pressure pump not
plausible
1631 524132 0 9-5-5 Kraftstoffniederdruck vor Kraftstoffpumpe; Druck über oberer Fuel low pressure upstream fuel low pressure pump,
Warnschwelle pressure above maximum warning threshold
1632 524132 0 9-5-5 Kraftstoffniederdruck vor Kraftstoffpumpe; Druck über oberer Fuel low pressure upstream fuel low pressure pump,
Abschaltschwelle pressure above maximum shut off threshold
1633 524132 1 9-5-5 Kraftstoffniederdruck vor Kraftstoffpumpe; Druck unter Fuel low pressure upstream fuel low pressure pump,
unterer Abschaltschwelle pressure below minimum shut off threshold
1634 524132 1 9-5-5 Kraftstoffniederdruck vor Kraftstoffpumpe; Druck unter Fuel low pressure upstream fuel low pressure pump,
unterer Warnschwelle pressure below minimum warning threshold
1635 3699 0 8-1-8 Maximale Stand-still-Dauer erreicht; Ölwechsel-Anforderung Maximum standstill time reached; oil exchange request
ignoriert ignored
1639 524147 13 966 SCR Koordinator; Timer abgelaufen, Initialisierung nicht SCR System,pressure build up not possible
erfolgreich -->Druckleitungen periodisch leeren
Druckaufbau Problem

1646 524063 12 869 DEF Supply Modul, Auftauphase zu lang DEF supply modul, time for defrosting too long

527
528

1647 524063 12 8-6-9 DEF Tank, Auftauphase zu lang DEF tank, time for defrosting too long
1654 1761 14 1-3-8 Urea Tank Level unterhalb Level 1 Urea Tank Signal to HMI for indicating the Urea Tank-Level
(Urea tank volume ratio low threshold 1)
1655 1761 14 138 Urea Tank Level unterhalb Level 2 DEF tank, DEF level below first warning threshold
1656 1761 14 138 Urea Tank Level unterhalb Level 3 DEF tank, DEF level below second warning threshold
1658 524096 14 1-9-6 Engine will not be started, because of EPA-Counter Control of the SCR system; If the start stop counter
(EPA-Counter) exceeds the threshold
SCRCtl_ctEngStrtStopThresh_C. This counter will increment
only once in each driving cycle in case of an SCR error. If the
counter reaches the threshold, the DFC will be set to inhibit
the engine start
Engine will not be started, because of EPA-Counter
1659 524114 9 9-3-8 Timeout der CAN-Sendebotschaft A1DOC Timeout error of CAN-Transmit-Frame A1DOC
1660 524115 9 9-3-9 Timeout der CAN-Sendebotschaft AT1S Timeout error of CAN-Transmit-Frame AT1S
1661 524116 9 1-9-4 CAN; Timeout error of transmit frame SCR2 (Sendefehler) Timeout error of CAN-Transmit-Frame SCR2
Timeout der CAN-Sendebotschaft SCR2
1662 524117 9 9-4-1 CAN; Timeout error of transmit frame SCR3 (Sendefehler) Timeout error of CAN-Transmit-Frame SCR3
Timeout der CAN-Sendebotschaft SCR3
1663 524097 9 9-2-1 Timeout der CAN-Sendebotschaft DPFBrnAirPmpCtl Timeout error of CAN-Transmit-Frame DPFBrnAirPmpCtl
1664 524098 9 9-2-2 Timeout der CAN-Sendebotschaft ComDPFBrnPT Timeout error of CAN-Transmit-Frame ComDPFBrnPT
1665 524099 9 9-2-3 Timeout der CAN-Sendebotschaft ComDPFC1 Timeout error of CAN-Transmit-Frame ComDPFC1
1666 524100 9 924 Timeout der CAN-Sendebotschaft ComDPFHisDat Timeout error of CAN-Transmit-Frame ComDPFHisDat.

1667 524101 9 9-2-5 Timeout der CAN-Sendebotschaft ComDPFTstMon Timeout error of CAN-Transmit-Frame ComDPFTstMon
1668 524105 9 9-2-9 Timeout der CAN-Sendebotschaft ComEGRMsFlw Timeout error of CAN-Transmit-Frame ComEGRMsFlw


1669 524108 9 932 Timeout der CAN-Sendebotschaft ComEGRTVActr Timeout error of CAN-Transmit-Frame ComEGRTVActr.
1670 524110 9 9-3-4 Timeout der CAN-Sendebotschaft ComETVActr
1671 524112 9 9-3-6 Timeout ComIntake Drosselklappe Actr. Timeout ComIntake Throttle Valve Actr.
1672 524118 9 9-4-2 Timeout der CAN-Empfangsbotschaft ComRxCM1 Timeout error of CAN-Receive-Frame ComRxCM1
1673 524119 9 9-4-3 Timeout der CAN-Empfangsbotschaft ComRxCustSCR3 Timeout error of CAN-Receive-Frame ComRxCustSCR3
1674 524102 9 9-2-6 Timeout der CAN-Empfangsbotschaft Timeout error of CAN-Receive-Frame

ComRxDPFBrnAirPmpCtl ComRxDPFBrnAirPmpCtl
1675 524103 9 9-2-7 Timeout der CAN-Empfangsbotschaft ComRxDPFBrnAirPmp Timeout error of CAN-Receive-Frame ComRxDPFBrnAirPmp
1676 524104 9 928 Timeout der CAN-Empfangsbotschaft ComRxDPFCtl Timeout error of CAN-Receive-Frame ComRxDPFCtl.
1677 524106 9 1-9-5 Timeout der CAN-Empfangsbotschaft ComRxEGRMsFlw1 Timeout error of CAN-Receive-Frame ComRxEGRMsFlw1
1678 524107 9 9-3-1 Timeout der CAN-Empfangsbotschaft ComRxEGRMsFlw2 Timeout error of CAN-Receive-Frame ComRxEGRMsFlw2
1679 524109 9 933 Timeout der CAN-Empfangsbotschaft ComRxEGRTVActr Timeout error of CAN-Receive-Frame ComRxEGRTVActr
1680 524111 9 9-3-5 Timeout der CAN-Empfangsbotschaft ComRxETVActr Timeout error of CAN-Receive-Frame ComRxETVActr
1681 524113 9 9-3-7 Timeout der CAN-Empfangsbotschaft ComRxITVActr Timeout error of CAN-Receive-Frame ComRxITVActr
1682 524120 9 9-4-4 CAN Timeout Error of receive frame SCRHtDiag Timeout error of CAN-Receive-Frame ComRxSCRHtDiag
(Empfangsfehler)
Timeout der CAN-Empfangsbotschaft ComRxSCRHtDiag
1683 524121 9 9-4-5 Timeout der CAN-Empfangsbotschaft ComRxTrbChActr Timeout error of CAN-Receive-Frame ComRxTrbChActr

529
530

1684 524122 9 9-4-6 SCR; Urea Quality; CAN Timeout Error of receive frame Timeout error of CAN-Receive-Frame ComRxUQSens
UQSens (Empfangsfehler)
Timeout der CAN-Empfangsbotschaft ComRxUQSens
1685 524123 9 9-4-7 CAN Timeout error of receive frame SCRHtCtl (Sendefehler) Timeout error of CAN-Receive-Frame ComSCRHtCtl
Timeout der CAN-Empfangsbotschaft ComSCRHtCtl
1686 524124 9 9-4-8 CAN Timeout error of receive frame AT1IMG (Sendefehler) Timeout error of CAN-Receive-Frame ComTxAT1IMG
Timeout der CAN-Empfangsbotschaft ComTxAT1IMG
1687 524125 9 9-4-9 Timeout der CAN-Empfangsbotschaft ComTxTrbChActr Timeout error of CAN-Receive-Frame ComTxTrbChActr
1698 524133 2 9-5-6 HMI-System; wird gesetzt, wenn der Restore button blockiert HMI system; set if restore button blocked
ist
1699 524134 0 957 DPF; Aschebeladung Partikelfilter überschreitet den DPF, ash load exceeds the shutoff threshold
Grenzwert.
1700 524134 0 957 DPF; Aschebeladung Partikelfilter überschreitet die DPF, ash load exceeds the warning threshold
Warnschwelle
1701 524135 0 958 Die Rußbeladung des DPF hat die Abschaltgrenze DPF, soot load exceeds the shutoff threshold
überschritten
1702 524135 14 958 Die Rußbeladung des DPF hat die Grenze DPF, soot load exceeds the service request threshold
Serviceanforderung überschritten
1703 524135 0 958 Die Rußbeladung des DPF hat die Warnschwelle DPF, soot load exceeds the warning threshold
überschritten
1705 524156 9 972 Timeout Fehler für die Radgeschwindigkeits Information Timeout error of CAN-Receive-Frame ComRxEBC2.
1752 2791 7 415 SCR Überwachung, Blockierung AGR Steller erkannt. EGR actuator, actuator blocked

1753 2791 2 415 AGR Steller, CAN Fehler EGR actuator, CAN error


1754 2791 13 415 AGR Steller, EOL Lernfehler EGR actuator, EOL calibration error
1755 2791 12 415 AGR Steller CAN, interner elektrischer Fehler. EGR Actuator, internal electrical fault
1756 2791 13 415 AGR Steller, Einlernen nicht komplett EGR actuator, learning process aborted
1757 2791 6 415 AGR Steller, Strom über Grenzwert EGR actuator current is above maximum threshold
1758 2791 3 415 AGR Steller CAN, Spannungsversorgung zu hoch EGR actuator supply voltage is above the maximum
threshold
1759 2791 4 415 AGR Steller CAN; Spannungsversorgung zu niedrig EGR actuator supply voltage is below minimum threshold.
1760 2791 13 415 AGR Steller, Lernfehler EGR actuator, learning process out of range
1761 2791 7 415 AGR Steller, Federbruch detektiert EGR actuator, broken spring detected.
1762 2791 16 415 AGR Steller, Temperatur über Grenzwert. EGR actuator, temperature high.
1763 2791 0 415 AGR Steller, Temperatur über kritischem Grenzwert. EGR actuator, temperature critical high
1788 1188 7 8-1-4 Turbolader Wastegate, mechanische Blockierung erkannt. Turbocharger wastegate, mechanical blocking detected.
1789 1188 2 8-1-4 Turbolader Wastegate CAN, CAN Fehler Turbocharger wastegate, CAN Error
1790 1188 13 8-1-4 Turbolader Wastegate CAN, EOL Kalibrierungsfehler. Turbocharger wastegate, EOL calibration error.
1791 1188 12 8-1-4 Turbolader Wastegate, interner elektrischer Fehler. Turbocharger wastegate, internal electrical error.
1792 1188 13 8-1-4 Turbolader Wastegate, Fehler während des Turbocharger wastegate, learning process aborted.
Einlernprozesses.
1793 1188 6 8-1-4 Turbolader Wastegate, Strom über Grenzwert. Turbocharger wastegate, current above maximum threshold.

1794 1188 3 8-1-4 Turbolader Wastegate, Spannungsversorgung zu hoch. Turbocharger wastegate, supply voltage above maximum
threshold.

531
532

1795 1188 4 8-1-4 Turbolader Wastegate, Spannungsversorgung zu niedrig. Turbocharger wastegate, supply voltage below minimum
threshold.
1796 1188 13 8-1-4 Turbolader Wastegate, Lernfehler (Bereicherkennung). Turbocharger wastegate, learning process out of range.
1797 1188 7 8-1-4 Turbolader Wastegate, Federbruch detektiert. Turbocharger wastegate, broken spring detected.
1799 1188 0 8-1-4 Turbolader Wastegate, Temperatur über Grenzwert. Turbocharger wastegate, temperature critical high.
1827 524141 7 192 SCR Überwachung; Blockierung an AdBlue Dosierventil DEF dosing valve, dosing valve blocked
erkannt
1857 523612 12 555 Plausibilitätsfehler Freigabe Starter Engine starter, plausibility error of starter release condition
1858 524147 7 966 SCR Überwachung; Umkehrventil blockiert --> AdBlue SCR-System, reverting valve blocked
Pumpendruck steigt während der Systementleerung.
1859 524175 0 993 SCR Überwachung; NOX-Wert nach SCR Kat, oberen SCR-CAT, Nox emissions above maximum threshold
Grenzwert erreicht
1860 524074 2 2-4-6 Unplausibler Wert des Nox-Sensors nach Kat NOx-Sensor after SCR-Cat: Nox-Sensor dew point problem
or plausibility problem
1861 524076 2 2-4-8 Unplausibler Wert des Nox-Sensors vor Kat NOx-Sensor before SCR-Cat: Nox-Sensor dew point
problem or plausibility problem
1863 524177 7 995 SCR Systemdrucküberwachung; Saugleitung Blockierung SCR System, DEF suction line blocked
erkannt
1864 524178 7 996 SCR Systemdrucküberwachung; Systemdruck Fehler SCR System, DEF pressure out of range
1865 4360 2 668 Temperatur vor SCR Kat nicht plausibel Exhaust temperature sensor upstream SCR, plausibility error
1866 4334 2 665 DEF Supply Modul Druck, Signal unplausibel DEF supply module pressure, plausibility error

1867 524067 2 894 Heiztemperatur supply module unplausibel Supply module heater temperature, plausibility error
1868 524067 2 894 Temperatur supply module unplausibel Supply module temperature, plausibility error


1869 1761 2 129 AdBlue Tankfüllstand; Tanklevelwert nicht plausibel DEF tank level, plausibility error
1874 524152 2 971 Urea Quality Sensor; Timeout CAN-Botschaft Urea Quality Sensor; Timeout CAN message
1875 524153 2 997 SCR Heizer Diagnosenachricht; Timeout CAN-Botschaft Urea tank level & urea tank temperature via CAN bus,
timeout of CAN message
1880 1761 14 138 Urea Tank Level unterhalb Level 4 DEF tank, DEF level below third warning threshold
1881 4768 2 683 Plausibilitätsprüfung Temperatursensoren vor und nach DOC exhaust gas temperature sensors up- and downstream DOC
are physically swapped
1882 524025 14 8-4-5 Zeit des Motors im Modus Stillstandsregeneration größer als The standstill-regeneration mode time exceeds the long-limit.
Grenze Langzeitinterval.
Der Motor war zu lange oder zu oft im Modus Vehicle was too long or too often in standstill mode.
Stillstandsregeneration. Make oil change and reset counter.
Ölwechsel durchführen und Zähler zurücksetzen.
1883 524025 14 8-4-5 Zeit des Motors im Modus Stillstandsregeneration größer als The standstill-regeneration mode time exceeds the
Grenze Kurzzeitinterval short-limit.
Der Motor war zu lange oder zu oft im Modus Vehicle was too long or too often within a short time in
Stillstandsregeneration. standstill mode.
Ölwechsel durchführen und Zähler zurücksetzen. Make oil change and reset counter.
1889 524189 9 2-6-9 Master / Slave Can gestört. Master / Slave Can disturbed.
1891 524190 14 272 Leistungsreduktion Schritt 1 Inducement level 1 activ
1892 524191 14 273 Leistungsreduktion Schritt 2 Inducement level 2 activ
1893 524193 8 275 Zeit des Motors im Modus Stillstandsregeneration größer als The standstill-regeneration mode time exceeds the long limit
Grenze Langzeitinterval. threshold.
Der Motor war zu lange oder zu oft im Modus Vehicle was too long or too often in standstill mode.
Stillstandsregeneration.

533
534

1894 524194 8 276 Zeit des Motors im Modus Stillstandsregeneration größer als The standstill-regeneration mode time exceeds the
Grenze Kurzzeitinterval short-limit.
Der Motor war zu lange oder zu oft im Modus Vehicle was too long or too often within a short time in
Stillstandsregeneration. standstill mode.
1895 3519 12 277 DEF Tank Temperatur, Temperatur zu hoch DEF tank temperature, temperature too high
1896 3520 3 278 DEF Qualitätssensor, Kurzschluss gegen Batterie oder DEF quality sensor, short circuit to battery or open load
Kabelbruch
1897 3520 4 278 DEF Qualitätssensor, Kurzschluss gegen Masse DEF quality sensor, short circuit to ground
1898 3519 3 277 DEF Qualitätssensor, Kurzschluss gegen Batterie oder DEF quality sensor, internal temperature sensor short circuit
Kabelbruch des internen Temperatursensors to battery or open load
1899 3519 4 277 DEF Qualitätssensor, Kurzschluss gegen Masse des internen DEF quality sensor, internal temperature sensor short circuit
Temperatursensors to ground
1900 524195 14 279 Aufforderung zur Stillstandsregeneration auf Grund von Standstill request due to crystalisation ignored too long
Kristallisation zu lange ignoriert
1901 524196 13 2-8-3 Variantenumschaltung, Adressenkonflikt Variant handling, address error
1902 524196 2 2-8-3 Variantenumschaltung, Synchronisationsfehler Variant handling, Synchronisation error
1904 3520 2 2-7-8 DEF Qualitätssensor, schlechte DEF Qualität erkannt oder DEF quality seonsor, bad DEF quality detected or no DEF
keine Qualitätsmessung möglich measuring possible.
1905 3520 8 2-7-8 DEF Qualitätssensor, Messbedingungen nicht erfüllt DEF quality seonsor, measurement conditions not fulfilled
1906 524197 7 2-8-4 SCR; Pressure Monitoring; Back flow line; Blockierungs Urea backflow line is blocked
Erkennung

1907 3520 13 278 Urea Quality Überwachung; (Diesel Exhaust Fluid) Urea quality at UQS invalid
ultrasonic/properties sensor; Urea Konzentration/Qualität
ausserhalb der physikalischen Grenzen


1908 3519 13 277 Urea Quality Überwachung; (Diesel Exhaust Fluid) Temperature at UQS invalid
temperature sensor; Temperatur ausserhalb der
physikalischen Grenzen
1911 3532 3 127 Urea Qualität Sensor; Signalwert größer als max. Grenze Quality at UQS out of max. physical range
1912 3532 4 127 Urea Qualität Sensor; Signalwert kleiner als min. Grenze Quality at UQS out of min. physical range
1914 4365 3 669 DEF Qualitätssensor, Tank Temperatur; Kurzschluss gegen DEF qualitysensor, tank temperatur; Short circuit to battery or
Batterie oder Kabelbruch open load
1915 4365 4 6-6-9 DEF Qualitätssensor, Tank Temperatur; Kurzschluss gegen DEF qualitysensor, tank temperatur; Short circuit to ground
Masse
1917 3936 14 2-8-6 Aufforderung Stillstandsregeneration zu lange ignoriert Standstill request ignored too long.
1918 3936 14 2-8-6 Stillstand Eskalation nach Zeit, Leistungsreduktion Schritt 2 Standstill time based escalation requests Inducement step 2
1921 51 5 5-9-4 Drosselklappe, H-Brückenausgang, Kabelbruch am Intake Throttle Flap, H-Bridge, wiring harness broken at
angeschlossenen Steller connected actuator
1922 51 6 5-9-4 Drosselklappe, H-Brückenausgang, Strom über maximaler Intake Throttle Flap, H-Bridge, current above maximum
oberer Grenze threshold
1924 51 3 5-9-4 Drosselklappe, H-Brückenausgang, Kurzschluss gegen Intake Throttle Flap, H-Bridge, short circuit to battery (A02)
Batterie (A02)
1925 51 3 5-9-4 Drosselklappe, H-Brückenausgang, Kurzschluss gegen Intake Throttle Flap, H-Bridge, short circuit to battery (A67)
Batterie (A67)
1926 51 4 5-9-4 Drosselklappe, H-Brückenausgang, Kurzschluss gegen Intake Throttle Flap, H-Bridge, short circuit to ground (A02)
Masse (A02)

1927 51 4 5-9-4 Drosselklappe, H-Brückenausgang, Kurzschluss gegen Intake Throttle Flap, H-Bridge, short circuit to ground (A67)
Masse (A67)

535
536

1931 51 7 5-9-4 Drosselklappe, H-Brückenausgang, Position des Stellers Intake Throttle Flap, H-Bridge, position of actuator not
nicht plausibel (Abweichung vom soll 7%) plausible (deviation from setpoint more than 7%)
1935 51 3 5-9-4 Drosselklappe, H-Brückenausgang, Kurzschluss gegen Intake Throttle Flap, H-Bridge, short circuit to battery oder
Batterie oder Kabelbruch broken wiring harness
1936 51 4 5-9-4 Drosselklappe, H-Brückenausgang, Kurzschluss gegen Intake Throttle Flap, H-Bridge, short circuit to ground
Masse
1939 524198 11 3-1-3 Hardware failure Fehlercode aktiv im Master Steuergerät Inducement HW Failure Master
1940 524199 11 3-1-3 Hardware tampering Fehlercode aktiv im Master Steuergerät Inducement SCR Tamp Master
1941 524200 11 3-1-3 DEF Qualität Fehlercode aktiv im Master Steuergerät Inducement Urea QTY Master
1942 524201 11 3-1-3 DEF Level Fehlercode aktiv im Master Steuergerät Urea Level Error Master
1943 524202 11 3-1-3 SCR Fehlercode aktiv im Master Steuergerät Urea Temp. Error Master
1944 524203 11 3-1-3 M/S Monitoring Fault Coupling: FID6 in the slave not present Urea Level Replace Master
1945 524204 11 3-1-3 M/S Monitoring Fault Coupling: FID7 in the slave not present SCR System Afterrun Master
1946 524205 11 3-1-3 M/S Monitoring Fault Coupling: FID8 in the slave not present Switch Off SCR System Master
1947 524206 11 3-1-3 M/S Monitoring Fault Coupling: FID9 in the slave not present Disable SCR Dosing Master
1948 524207 11 3-1-3 M/S Monitoring Fault Coupling: FID10 in the slave not INH EAT Regeneration Master
present
1949 524208 11 3-1-3 M/S Monitoring Fault Coupling: FID11 in the slave not Power Reduction 1 Master
present

1950 524209 11 3-1-3 M/S Monitoring Fault Coupling: FID12 in the slave not Power Reduction 2 Master
present


1951 524210 11 3-1-3 M/S Monitoring Fault Coupling: FID13 in the slave not Urea CONC Replace Master
present
1952 524211 11 3-1-3 M/S Monitoring Fault Coupling: FID14 in the slave not Urea Quality Error Master
present
1953 524212 11 3-1-3 M/S Monitoring Fault Coupling: FID15 in the slave not DEF Sensor Diag. Off Master
present
1954 524213 11 3-1-3 M/S Monitoring Fault Coupling: FID16 in the slave not DEF Sens Temp. Replace Master
present
1971 524230 11 3-1-5 Hardware failure Fehlercode aktiv im Slave Steuergerät. Inducement HW Failure Slave
1972 524231 11 3-1-5 Hardware tampering Fehlercode aktiv im Slave Steuergerät Inducement SCR Tamp. Slave
1973 524232 11 3-1-5 DEF Qualität Fehlercode aktiv im Slave Steuergerät Inducement Urea QTY Slave
1974 524233 11 3-1-5 DEF level Fehlercode aktiv im Slave Steuergerät Urea Level Error Slave
1975 524234 11 3-1-5 SCR Fehlercode aktiv im Slave Steuergerät Urea Temp. Error Slave
1976 524235 11 3-1-5 M/S Monitoring Fault Coupling: FID6 in the master not Urea Level Replace Slave
present
1977 524236 11 3-1-5 M/S Monitoring Fault Coupling: FID7 in the master not SCR System Afterrun Slave
present
1978 524237 11 3-1-5 M/S Monitoring Fault Coupling: FID8 in the master not Switch Off SCR System Slave
present
1979 524238 11 3-1-5 M/S Monitoring Fault Coupling: FID9 in the master not Disable SCR Dosing Slave
present

1980 524239 11 3-1-5 M/S Monitoring Fault Coupling: FID10 in the master not INH EAT Regeneration Slave
present

537
538

1981 524240 11 3-1-5 M/S Monitoring Fault Coupling: FID11 in the master not Power Reduction 1 Slave
present
1982 524241 11 3-1-5 M/S Monitoring Fault Coupling: FID12 in the master not Power Reduction 2 Slave
present
1983 524242 11 3-1-5 M/S Monitoring Fault Coupling: FID13 in the master not Urea CONC Replace Slave
present
1984 524243 11 3-1-5 M/S Monitoring Fault Coupling: FID14 in the master not Urea Quality Error Slave
present
1985 524244 11 3-1-5 M/S Monitoring Fault Coupling: FID15 in the master not DEF Sensor Diag. Off Slave
present
1986 524245 11 3-1-5 M/S Monitoring Fault Coupling: FID16 in the master not DEF Sens Temp. Replace Slave
present


Trouble shooting – Trouble shooting, hydraulics
12.5 Trouble shooting, hydraulics
12.5.1 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.
Diesel engine running, travel lever

position "0"
Fig. 394: Charge pressure (6S) present

1 Charge pump
2 Variable displacement pump
3 Hydraulic motor
4 Charge pressure relief valve (example 30 bar)
5 Pressure relief valve (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.
Trouble shooting closed travel cir-
cuit, example travel circuit
Fig. 395
10 Pressure resistance plugs
1. Connect pressure gauges (6) for high pressure and charge
pressure.
2. Disconnect hydraulic motor / ´hydraulic motors (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 /hydraulic motors (3).

12.5.2 Trouble shooting axial piston pumps

The following table should be of help when performing trouble-
shooting. This table is by no means complete. In practice you may
encounter problems 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 over the function of the product in connec-
tion 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 occur?
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 relief 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.


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.


Insufficient suction conditions, e.g. air in the Remove foreign bodies from
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 relief 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.
12.5.3 Trouble shooting axial piston motors

The following table should be of help when performing trouble-
shooting. This table is by no means complete. In practice you may
encounter problems 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 over the function of the product in connec-
tion 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 occur?

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!


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 relief 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

Trouble shooting – Trouble shooting, air conditioning system
12.6 Trouble shooting, air conditioning system

General 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.
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 discolorations on conductors
are found, these should 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 in 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 Measuring the pressure in the refrigerant circuit
12.6.1 Trouble shooting in refrigerant circuit, basic principles

Requirements For trouble shooting two requirements must be fulfilled:
n Expert knowledge
n technical equipment

Technical equipment Pressure gauge and thermometer are the most important auxiliary
means for trouble shooting. The refrigerant states, such as over-
heating and undercooling, provide important information when per-
forming trouble shooting. Even your own senses should not be
underrated in trouble shooting. Bubbles in the inspection glass,
contamination and white frost are visible indicators. If the com-
pressor 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 should be available for
trouble shooting:
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
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) over-
pressure 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 pres-
sure is needed for the calculation and determination of material
data.
Pabs = Pamb + Pe
Pabs = absolute pressure
Pamb = atmospheric air pressure (ambient pressure)
Pe = Overpressure (pressure gauge reading)

Example:
A totally empty air conditioning system holds an atmospheric pres-
sure of approx. Pambp = 1 bar.
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
Fig. 396: Pressure gauge
Pressure gauge with saturation

temperature scale
Temperature 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 indi-
cated temperatures 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, high pressure gauges a red
border.
Fig. 397: Absolute pressure gauge
Thermometer The thermometers used are normally digital thermometers with

surface or attachment sensors. Good heat insulation of the meas-
uring location must be assured, especially in case of big tempera-
ture differences. An economical use of heat-conduction paste is
recommended. If the measuring location is excessively contami-
nated, 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.
Overheating
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, overheating
has further advantages. Since the fluid proportions in the drawn in
steam reduces the flow rate of the compressor, it may be
increased by a overheating. Overheating also improves the oil
recirculation.
Common overheating values The optimal overheating value is approx. 5 - 8 Kelvin. With this
overheating the maximum system power is reached. However, the
thermostatic expansion valve is unable to regulate this value
exactly. Depending on design and operating conditions over-
heating fluctuates within a range between 4 and 12 Kelvin. The
influence of the ambient air on the suction line causes an additional
overheating effect.
Overheating is calculated as fol- Δ t o2h = t o2h - t o

lows:
Δ t o2h, overheating at evaporator outlet in K
to2h, temperature at evaporator outlet in °C
to, evaporation temperature in °C
"h" represents "overheated"
Supercooling
It is the function of the expansion valve to reduce the refrigerant to

a lower pressure level (evaporation pressure) after it has been liq-
uefied. For an optimal function of the valve 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's why the vaporous refrigerant needs a much longer
time to "squeeze" through the throttle gap.
Vaporous refrigerant in front 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" condition directly on the boiling curve, slightest fluctuations in
operating condition may cause a formation of bubbles in front of
the expansion element.

For this reason one shifts the condition "Expansion Valve Inlet"
away from the boiling curve into the fluid area and refers to this
condition as Supercooling. This supercooling ensures a fluid
supply in front of the expansion valve.
Common supercooling values In systems with fluid container the supercooling at the fluid con-
tainer outlet is approx. Zero "0" Kelvin (assumed that the system is
filled with the correct refrigerant quantity). In this case the fluid con-
tainer provides the required fluid supply.
Supercooling is calculated as fol- Δ t c2u = t c - t c2u

lows:
Δ t c2u, supercooling at evaporator outlet in K
tc2u, temperature at evaporator outlet in °C
tc, evaporation temperature in °C
"u" represents "supercooled"

Fig. 398: Refrigerant circuit with t, h- diagram

1 Hot gas line (overheated steam) 9 Evaporator
2 Deheating (overheated steam) 10 Overheating (overheated steam)
3 Condenser / liquefier 11 Suction steam line (overheated steam)
4 Condensation (wet steam) 12 Compressor
5 Fluid line (supercooled fluid) 13 Supercooling (fluid)
6 Expansion valve 14 Compaction
7 Injection line (wet steam) 15 Expansion
8 Evaporation (wet steam)

Fig. 399: Refrigerant circuit diagram

1 Cold air 9 Pressure switch with high and low pressure contacts
2 Evaporator 10 Dryer
3 Thermostat 11 Fluid container
4 Warm air 12 Hot air
5 Gebläse 13 Compressor
6 Inspection glass 14 Condenser
7 Expansion valve 15 Cooling air
8 Pressure gauge, high pressure 16 Pressure gauge, low pressure

12.6.2 Trouble shooting procedure

Knowledge Trouble shooting is not possible with exact knowledge about the
system design, the installed components and their function in the
system trouble shooting is not possible:
Visual inspection With the appropriate experience some faults can be visually
detected or felt. Frequently occurring condenser soiling or forma-
tion of steam bubbles in the inspection glass can be quickly
detected.
In case of unusual formation of hoarfrost on the evaporator the
hoarfrost pattern provides useful information. Hoarfrost only occur-
ring at the inlet side is a clear indication of insufficient refrigerant
feed, which in turn indicates an incorrectly working expansion valve
or a lack of refrigerant.. Complete hoarfrost covering indicates load
problems, i.e. no or insufficient air flow.
Even overheating 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 indicator for
an extreme pressure drop in the line. Similar phenomena can be
noticed in 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. Discoloration informs about 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 components must
therefore be exactly determined by means of pressure
and temperature measurements.
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.
Measuring points and measure-

ments
Fig. 400: 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?
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.
Solution: n a) Pressure gauge, thermometer, steam table

n b) Evaporation pressure "Peo2" and temperature "to2h" are
measured at the same point on the evaporator outlet.
n c) Po = Peo2 + Pamb, "Evaporation pressure = pressure on evap-
orator + atmospheric pressure" = 1.7 bar + 1 bar = 2.7 bar.
n d) "Pc" = 2,7 bar can then be used to derive an condensing
temperature "to" of -2,2 °C from the steam table for R134a.
n e) Δto2h = to2h - to, „Overheating at evaporator outlet = evapo-
rator outlet temperature - evaporation temperature" = 3 °C -
(-2.2 °C) = 5.2 Kelvin.
n f) The determined overheating is within the usual range of 4 -
12 Kelvin.
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
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

increases drops increases drops
Compressor increases X X
speed
drops X X
Vehicle interior increases X X
temperature
drops X X
Ambient tem- increases X X
perature
drops X X

Measured variable Suction pressure High pressure

Humidity increases X X
drops X X
Suction pressure too low (1), high

pressure too low to normal (2)
Fig. 401
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

Suction pressure normal (1), high

pressure too high (2)
Fig. 402

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

Suction pressure too high (1), high

pressure too low to normal (2)
Fig. 403

Compressor defective Cooling power too low Replace the compressor

Suction pressure too high (1), high

pressure too high (2)
Fig. 404

Expansion valve defective overheating too low, wet operation of compressor Replace the valve
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

Symptom Cause Possible effect Remedy

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
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
12.6.3 Leak test
NOTICE!
The use of leak detection colouring matter is not per-
mitted, 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. 405
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. 406: Soap bubble test
12.6.4 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. 407

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. 408: Measuring the air gap
at 24 Volt vehicle voltage approx. 1.75 Amp.
Overcurrent indicates a short circuit inside the mag-
netic coil.
No current indicates an interrupted electric circuit.

Trouble shooting – Troubleshooting, additional heating
12.7 Troubleshooting, additional heating
Assembly drawing
9
11
8
7
10
6 5
4
12
2
13
S-586-0262
Fig. 409
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)
10 Lining – plug socket, with assembly tool
11 Cover
12 Outer shell (bottom part)
13 Flange gasket
12.7.1 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.

12.7.2 Trouble shooting
WARNING!
Danger of burning on hot components!
Wear your personal protective outfit (protective gloves,
protective clothing).
NOTICE!
For repair work the AIRTRONIC must generally be de-
energized. For this purpose pull the plug-in connection
off the AIRTRONIC.
If the AIRTRONIC does not start after being switched on:

n Switch the AIRTRONI Off and on again, but not more than 2
times in succession.
If the AIRTRONIC still does not start, please check:
n Fuel in tank?
n Fuses O.K.?
n Electric cables, connections, terminals O.K.?
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 unit for short circuit.
In this case no fault code will be submitted.

12.7.3 Diagnostics with the module clock

Diagnostics with module clock, S28
The electronic control unit is able to store up to 5
faults, which can then be read out with the module
clock and displayed.
If the control unit detects a fault when the heater is switched on or

during heater operation, this will be displayed by the module clock
with F:XX within a period of approx. 15 seconds.
Example
F:64 and flashing heating symbol Ä Fig. 410.
Fig. 410
1 Display field with fault display
2 Rotary switch for temperature pre-selection
3 Push button to set time/week day
4 Push button to activate switch on period
5 Push button auxiliary heating On/Off
6 Push button to reduce the heating period
7 Push button to extend the heating period
Querying the fault log with the

module clock
1. Press push button (5).
ð The heater is switched on.
2. Press push button (3), hold it depressed and press push
button (4) within 2 seconds.
ð The current fault is displayed, e.g. F:64
Querying all other faults

Fig. 411
With button (6) and button (7) you can call up
all other saved faults (max. 5 faults).

Deleting the error log

1.
Condition
There must be an electrical connection between
terminal 15 (ignition) and the module clock, 12-
pin plug, pin 10.
Turn the ignition key to position "I".
Fig. 412: Switch the ignition on
2. Press push button (5).

ð The current fault is displayed.
3. Press push button (3), hold it depressed and press push
button (4) within 2 seconds.
ð The module clock is now in the program “Query error
log”.
Fig. 413
4. Turn the ignition key to position "0".
Fig. 414: Switch the ignition off
5. Press button (3) and button (4) simultaneously, switch the

ignition on at the same time and wait until the display shows
the following reading Ä Fig. 416.
Fig. 415

ð Display flashing, heating symbol not flashing.

After 3 seconds the control unit is unlocked, the heater
unit will then start and the display will show the following
reading Ä Fig. 417.
Fig. 416: Display reading after igni-

tion “On”
ð No actual fault, heating symbol.
Fig. 417: Display reading after the

heater unit has been started

12.7.4 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 con-
trol 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. 418.
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. 418
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.

If the measured fuel quantity is outside the values listed

above, the dosing pump needs to be replaced.

12.7.5 Circuit diagram, AIRTRONIC D2/D4
Fig. 419
1 Overheating and flame sensor
2 Fan motor
3 Glow pin

4 Control unit
5 Control elements, module clock
6 Fuel dosing pump
7 Fuses
8 Ignition switch
sw black
ws white
rt red
ge yellow
gn green
vi violet
br brown
gr grey
bl blue
li lilac
Resistance values
Component AIRTRONIC D2 AIRTRONIC D2 AIRTRONIC D4 AIRTRONIC 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
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 AIRTRONIC D2 AIRTRONIC D4

Power 4800 rpm ± 140 rpm 4400 rpm ± 130 rpm
High 4000 rpm ± 120 rpm 3600 rpm ± 100 rpm
Medium 2800 rpm ± 80 rpm 2800 rpm ± 80 rpm
Low 2000 rpm ± 60 rpm 1600 rpm ± 50 rpm
Ventilation 4800 rpm ± 140 rpm 3600 rpm ± 100 rpm

12.7.6 Fault code, AIRTRONIC D2/D4

Fault code Description of fault Remedy
000 Without fault
004 Warning: Short circuit in control unit, n Replace the control unit.
output fresh air Pin16: Output not used by
BOMAG.
005 Warning: Short circuit in control unit, n Replace the control unit.
output anti-theft system Pin15: Output not
used by BOMAG.
009 Shut down by emergency stop function n Replace the control unit.
Pin13 and Pin14: Inputs not used by BOMAG.
010 Overvoltage applied for at least 20 sec- n Disconnect the plug-in connection from the
onds without interruption on the control AIRTRONIC, then start the engine, measure
unit – AIRTRONIC without function. the voltage on plug (PIN1) and (PIN10).
AIRTRONIC 12 Volt - Voltage > 16 Volt ®
Check the generator regulator
AIRTRONIC 24 Volt - Voltage > 32 Volt ®
Check the generator regulator.
011 Undervoltage applied for at least 20 n Disconnect the plug-in connection from the
seconds without interruption on the AIRTRONIC, the engine is shut down,
control unit – AIRTRONIC without func- measure the voltage on plug (PIN1) and
tion. (PIN10).
Measuring value and voltage on battery should
not deviate. In case of a voltage drop check the
fuses, the supply lines, the ground connections
and the plus point on the battery for corrosion
and correct contact.
012 Overheating sensor report a too high n Check the hot air lines for confinement ®
temperature. Remove the confinement.
n Check the overheating sensor, if O.K. ®
Check the fuel supply: Check the strainer in
the dosing pump, Check fuel lines for leaks,
check hose connections and retighten.
013 The flame sensor report too high tem- n Check the hot air lines for confinement ®
perature on the heat exchanger. Remove the confinement.
Check the overheating sensor, if O.K. ®
014 Temperature difference between flame n Check the hot air lines for confinement®
sensor and overheating sensor too Remove the confinement.
high. n Check the overheating sensor, if O.K. ®
Check the overheating sensor, if O.K. ®


015 Operation blocked: n Replace the control unit.
Fault code 015 is displayed after the
AIRTRONIC has been switched on
again after the fault code 017 had been
displayed.
The hardware threshold for the over-
heating sensor has been exceeded ®,
the control unit is locked.
017 Overheating: n Replace the control unit.
The hardware threshold for the over-
heating sensor has been exceeded,
because the control unit did not recog-
nize the fault codes 012 or 013 ®, the
control unit is locked.
020 Glow pin - interruption n Check the glow pin for continuity.
021 Glow pin output – Short circuit n If the values of the continuity test are func-
tion test are O.K. ®
Check the glow pin for damage and con-
tinuity, if O.K. ®
Replace the control unit.
031 Fan motor – Interruption n Check cables and fan motor for damage and
continuity, if O.K. ®
032 Fan motor - short circuit
Check the function of the fan motor, if O.K.
®
033 The fan motor does not turn, speed n Check the speed of the combustion air fan
deviation > 10 % of nominal value and with a contact free rpm-meter.
longer than 30 seconds.
Speed too low:
n Fan blocked – Check free-running of the fan,
if necessary remove any foreign matter, if
O.K. ®
Check the fan motor (see fault code 032).
Engine speed to high:
n Magnet missing on impeller ®
Replace the fan.
If the rotary speed sensor in the control unit is

defective ® Replace the control unit.


047 Dosing pump - short circuit or overload n Pull the plug off the dosing pump, if the fault
code 048 (interruption) is displayed, the
dosing pump is defective ®
Replace the dosing pump.
n If the fault code 047 stays on, disconnect the
plug-in connection from the AIRTRONIC, on
the plug (PIN 5) check the line to the dosing
pump for short circuit to ground (PIN 10), if
O.K. ®
048 Dosing pump - interruption n Pull the plug off the dosing pump and
measure the resistance value of the dosing
pump, if the resistance value is O.K. ®
Reconnect the wiring loom to the dosing
pump.
n Disconnect the plug-in connection from the
AIRTRONIC and measure the resistance
between (PIN 5) and (PIN 10), if O.K. ®
050 Locking of the control unit after too n Unlocking of the control unit by deleting the
many unsuccessful starting attempts fault log.
(max. 255 starting attempts).
051 Flame detected when switching on If the resistance of the flame sensor is 1274 W (>
70 °C) after switching on, the fan of the AIR-
TRONIC will run for approx. 15 minutes for
cooling. If the resistance value (1274 W) is not
fallen short of within 15 minutes, a fault related
shut down will take place.
052 Exceedance of safety time No flame detected during the starting phase.
n Check the exhaust gas and combustion air
ducts.
n Check the fuel supply / measure the fuel
quantity.
n Check the glow pin (see fault code 020 and
021).
053 Flame cut-off in control stage
AIRTRONIC has ignited and reports a flame cut-
“POWER”
off in a power stage.
054 Flame cut-off in control stage “HIGH” n Check the exhaust gas and combustion air
055 Flame cut-off in control stage ducts.
“MEDIUM” n Check the fuel supply / measure the fuel
quantity.
n Check the glow pin (see fault code 020 and
021).


056 Flame cut-off in control stage “LOW”
060 Interruption - external temperature
sensor not used by BOMAG.
061 Short circuit - external temperature
sensor connection not live on BOMAG.
062 Control element - interruption n Pull the plug off the control element and
measure the resistance of the nominal value
potentiometer between (PIN 9 and PIN 6). If
the resistance value is O.K. ®
Reconnect the plug.
n Disconnect the plug-in connection from the
AIRTRONIC and measure the resistance
between (PIN 6 and PIN 7), if O.K. ®
063 Control element - short circuit n Disconnect the plug from the control ele-
ment, if fault code 062 is displayed ®
The fault detection only works in heater
operation. However, if the short circuit Replace the control element.
is already present and the AIRTRONIC n If the control element is O.K. ® check the
is switched on, “Ventilation” will be connecting lines 0.5 gr/rt and 0.5 br/ws for
active (no fault code). short circuit, if O.K. ®
Reconnect the plug to the control element.
064 Flame sensor -interruption n Disassemble the control unit and pull the
green plug off the control unit. Check the
flame sensor, if O.K. ®
065 Flame sensor - short circuit n Disassemble the control unit, pull the green
plug off the control unit, if fault 064 is dis-
played ®
Replace the combined sensor.
If fault 065 is still displayed ®
071 Overheating sensor - interruption n Disassemble the control unit and pull the
blue and green plugs off the control unit.
Measure the resistance on the blue plug
(PIN 1) and on the green plug (PIN 2), if
O.K. ®
072 Overheating sensor - short circuit n Disassemble the control unit, pull the blue
plug off the control unit, if fault 071 is dis-
played ®
Replace the combined sensor.
If fault 072 is still displayed ®
090 Control unit defective (internal fault) n Replace the control unit.


091 External interference voltage Disturbance of the control unit by interference
voltage from the vehicle network. Possible
cause:
n Poor battery, battery charger ®
Rectify the interference voltage.
092 Control unit defective (ROM fault) n Replace the control unit.
094 Control unit defective (EEPROM fault) n Replace the control unit.
096 Internal temperature sensor defective n Replace the control unit or use an external
temperature sensor.
097 Control unit defective n Replace the control unit.

Special tools
13 Special tools

Special tools – Special tools, electrics
13.1 Special tools, electrics
Special tool kit
n Special pliers tool kit consisting of:

n BOMAG part-no.: 079 950 03
n - different tool heads
n - unlocking tools
n - manual
n - operating instructions and plastic box to store the different
Fig. 420: TOO-07995003 contacts
The contacts are not contained in the kit. Depending

on the contact to be crimped, the matching tool head
must be attached to the handle.
Equipment kit for special tool kit (1)
n Equipment kit
Fig. 421
Electric measuring case
n Electric measuring kit consisting of:

n - Prong-type instrument
n - Measuring adapter
n - Measuring cables
n - Screwdriver
Fig. 422 n - Other accessories

Special tools – Special tools, hydraulic system
13.2 Special tools, hydraulic system

13.2.1 Special tools, tests and adjustments
n Hydraulic test case, large
4 X 600 bar pressure gauges

4 X 60 bar pressure gauges
8 pressure test hoses
Fig. 423
n Hydraulic test case, small

2X 60 bar pressure gauge

2X 600 bar pressure gauges
4 pressure test hoses
Fig. 424
n Pressure test hoses

n 1000 mm BOMAG part-no.: 079 930 02
n 2500 mm BOMAG part-no.: 079 930 03
Fig. 425

n Pressure gauge
n 60 bar BOMAG part-no.: 059 721 07
n 600 bar BOMAG part-no.: 059 721 04
Fig. 426
n Adapter for pressure test hose

Fig. 427
n Gear pump testing device

Fig. 428

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. 429
13.2.2 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. 430
n Flushing filter (S connection)

n Filter element 1μ
n Flushing hose 20S - 25S (2 pieces)
n Screw socket R1“ - 25S (2 pieces)
Fig. 431
n Flushing filter (L connection)

n Filter element
n Flushing hose 15L (2 pieces)
n Screw socket R3/4“ -- 15L (2 pieces)
Fig. 432

n SAE-flange 1“ - 20S
n O-ring
n BOMAG part-no. 062 203 30
Fig. 433
n Flanged plate 1“ - 25S

n O-ring
n BOMAG part-no. 062 202 22
Fig. 434
n Reducing fitting 18L - 15L

Fig. 435
n Reducing fitting 25S - 20S

Fig. 436

n Reducing fitting 20S - 16S

Fig. 437
n Connecting socket 15L

Fig. 438
n Connecting socket 18L

Fig. 439
n Connecting socket 16S

Fig. 440

n Connecting fitting 20S

Fig. 441
n Connecting fitting 25S

Fig. 442
n Angular fitting 18L

Fig. 443
n Elbow fitting 16L

Fig. 444

n Elbow 20S
Fig. 445
n Elbow 25S
Fig. 446
n Pipe connection 16S - 16S

Fig. 447
n Connecting hose 15L

Fig. 448

Special tools – Special tools for oscillating articulated joint
13.3 Special tools for oscillating articulated joint

n Pressing device for rocker bearings
Fig. 449
n Pressing bushing for outer rocker bearing race
Fig. 450
n Pressing bushing for inner rocker bearing race
Fig. 451
n Guide pin
Fig. 452

Special tools – Special tools for oscillating articulated joint
n Clamping device
Fig. 453
n Disassembly device
Fig. 454

Special tools – Special tools, drum
13.4 Special tools, drum

n Disassembly device for side plate
Fig. 455
n Assembly device for side plate

Fig. 456
n Assembly device for coupling hub and flanged hub
Fig. 457
n Pressing plate for cylinder roller bearing
Fig. 458

Special tools – Special tools, drum
n Pressing plate for travel bearing
Fig. 459
n Pressing bushing for radial seal
Fig. 460
n Lifting device for exciter unit

Fig. 461

Special tools – List of special tools
13.5 List of special tools

Belt tension tester
BOMAG No. 079 947 09
Fig.
Rotation angle disc

BOMAG 057 250 72
Fig.

Index
14 Index
C
Circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607
E
Electric systems
Circuit diagram for optional heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 574
Electrics training
Machine control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
F
Fuels and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
H
Hydraulic units
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
L
List of fault codes
Engine control, DTC-list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480
Machine control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
Optional heating, AIRTRONIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578
List of fuels and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
M
Maintenance
Fuels and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
List of fuels and lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Maintenance intervals
Additional heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Drive axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
Electric systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
O
Operating means
A01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
A02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
A12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 90, 632
A15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 83, 96, 113, 156, 632
A16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 90, 632
A34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59, 70, 75, 96, 98, 156, 632
A48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59, 60, 70, 75, 96, 98, 136, 155, 156, 632
A67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 92, 96, 156, 632
A83 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59, 70, 75, 95, 96, 98, 156, 632
A87 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 94, 96, 156, 632
A93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74, 75, 632
A108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
A124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59, 70, 75, 91, 96, 98, 156, 632
A138 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 91, 632
A144 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96, 156
A162 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96, 156

Index
A175 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96, 156

A177 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96, 156
B03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 84, 128, 632
B11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
B11.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 85, 632
B11.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 85, 632
B11.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
B11.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
B21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 85, 127, 217, 632
B30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
B51.L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
B51.R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
B51L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
B51R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
B55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 84, 130, 632
B57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59, 70, 75, 98, 632
B59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 88, 632
B60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
B62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 95, 123, 632
B88 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 167, 632
B93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 167, 632
B97 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
B104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 284, 632
B105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268, 279
B113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 167, 632
B114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 167, 632
B124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60, 75, 84, 129, 136, 155, 174, 632
B130 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 167, 632
B133 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 167, 632
B145 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 167, 632
B171 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 95, 123, 632
B208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
B209 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
B218 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
B234 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62, 75, 197, 223, 225, 632
B235 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62, 75, 197, 223, 225, 632
B236 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62, 75, 197, 223, 225, 632
B237 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62, 75, 197, 223, 225, 632
B238 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
B312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
B313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
D2.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 107, 632
D2.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 107, 632
D2.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 107, 632
D2.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 107, 632
D05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 102, 632
D6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
D09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 102, 632
D11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 102, 632
D13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 102, 632
D16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 102, 632
D22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 102, 632
D38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 102, 632
D41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 102, 632
D43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 102, 632
D48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 102, 632
D61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 102, 632
D118 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
D145 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 102, 632

Index
D209 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 102, 632

DX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 102, 106, 632
E08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
E09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
E10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
E11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
E12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
E13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
E14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
E15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
E16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
E17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
E23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 89, 632
E25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 89, 632
E27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 89, 632
E28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 89, 632
E29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
E30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
E32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 89, 632
E72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
E243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
F00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 86, 632
F05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 105, 632
F07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 105, 632
F08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 105, 632
F09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 105, 632
F10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 105, 632
F11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 105, 632
F13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 105, 632
F17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 107, 632
F19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 105, 632
F22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 105, 632
F23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 105, 632
F24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 105, 632
F27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 107, 632
F28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 107, 632
F29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 105, 632
F39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 105, 632
F40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 105, 632
F48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 86, 632
F67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 105, 632
F68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 105, 632
F84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 105, 632
F91 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 105, 632
F95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 86, 632
F103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 105, 632
F122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 105, 632
F124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 105, 632
F143 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 107, 632
F146 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 105, 632
F148 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 105, 632
F150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 107, 632
F157 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 105, 632
F164 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 86, 632
F169 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 105, 632
F243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
F244 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 105, 632
F264 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 107, 632
F266 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 107, 632

Index
F268 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 105, 632

F271 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 107, 632
F272 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 107, 632
F279 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 107, 632
F320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 93, 330, 632
F321 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 93, 330, 632
FM1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 105, 632
FM2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 105, 632
FX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
G01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 87, 632
G02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 84, 86, 632
G03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 87, 632
H06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
H07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 83, 632
H14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 85, 632
K05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 104, 632
K06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 104, 632
K09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 104, 632
K11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 104, 632
K13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 104, 632
K14.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
K16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 104, 632
K20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 107, 632
K21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 107, 632
K22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 104, 632
K32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 107, 632
K38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 104, 632
K39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
K41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 104, 632
K43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 104, 632
K48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 104, 632
K61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 104, 632
K78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
K141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 107, 632
K145 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 104, 632
K209 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
M01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 86, 632
M04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
M05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
M06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 83, 632
M07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 83, 632
M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
M25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
P09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 90, 632
P11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
P15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 96, 156, 632
P32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
P42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
P43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
R03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 131, 632
R06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
R10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 102, 632
R19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 173, 632
R20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
R21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
R22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
R23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
R24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
R25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632

Index
R26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632

R27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
R28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
R29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
R30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
R31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
R32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
R79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 174, 632
R80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
R80.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
R80.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
S00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 83, 113, 632
S01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 83, 113, 632
S06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
S09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 83, 113, 632
S14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
S15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 113, 632
S25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
S26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 113, 632
S28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 330, 569, 632
S29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
S30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 86, 87, 632
S35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 83, 632
S36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 83, 632
S37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 113, 632
S42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 83, 113, 632
S55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 83, 96, 113, 156, 632
S64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 83, 632
S107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 83, 632
S127 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 83, 113, 632
S139 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
S154 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
S299 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
V01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
V02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
V03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
V04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
V05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
V06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
V07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
V08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
V09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
V10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
Y04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61, 75, 85, 196, 217, 223, 225, 632
Y07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63, 75, 85, 198, 228, 632
Y08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63, 75, 85, 198, 228, 632
Y14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93, 330
Y15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 84, 268, 632
Y16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63, 75, 85, 198, 226, 632
Y17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63, 75, 85, 198, 226, 632
Y30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61, 75, 85, 88, 196, 223, 632
Y31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61, 75, 85, 196, 225, 632
Y60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
Y72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63, 75, 85, 198, 224, 632
Y73 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63, 75, 85, 198, 224, 632
Y98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
Y102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
Y122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
Y123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632

Index
Y137 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632

Y140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
Y141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
Y142 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
Y143 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
Y144 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
Y145 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
Y147 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
Y148 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
Y149 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
Y166 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
Y170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
Y174 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
Y261 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
Y378 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
Y379 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
Y380 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75, 632
Overview
Central electrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59, 70, 98
Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60, 136, 155
Diesel engine, coolant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Diesel engine, exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Diesel engine, injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144, 164
Diesel engine, lubrication oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64, 221, 231, 310
Electric system, CAN-BUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96, 156
Electric system, fuse assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Electric system, wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Electrics, cabin control console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Electrics, diesel engine with sensors and actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Electrics, power board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61, 196
Hydraulic system, charge circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Hydraulic system, pump overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62, 197
Hydraulic system, steering circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Hydraulic system, travel circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Hydraulic system, vibration circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Hydraulics, closed circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Hydraulics, flushing diagram for axle drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
Hydraulics, flushing diagram for drum drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Hydraulics, flushing diagram for vibration circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
Hydraulics, open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Optional heating, AIRTRONIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
P
Plugs
X0A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86, 101
X0B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84, 101
X0C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86, 101
X1A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84, 101
X1B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
X2A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85, 101
X2B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85, 101
X4A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83, 101
X4B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83, 101
X4D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83, 101
X4E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89, 102

Index
X5A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
X5B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
X5E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95, 101
X6B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83, 101
X6C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83, 101
X6D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91, 101
X7A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83, 101
X7B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92, 101
X7C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93, 101
X7D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
X8A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89, 102
X8B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89, 102
X10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
X11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
X12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
X14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83, 89
X15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
X16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
X20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
X21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
X23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
X24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
X25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
X26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
X30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
X31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
X32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59, 60, 70, 96, 98, 99, 136, 155, 156, 162
X33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
X34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59, 70, 96, 98, 99, 156
X41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60, 136, 155
X50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
X55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
X56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
X57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
X58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
X65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
X66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
X67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
X68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
X69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
X72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
X73 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
X76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
X78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
X79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
X80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
X81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
X82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
X83 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
X85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89, 94
X87 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
X88 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
X90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
X91 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
X93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
X94 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
X95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
X96 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
X99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Index
X100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
X101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84, 99
X102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83, 99
X103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85, 99
X104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88, 99
X105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
X106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
X107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95, 99
X108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84, 99
X109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
X200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89, 107
X201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89, 107
X202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89, 107
X203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89, 107
X204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94, 107
X205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90, 107
X206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
X207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
X210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
X211 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
X400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96, 156
XS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
XS28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
T
Table of operating means . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Trouble shooting
Additional heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 566
Axial piston motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 545
Axial piston pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 543
Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 476
Electric systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540

Appendix
Appendix

Appendix
A Circuit diagrams
A.A Hydraulic diagram, 372
A.B Hydraulic diagram, 374
A.C Wiring diagram, 354

Circuit diagrams
A Circuit diagrams

Circuit diagrams
A.A Hydraulic diagram, 372

F26_FT001
Bomag GmbH
Hellerwald Hydraulikschaltplan
56154 Boppard
Hydraulic schematic
Projektbeschreibung BW 219 DH -5
Project description
Zeichnungsnummer 372
Drawing number
Typ BW 219 DH -5; BW 219 BVC-5; BW 219 PDH-5;
Type
Maschinenhochnummer 58600033
Machine index 58600034
58600037
58600038
58600039
Erstellt am
Created on 12.11.2015
von (Kürzel)
Bearbeitet am 01.02.2016 hagen
Edit date by (short name)

0 1 2 3 4 5 6 7 8 9
Zeichnungsnummer
Bearb. I. Hagen drawing number
Blatt
Ed. by 12.11.2015 BW 219 DH -5 Deckblatt 372 Page 1
Dokumentart
Gepr H. Christ Cover sheet document type
Blatt
Appr 01.02.2016 EPH Page 11
Circuit diagrams
609
610
Spalte X: eine automatisch erzeugte Seite wurde manuell nachbearbeitet
Inhaltsverzeichnis / Table of contents Column X: An automatically generated page was edited F06_001
Bearbeiter /
Seite / Page Seitenbeschreibung Page description Datum / Date Edited by
X
1 Deckblatt Cover sheet 12.11.2015 hagen X
2 Inhaltsverzeichnis : 1 - Legende.a Table of contents : 1 - Legende.a 01.02.2016 hagen
3 Übersicht DH Übersicht DH 12.11.2015 hagen
4 Fahrkreis DH Fahrkreis DH 01.02.2016 hagen
5 Lenkung / Einspeisung DH Lenkung / Einspeisung DH 12.11.2015 hagen
Circuit diagrams
6 Vibration DH Vibration DH 12.11.2015 hagen

7 Vario Vario 12.11.2015 hagen
8 Rückläufe Return flows 01.02.2016 hagen
9 Logiktabelle Logic table 12.11.2015 hagen
Legende Betriebsmittelliste : 01 - 23 Device tag list : 01 - 23 06.11.2015 hagen
Legende.a Betriebsmittelliste : 30 - 31 Device tag list : 30 - 31 12.11.2015 hagen

0 1 2 3 4 5 6 7 8 9
Zeichnungsnummer
Blatt
Ed. by 01.02.2016 BW 219 DH -5 Inhaltsverzeichnis : 1 - Legende.a 372 Page 2
Dokumentart
Gepr H. Christ Table of contents : 1 - Legende.a document type
Blatt
0 1 2 3 4 5 6 7 8 9
Zeichnungsnummer
Blatt
Ed. by 12.11.2015 BW 219 DH -5 Übersicht DH 372 Page 3
Dokumentart
Gepr H. Christ document type
Blatt
Circuit diagrams
611
612
5.5 / A
M14 4.6 / Q M14 A1 A2

01 02
fahren vorwärts fahren rückwärts 6.4 / R fahren rückwärts fahren vorwärts 07
to drive forward to drive backward to drive backward to drive forward 37 +/- 2 bar
Y16 Y73 6.4 / F

C1 C2 C1 C2
4.2
Y17 Y72 Q
E MA E MA
M3 L2 M3 L2 Y04
Circuit diagrams
A A P1 P2 T
8.5 / H
Δ 450 bar Δ 450 bar
25 bar (34 bar)
M4 Δ 450 bar M4 Δ 450 bar

31
Option
Option
CW CW
6.4 / J
M5 M5 OUT
B B
3,5 bar
L4 MB L4 MB 1µm nom.
6.2 M
D 2 L/min
IN
B / 8.5 G / 8.6
L2 MA N L2 MA N
09
A A
08 08 10
C6 C6
12 l/min 12 l/min
Max Min Max Min
B B
L1 L1

M4 M5 MB M4 M5 MB
0 1 2 3 4 5 6 7 8 9
Zeichnungsnummer
Blatt
Ed. by 01.02.2016 BW 219 DH -5 Fahrkreis DH 372 Page 4
Dokumentart
Blatt
12 12
links rechts
L R

11
Δ 175 bar
P T
6.4
N
30
nur bei Maschinen mit Kabine 13
Δp = 3,5 bar
Δp = 2,5 bar
04
4.2 / A
E / 8.7

0 1 2 3 4 5 6 7 8 9
Zeichnungsnummer
Blatt
Ed. by 12.11.2015 BW 219 DH -5 Lenkung / Einspeisung DH 372 Page 5
Dokumentart
Blatt
Circuit diagrams
613
614
4.8
J
4.6 / F K / 8.5
M14
4.2
03 R
große Vibration kleine Vibration
Circuit diagrams
large vibration small vibration

N / 5.4
C1 C2
Y07 Y08
F E MA
M3 L2
A
M1
14
A
(34 bar) Δ 400 bar
M4 Δ 400 bar
14,2 l/min
CW L1
17 cm³ B
M5
M2 L2
B
S L4 MB
4.2 L / 8.6
D
C / 8.7

0 1 2 3 4 5 6 7 8 9
Zeichnungsnummer
Blatt
Ed. by 12.11.2015 BW 219 DH -5 Vibration DH 372 Page 6
Dokumentart
Blatt
23
Ø 0,5
vorne P T hinten
A B
22 120 bar (±3 bar)
120 bar (±3 bar)
P5 T
P4 P6 a b
Speicher 1,4 L
20 Accumulator 1,4 L P2
Y140 Y141
Gasdruck 85 bar
Gas pressure 85 bar T2
T1
M
110 bar (±2 bar)
99 bar
P3 T
130 bar (+5 bar)
P1 T1
21
X / 8.4 8.3 / I
P1 P2
05
S1 S2

M / 8.7
0 1 2 3 4 5 6 7 8 9
Zeichnungsnummer
Blatt
Ed. by 12.11.2015 BW 219 DH -5 Vario 372 Page 7
Dokumentart
Gepr H. Christ Vario document type
Blatt
Circuit diagrams
615
616
Circuit diagrams
K / 6.6
B / 4.1
4.9 / H
L / 6.7
G / 4.5
M / 7.2
X / 7.4
I C H A F G E D E / 5.4
C / 6.4
16
7.7 / I
B
55°C - 70°C

0 1 2 3 4 5 6 7 8 9
Zeichnungsnummer
Blatt
Ed. by 01.02.2016 BW 219 DH -5 Rückläufe 372 Page 8
Dokumentart
Gepr H. Christ Return flows document type
Blatt
0 1 2 3 4 5 6 7 8 9
Zeichnungsnummer
Blatt
Ed. by 12.11.2015 BW 219 DH -5 Logiktabelle 372 Page 9
Dokumentart
Gepr H. Christ Logic table document type
Blatt
Circuit diagrams
617
618
Betriebsmittelliste Device tag list F03_001
Technische Daten Technische Daten
Betriebsmittelkennzeichen Funktionstext QVW technical data Symbol Betriebsmittelkennzeichen Funktionstext QVW technical data Symbol
Device tag Function text X-Ref Messwert Symbol Device tag Function text X-Ref Messwert Symbol
Metered value Metered value
M14 L R
C1 C2
01 Fahrpumpe vorne 4.0 89 cm³ 11 Lenkventil 5.3 500 cm³

E MA
M3 L2
A
Drive pump forwand steering valve
M4
CW
M5
B
L4 MB P T
M14
Circuit diagrams
C1 C2
02 Fahrpumpe 4.4 89 cm³ 12 Lenkzylinder 5.4 100/50/320 Hub

E MA
M3 L2
A
drive pump Steering cylinder 5.5 100/50/320 Hub
M4
CW
M5
B
L4 MB
M14
C1 C2
F E MA
03 Vibrationspumpe 6.2 78 cm³ M3 L2
A
13 Filter 5.5 12 µm abs.
vibration pump Filter
M4
CW
M5
B
Δp = 3,5 bar
S L4 MB
Δp = 2,5 bar
M1
04 Lenkpumpe 5.4 16 cm³ 14 Vibrationsmotor 6.6 63 cm³ A
Steering pump vibration motor
L1
B
M2 L2
I C H A F G E D
P1 P2
05 Zahnradpumpe 7.2 16/8 cm³ 16 Rücklaufsammler mit Thermoregler 8.6 B
Gear pump Return flows collector with thrmostat 55°C - 70°C
S1 S2
A1 A2 P5 T
P4 P6
07 Bremslöseventil 4.8 37 +/- 2 bar 20 Druckabschaltventil 7.3
brake opening velve Pressure shut-off valve
T1
P1 P2 T P3 T
L2 MA N
A
08 Fahrmotor C6 21 Hochdruckfilter
4.0 110/50 cm³ 7.2 100 µm
drive motor 4.4 110/50 cm³ High pressure filter
Max Min
B
L1
M4 M5 MB
A B
09 Achse 4.3 i= 93,74 22 Ventil 7.6 130 bar

Axis Valve
P2
T2
M
P1 T1
10 Getriebe 4.7 i=93,9 23 Schwenkantrieb 7.6 STF1-00-22

Gearbox Swivel drive

P T
* alle Drücke gemessen bei einer Öltemperatur von ca. 50°C; Verbrennungsmotor im hohen Leerlauf
* all pressure measurement at oil temperature 50 °C; combustion engine at high idle
0 1 2 3 4 5 6 7 8 9
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Ed. by 06.11.2015 BW 219 DH -5 Betriebsmittelliste : 01 - 23 372 Page Legende
Dokumentart
Gepr H. Christ Device tag list : 01 - 23 document type
Blatt
30 Silencer 5.3
Silencer
OUT
31 Nebenstromfilter 4.8 1 µm nom. 3,5 bar
1µm nom.
Partial flow filter
M
2 L/min
IN

0 1 2 3 4 5 6 7 8 9
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Ed. by 12.11.2015 BW 219 DH -5 Betriebsmittelliste : 30 - 31 372 Page Legende.a
Dokumentart
Blatt
Circuit diagrams
619
Circuit diagrams
A.B Hydraulic diagram, 374

F26_FT001
Bomag GmbH
Hellerwald Hydraulikschaltplan
56154 Boppard
Hydraulic schematic
Projektbeschreibung BW 226 DH -5
Project description
Zeichnungsnummer 374
Drawing number
Typ BW 226 DH -5; BW 226 BVC-5; BW 226 PDH-5; BW 226 DI-5; BW 226 RC-5
Type
Maschinenhochnummer 58600040
Machine index 58600041
58600042
58600043
58600044
58600045
58600046
Erstellt am
Created on 17.05.2013
von (Kürzel)
Bearbeitet am 01.02.2016 hagen
Edit date by (short name)

0 1 2 3 4 5 6 7 8 9
Zeichnungsnummer
Blatt
Ed. by 27.05.2015 BW 226 DH -5 Deckblatt 374 Page 1
Dokumentart
Gepr H. Christ Cover sheet document type
Blatt
Circuit diagrams
621
622
Spalte X: eine automatisch erzeugte Seite wurde manuell nachbearbeitet
Inhaltsverzeichnis / Table of contents Column X: An automatically generated page was edited F06_001
Bearbeiter /
Seite / Page Seitenbeschreibung Page description Datum / Date Edited by
X
1 Deckblatt Cover sheet 27.05.2015 hagen X
2 Inhaltsverzeichnis : 1 - Legende.a Table of contents : 1 - Legende.a 01.02.2016 hagen
3 Übersicht DH Übersicht DH 27.05.2015 hagen
4 Fahrkreis DH Fahrkreis DH 01.02.2016 hagen
5 Lenkung / Einspeisung DH Lenkung / Einspeisung DH 30.06.2015 hagen
Circuit diagrams
6 Vibration DH Vibration DH 30.06.2015 hagen

7 Vario Vario 30.06.2015 hagen
8 Rückläufe Return flows 30.06.2015 hagen
9 Logiktabelle Logic table 06.11.2015 hagen
Legende Betriebsmittelliste : 01 - 23 Device tag list : 01 - 23 06.11.2015 hagen
Legende.a Betriebsmittelliste : 30 - 31 Device tag list : 30 - 31 06.11.2015 hagen

0 1 2 3 4 5 6 7 8 9
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Ed. by 01.02.2016 BW 226 DH -5 Inhaltsverzeichnis : 1 - Legende.a 374 Page 2
Dokumentart
Gepr H. Christ Table of contents : 1 - Legende.a document type
Blatt
0 1 2 3 4 5 6 7 8 9
Zeichnungsnummer
Blatt
Ed. by 27.05.2015 BW 226 DH -5 Übersicht DH 374 Page 3
Dokumentart
Blatt
Circuit diagrams
623
624
5.5 / A
M14 4.6 / Q M14 A1 A2

01 02
fahren vorwärts fahren rückwärts 6.4 / R fahren rückwärts fahren vorwärts 07
to drive forward to drive backward to drive backward to drive forward 37 +/- 2 bar
Y16 Y73 6.4 / F

C1 C2 C1 C2
4.2
Y17 Y72 Q
E MA E MA
M3 L2 M3 L2 Y04
Circuit diagrams
A A P1 P2 T
8.5 / H
25 bar (34 bar)
M4 Δ 450 bar M4 Δ 450 bar

31
Option
Option
CW CW
6.4 / J
M5 M5 OUT
B B
3,5 bar
L4 MB L4 MB 1µm nom.
6.2 M
D 2 L/min
IN
B / 8.5 G / 8.6
L2 MA N L2 MA N
09
A A
08 08 10
C6 C6
12 l/min 12 l/min
Max Min Max Min
B B
L1 L1

M4 M5 MB M4 M5 MB
0 1 2 3 4 5 6 7 8 9
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Dokumentart
Blatt
12 12
links rechts
L R

11
Δ 175 bar
P T
6.4
N
30
nur bei Maschinen mit Kabine 13
Δp = 3,5 bar
Δp = 2,5 bar
04
4.2 / A
E / 8.7

0 1 2 3 4 5 6 7 8 9
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Ed. by 30.06.2015 BW 226 DH -5 Lenkung / Einspeisung DH 374 Page 5
Dokumentart
Blatt
Circuit diagrams
625
626
4.8
J
4.6 / F K / 8.5
M14
4.2
03 R
große Vibration kleine Vibration
Circuit diagrams
large vibration small vibration

N / 5.4
C1 C2
Y07 Y08
F E MA
M3 L2
A
M1
14
A
(34 bar) Δ 400 bar
M4 Δ 400 bar
14,2 l/min
CW L1
17 cm³ B
M5
M2 L2
B
S L4 MB
4.2 L / 8.6
D
C / 8.7

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Dokumentart
Blatt
23
Ø 0,5
vorne P T hinten
A B
22 120 bar (±3 bar)
120 bar (±3 bar)
P5 T
P4 P6 a b
Speicher 1,4 L
20 Accumulator 1,4 L P2
Y140 Y141
Gasdruck 85 bar
Gas pressure 85 bar T2
T1
M
110 bar (±2 bar)
99 bar
P3 T
130 bar (+5 bar)
P1 T1
21
X / 8.4 8.3 / I
P1 P2
05
S1 S2

M / 8.7
0 1 2 3 4 5 6 7 8 9
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Dokumentart
Gepr H. Christ Vario document type
Blatt
Circuit diagrams
627
628
Circuit diagrams
K / 6.6
B / 4.1
4.9 / H
L / 6.7
G / 4.5
M / 7.2
X / 7.4
I C H A F G E D E / 5.4
C / 6.4
16
7.7 / I
B
55°C - 70°C

0 1 2 3 4 5 6 7 8 9
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Ed. by 30.06.2015 BW 226 DH -5 Rückläufe 374 Page 8
Dokumentart
Gepr H. Christ Return flows document type
Blatt
0 1 2 3 4 5 6 7 8 9
Zeichnungsnummer
Blatt
Ed. by 06.11.2015 BW 226 DH -5 Logiktabelle 374 Page 9
Dokumentart
Gepr H. Christ Logic table document type
Blatt
Circuit diagrams
629
630
M14 L R
C1 C2
01 Fahrpumpe vorne 4.0 89 cm³ 11 Lenkventil 5.3 500 cm³

E MA
M3 L2
A
Drive pump forwand steering valve
M4
CW
M5
B
L4 MB P T
M14
Circuit diagrams
C1 C2
02 Fahrpumpe 4.4 89 cm³ 12 Lenkzylinder 5.4 100/50/320 Hub

E MA
M3 L2
A
drive pump Steering cylinder 5.5 100/50/320 Hub
M4
CW
M5
B
L4 MB
M14
C1 C2
F E MA
03 Vibrationspumpe 6.2 78 cm³ M3 L2
A
13 Filter 5.5 12 µm abs.
vibration pump Filter
M4
CW
M5
B
Δp = 3,5 bar
S L4 MB
Δp = 2,5 bar
M1
04 Lenkpumpe 5.4 16 cm³ 14 Vibrationsmotor 6.6 80 cm³ A
Steering pump vibration motor
L1
B
M2 L2
I C H A F G E D
P1 P2
05 Zahnradpumpe 7.2 16/8 cm³ 16 Rücklaufsammler mit Thermoregler 8.6 B
Gear pump Return flows collector with thrmostat 55°C - 70°C
S1 S2
A1 A2 P5 T
P4 P6
07 Bremslöseventil 4.8 37 +/- 2 bar 20 Druckabschaltventil 7.3
brake opening velve Pressure shut-off valve
T1
P1 P2 T P3 T
L2 MA N
A
08 Fahrmotor C6 21 Hochdruckfilter
4.0 110/50 cm³ 7.2 100 µm
drive motor 4.4 110/50 cm³ High pressure filter
Max Min
B
L1
M4 M5 MB
A B
09 Achse 4.3 i= 93,74 22 Ventil 7.6 130 bar

Axis Valve
P2
T2
M
P1 T1
10 Getriebe 4.7 i=129,2 23 Schwenkantrieb 7.6 STF1-00-22

Gearbox Swivel drive

P T
0 1 2 3 4 5 6 7 8 9
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Ed. by 06.11.2015 BW 226 DH -5 Betriebsmittelliste : 01 - 23 374 Page Legende
Dokumentart
Blatt
30 Silencer 5.3
Silencer
OUT
31 Nebenstromfilter 4.8 1 µm nom. 3,5 bar
1µm nom.
Partial flow filter
M
2 L/min
IN

0 1 2 3 4 5 6 7 8 9
Zeichnungsnummer
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Ed. by 06.11.2015 BW 226 DH -5 Betriebsmittelliste : 30 - 31 374 Page Legende.a
Dokumentart
Blatt
Circuit diagrams
631
Circuit diagrams
A.C Wiring diagram, 354

Bomag GmbH
Industriegebiet Hellerwald
D-56154 Boppard

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Created EFS M. Vogt Funktion == Blatt 1 von 85
Erstellt MFS 12.11.2015 BW 213-226 D+DH-5 Cover sheet Higher-level function
=
Anlage 354
Circuit diagrams
Checked C. Stahl Mounting location

Deutz TCD 4.1+6.1 Tier 3a Deckblatt Einbauort +
Geprüft 12.11.2015
633
EPE / 000 / 00
634
Table of contents
Inhaltsverzeichnis
Page Higher-level function Function
Blatt Anlage Funktion Description Beschreibung
1 Cover sheet Deckblatt
Circuit diagrams
2 Table of contents Inhaltsverzeichnis

5 Structure identifier overview Strukturkennzeichenübersicht
6 Structure identifier overview Strukturkennzeichenübersicht
7 Layout mounting locations Übersicht Einbauorte
8 =SUPL ==SDR Supply, Starting unit Versorgung, Starten
9 =SUPL ==SDR Fuse protection potential 30 Absicherung Potential 30
10 =SUPL ==SDR Fuse protection potential 15 Absicherung Potential 15
11 =SUPL ==SDR Supply Driving Controller Versorgung Fahrsteuerung
12 =SUPL ==SDR Supply Measurement controller Versorgung Messtechniksteuerung
13 =SUPL ==SDR Supply 8,5V sensors Versorgung 8,5V Sensoren
14 =SUPL ==SDR Supply Monitoring module, Travel lever Versorgung Überwachungsmodul, Fahrhebel
15 =COM ==SDR Communication, Diagnosis Kommunikation, Diagnose
16 =COM ==SDR Communication Kommunikation
17 =COM ==SDR Communication Kommunikation
18 =ENGI ==SDR Pre-heating, Fuel lift pump, Fuel-pre-heating Vorglühen, Kraftstoffförderpumpe, Kraftstoffvorwärmung
19 =ENGI ==SDR Engine speed, Regeneration mode Motordrehzahl, Regenerationsmodus
20 =ENGI ==SDR Engine - Machine-part Motor - Fahrzeugseite
21 =ENGI ==SDR Deutz TCD 3.6, 4.1 u. 6.1 Machine part Deutz TCD 3.6, 4.1 a. 6.1 Fahrzeugseite
22 =ENGI ==SDR Deutz TCD 4.1/6.1 Deutz TCD 4.1/6.1
23 =ENGI ==SDR Deutz TCD 4.1/6.1 Deutz TCD 4.1/6.1
24 =ENGI ==SDR Deutz TCD 4.1/6.1 - Exhaust aftertreatment Deutz TCD 4.1/6.1 - Abgasnachbehandlung
25 =MON ==SDR Monitoring, Failure indicators Überwachung, Störmeldungen
26 =DRIV ==SDR Slope sensor, Speed sensors Neigungssensor, Geschwindigkeitsaufnehmer
27 =DRIV ==SDR Pressure sensors Drucksensoren
28 =DRIV ==SDR Brake, Travel pumps, Speed ranges Bremse, Fahrpumpen, Fahrstufen
29 =DRIV ==SDR Warning horns, Back up alarm, Warnhörner, Rückfahralarm,
30 =DRIV ==SDR Travel lever Fahrhebel
31 =VIB ==SDR Vibration Vibration
32 =VIB ==SDR Variocontrol Variocontrol

33 =VIB ==SDR Dozer blade Planierschild
34 =VIB ==SDR Vibratory plate compactor Anbauplatten
35 =VIB ==SDR Vibratory plate compactor Anbauplatten
36 =MEAS ==SDR Measurement equipment Messtechnik
37 =OPT ==SDR Rops - Lighting, Socket Rops - Beleuchtung, Steckdose
38 =OPT ==SDR StVZO illumination StVZO Beleuchtung
39 =OPT ==SDR Electronical Burglary protection Elektronische Diebstahlsicherung
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=
Anlage 354
Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Inhaltsverzeichnis Einbauort + TOC EPE / 000 / 00
Table of contents
Inhaltsverzeichnis
40 =OPT ==SDR BOMAG Telematics BOMAG Telematik
41 =OPT ==SDR Cabin - Additional heater Kabine - Zusatzheizung
42 =OPT ==SDR Cabin - Heating, Air conditioning, Washer pumps Kabine - Heizung, Klimaanlage, Wascherpumpen
43 =OPT ==SDR Cabin - Supply Kabine - Versorgung
44 =OPT ==SDR Cabin - Fuse protection Kabine - Absicherung
45 =OPT ==SDR Cabin - Lighting Kabine - Beleuchtung
46 =OPT ==SDR Cabin - Cabin equipment Kabine - Kabinenausrüstung
47 =OPT ==SDR Cabin - Cabin equipment Kabine - Kabinenausrüstung
48 =OPT ==SDR Cabin - Radio, Tachograph, Printer measurement Kabine - Radio, Tachograph, Drucker Messtechnik
49 =OPT ==SDR BOMAG Compaction Management BCM, GPS BOMAG Verdichtungsmanagement BCM, GPS
50 =OPT ==SDR Back up monitoring Rückraumüberwachung
51 Device tag list Betriebsmittelliste
58 Pin overview A15 Pin Übersicht A15
64 Pin overview S55 Pin Übersicht S55
65 Plug overview Steckerübersicht

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=
Anlage 354
Circuit diagrams

Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Inhaltsverzeichnis Einbauort + TOC
635
EPE / 000 / 00
636
Table of contents
Inhaltsverzeichnis
Circuit diagrams

81 Overview CAN Communication Übersicht CAN Kommunkikation
82 Overview Central Electric Übersicht Zentralelektrik
83 Overview plugs X100 - X109 Übersicht Stecker X100 - X109
84 Overview Powerboard Übersicht Powerboard
85 Overview Powerboard Übersicht Powerboard

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=
Anlage 354
Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Inhaltsverzeichnis Einbauort + TOC EPE / 000 / 00
Structure identifier overview
Strukturkennzeichenübersicht
Functional assignment
Funktionale Zuordnung
Description Beschreibung
==SDR Basic machine Single drum roller Basismaschine Walzenzug
Higher-level function
Anlage
=COM Communication Kommunikation
=DRIV Drive functions Antriebsfunktionen
=ENGI Engine Motorraum
=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
Mounting location
Einbauort
+ARC Armature carrier Armaturenträger
+BAT Battery-box Batteriekasten
+CAB Cabin Kabine
+DPL Drivers platform Fahrerstand
+DRUM Drum Bandage
+DTLE Device tag list electrical devices Betriebsmittelliste Elektrische Betriebsmittel
+EBOX Central electric Zentralelektrik
+FRFR Front frame Vorderrahmen
+MOT Engine and attachment parts Motor und Anbauteile
+PINO Pin overviews Controller Pin Übersichten Steuerungen
+PLA Vibratory plate compactor Anbauplatten
+PLGO Plug overview Steckerübersicht
+PUMP Pump mounting Pumpenanbau
+REFR Rear frame Hinterrahmen
+ROPS Roll-Over Protection System Überrollschutz System
+SEAT Seat console Sitzkonsole
+SIO Structure identifier overview Strukturkennzeichenübersicht
+TOC Table of contents Inhaltsverzeichnis

+VIEW Overviews general Übersichten allgemein
Kind of Document
Dokumentenart
&DOC1 Leading documentation Einleitende Dokumentation
&DOC2 Reports and drawings Auswertungen und Zeichnungen
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=
Anlage 354
Circuit diagrams

Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Strukturkennzeichenübersicht Einbauort + SIO
637
EPE / 000 / 00
638
Structure identifier overview
Strukturkennzeichenübersicht
Kind of Document
Dokumentenart
&EFS Circuit diagram Schaltpläne
Circuit diagrams

0 1 2 3 4 5 6 7 8 9
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Erstellt MFS 12.11.2015 BW 213-226 D+DH-5 Structure identifier overview Higher-level function
=
Anlage 354
Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Strukturkennzeichenübersicht Einbauort + SIO EPE / 000 / 00
+FRFR
+DRUM +REFR
+PLA
+CAB
+ROPS
+DPL
+SEAT
+MOT
+ARC +PUMP
+BAT
+EBOX

0 1 2 3 4 5 6 7 8 9
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Erstellt MFS 12.11.2015 BW 213-226 D+DH-5 Layout mounting locations Higher-level function
=
Anlage 354
Circuit diagrams

Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Übersicht Einbauorte Einbauort + VIEW
639
EPE / 000 / 00
640
F13:2 / 9.0
+REFR X4.A 9
RD
4 mm² F95:2 / 10.0
RD
X0.A 30 +ARC RD
25 mm² 30_PB / 9.0 1,5 mm²
RADSOK® 8mm RD
1,5 mm² S15:11 / =OPT/38.0
Ignition switch
Startschalter 30
RD
50 mm² S00
15/54 58 19 17 50a
1
Circuit diagrams
WH
F39 1,5 mm²
80A
MAXI Fuse
2
Fuse, main cabin WH
MAXI Sicherung
1,5 mm² S15:23 / =OPT/38.0
Hauptsicherung WH WH WH
1,5 mm² 1,5 mm² 1,5 mm²
RD
Kabine
70 mm²
X8.A
=OPT+CAB/43.1
Fuse, engine controller

Sicherung Motorsteuerung
Fuse, main battery
Hauptsicherung Batterie
Fuse, B+ charge
Sicherung B+
Ladeleitung
G02:B+ X4.A 13 3 20
2 2 2 =ENGI/18.1
S00:50a / 10.0
F95 4 F00 3 F164 1
30A 1 125A 1 150A 1 S00:19 / =ENGI/20.1
1
V01 15_CAB
=OPT+CAB/43.1
S5G-E3 2
+MOT 30
86 1 1
K61
RD
70 mm² K61 R10 /8.6 87 87a
D61
green
/8.7 2 82 Ω 2 Relay, charge control
85 Relais Ladekontrolle
12V/25A
!!! Auch bei ausgeschaltetem Batterietrennschalter unter Spannung

K39:2 / =ENGI/22.8
K39:1 / =ENGI/22.8
D+ / =MON/25.0
(86)
!!! There is still power supply even if the battery disconnector switch is turned off
4 88a 2
S30 K39 X1.A 7 X7.C 5

250A 3 K15 88 1
Disconnect switch, battery (85)
RD Batterietrennschalter
4 mm²
31_AH
=OPT+DPL/41.1
+BAT RD 30 50 B+ D+
70 mm²
86 1 86 1
RD M01 G
70 mm² G02 K09 K11
D09
D11
green
green
M1 14V / 150A 12V/25A 2 12V/70A 2

85 85
Starter - Generator B- W
Starter Relay, starter Generator 4
G03 + G01 + X7.C
31 Ground Engine Relais Anlasser
12V / 88 Ah Battery
Masse Motor
Battery Batterie 31 31
- -
Batterie at BW 219-226
bei BW 219-226
12V / 88Ah
at BW 211-216
Only at BW 219-226
Nur bei BW 219-226
bei BW 211-216
12V / 110Ah X0.B 31
BN
16 mm² Gnd_PB / 9.0
BK RADSOK® 6mm
70 mm²
BK
70 mm² 31_Eng / =ENGI/18.0 X8.B / =OPT+CAB/43.1

BK
70 mm² 31_EMR / =ENGI/21.0
31 Ground Central Electric
31_DCtrl / 11.0 87 30 87 /10.0
Masse Zentralelektrik 31_MCtrl / 12.0 87a 30 =OPT+CAB/42.1
31 31
Ground Frame Rear
31_RFr / =DRIV/28.0
Masse Hinterrahmen 31_Ar / 14.6
31 31 31 Relay, air conditioning Relay, potential 30 on 15
31_Db / 14.1 Relais Klimaanlage Relais Potential 30 auf 15
0 1 2 3 4 5 6 7 8 9
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Created M. Vogt Funktion == SDR Blatt 8 von 85
Erstellt 12.11.2015 BW 213-226 D+DH-5 Supply, Starting unit Higher-level function
=
Anlage SUPL 354
Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Versorgung, Starten Einbauort + EBOX EPE / 000 / 00
8.6 / 30_PB 30_PB / 10.0
30
K06
=OPT/37.5 87 87a
Relay, headlights rear
Relais Scheinwerfer hinten
1 1 1 1 1 1 1 1 1 1 1 1
F13 F157 F68 F22 F19 F84 F23 F67 F146 F11 F07 F268
15A 2 30A 2 15A 2 15A 2 15A 2 10A 2 15A 2 15A 2 15A 2 15A 2 10A 2 20A 2
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

Sicherung Arbeitsscheinwerfer vorne links
F268:2
=ENGI/18.0
X4.A 19
8.9 / F13:2 F07:2

=OPT/38.0
WH
X7.C 1 1,5 mm²
F11:2
11 =OPT/38.0
21 A1
30 +ARC-S01
K145 Switch, emergency off 22 A2 F146:2
12
Schalter NOT AUS 12.0
=ENGI/20.8 87a 87
Relay, solenoid starter
/10.2
Relais Hubmagnet Starter WH F67:2
1,5 mm²
11.0
=DRIV/28.7
30 X4.A 10 F23:2
=DRIV/29.0
K38
=ENGI/20.6 87a 87
Relay, starter control F84:2
1 Relais Anlassteuerung =COM/15.0
Fx
Fuseholder, fuse test S01:12
2
Sicherungshalter Sicherungstest 11.0
X1.A 1 2
F19:2
=OPT/37.0
1 F22:2
=OPT/37.0
Dx
green 2
Indicator light, fuse test F68:2
Meldeleuchte Sicherungstest =OPT+DPL/41.1

8.9 / Gnd_PB Gnd_PB / =COM/15.0
0 1 2 3 4 5 6 7 8 9
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Erstellt 12.11.2015 BW 213-226 D+DH-5 Fuse protection potential 30 Higher-level function
=
Anlage SUPL 354
Checked
Circuit diagrams
C. Stahl Mounting location

Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Absicherung Potential 30 Einbauort + EBOX
641
EPE / 000 / 00
Erstellt
Geprüft
Created
Checked
0
9.9 / 30_PB
8.9 / S00:50a
8.6 / F95:2
M. Vogt
C. Stahl
12.11.2015
12.11.2015
Relais Potential 30 auf 15
Relay, potential 30 on 15
/8.8
K11
87
30
15A
F103
X7.C
Fuse, potential 15
1
2
1
Sicherung Potential 15
2
3
/9.4
+ARC-S01
10A
F122
X4.A
X4.A
Fuse, engine controller

2
1
Sicherung Motorsteuerung
1
22
21
WH
WH
12
1,5 mm²
1,5 mm²
2
10A
F148
BW 213-226 D+DH-5

2
1

Deutz TCD 4.1+6.1 Tier 3a
10A
F24
Fuse, monitoring module

2
1
Sicherung Überwachungsmodul
3
5A
F91
Fuse, sensors
2
1
Sicherung Sensoren
20A
F05
Fuse, socket
2
1
Sicherung Steckdose
4
10A
F08
Fuse, indicators
2
1
Sicherung Blinker
Absicherung Potential 15
25A
F124
Fuse, fuel-pre-heating
Fuse protection potential 15

2
1
Sicherung Kraftstoffvorheizung
5A
F244
Fuse, Bomag telematics (potential 15)

2
1
Sicherung Bomag Telematik (Potential 15)
6
25A
F40
Fuse, heating unit cabin

2
1
Sicherung Kabinenheizung
15A
F29
Fuse, compressor suspension seat

2
1
Sicherung Kompressor Luftfedersitz
7
5A
F169
Fuse, starting current

2
1
Sicherung Startstrom
Anlage
Function
Funktion
Einbauort
Mounting location
8
Higher-level function
7,5A
F243
X0.C
+
=
==
Fuse, Bomag telematics (potential 30)
2
1
Sicherung Bomag Telematik (Potential 30)

30
SDR
SUPL
EBOX
Blatt
Page
RADSOK® 3,6mm
14.0
14.0
11.0
F24:2
F91:2
F05:2
F08:2
F40:2
F29:2
10
F103:2
F148:2
F124:2
F244:2
F169:2
F243:2
S01:22
=OPT/37.0
=OPT/38.0
=OPT/40.1
=OPT/40.1
=DRIV/26.0
=ENGI/18.0
=ENGI/20.1
X0.C / =ENGI/20.1
9
=OPT+DPL/41.1
=OPT+CAB/42.1
=OPT+CAB/42.1
354
von
from
!!! There is still power supply even if the battery disconnector switch is turned off
85
!!! Auch bei ausgeschaltetem Batterietrennschalter unter Spannung
EPE / 000 / 00
Circuit diagrams
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
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, driving controller
Stecker Fahrsteuerung
WH
2,5 mm²
Splice
Spleiss 38
B57:2 / =DRIV/26.0
Splice
Spleiss 39
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)
8.4 / 31_DCtrl 31_DCtrl / =DRIV/26.0

0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 12.11.2015 BW 213-226 D+DH-5 Supply Driving Controller Higher-level function
=
Anlage SUPL 354
Checked
Circuit diagrams

Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Versorgung Fahrsteuerung Einbauort + EBOX
643
EPE / 000 / 00
644
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
Circuit diagrams
Measurement controller GND GND GND GND GND

Messtechnik Steuerung A83 A83 A83 A83 A83
GND GND GND GND GND
X88 55 X88 65 X88 66 X88 67 X88 68
X88 55 X88 65 X88 66 X88 67 X88 68
A83
X5.E 4 13 6
X88
Plug, measurement controller
Stecker Messtechniksteuerung
WH
2,5 mm²
Splice
Spleiss 43
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)
8.4 / 31_MCtrl 31_MCtrl / =VIB/32.1

0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 12.11.2015 BW 213-226 D+DH-5 Supply Measurement controller Higher-level function
=
Anlage SUPL 354
Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Versorgung Messtechniksteuerung Einbauort + EBOX EPE / 000 / 00
FM1 / =DRIV/26.0
AGND_DC / =COM/15.0
FM2 / =VIB/32.1
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
AGND / =DRIV/26.0 AGND_MC / =MEAS/36.1

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
Function Page from
Erstellt 12.11.2015 BW 213-226 D+DH-5 Supply 8,5V sensors Higher-level function
=
Anlage SUPL 354
Checked
Circuit diagrams

Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Versorgung 8,5V Sensoren Einbauort + EBOX
645
EPE / 000 / 00
646
10.9 / S01:22 S01:22 / =ENGI/20.1
10.9 / F24:2
X4.A 18 X4.B 7
Circuit diagrams
+ARC +SEAT
Splice Splice
Spleiss 48 Spleiss 51
15_Db / =ENGI/19.1 15_Ar / =DRIV+SEAT/30.0
A15 S55
Monitoring module Travel lever
Überwachungsmodul Fahrhebel
X33 26
X23 1
X33 26 X23 1
Power supply (8...32V) Power supply (8...32V)
A15 S55
+UB
+Ub
Power supply Power supply
Stromversorgung Stromversorgung
Ground Ground Ground Ground

Masse Masse Masse Masse
Gnd 0V ADR 1 ADR 2
GND
A15 S55
Ground Ground Adressing 1 Adressing 2
X33 25 X23 2 X23 9 X23 10
X23 2 X23 9 X23 10
X33 25
X33
Splice
Plug, monitoring module
Spleiss 83
Stecker Überwachungsmodul
31_Db_2 / =MON/25.0
Splice
Spleiss 67
BN
2,5 mm²
8.4 / 31_Db 31_Db / =DRIV/29.0 8.4 / 31_Ar 31_Ar / =DRIV/26.0

0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 12.11.2015 BW 213-226 D+DH-5 Supply Monitoring module, Travel lever Higher-level function
=
Anlage SUPL 354
Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Versorgung Überwachungsmodul, Fahrhebel Einbauort + EBOX EPE / 000 / 00
=SUPL/9.9 / F84:2 F84:2 / =OPT/39.1
=SUPL/12.9 / F148:2 F148:2 / 17.0
=SUPL/13.9 / AGND_DC AGND_DC / =DRIV/26.0
CAN1+ / 16.0
CAN1- / 16.0
CAN2+ / 16.0
X7.D 15 13 5
CAN2- / 16.0
M_CAN1+ / 17.0
M_CAN1- / 17.0
X34 Diagnosis interface BOMAG
30 (12V)
15 (12V)
AGND No1
N P R J A B C D E F X34 = Diagnosesteckdose BOMAG
GND
CAN 1 -
CAN 2 -
CAN 3 -
CAN 1 +
CAN 2 +
CAN 3 +
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
R21 R25
1 2 1 2
120 Ω 120 Ω
X7.C 13 X7.C 14
X5.A 12 15 6 9 X5.E 15 12
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

=SUPL/9.2 / Gnd_PB Gnd_PB / 17.0
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 12.11.2015 BW 213-226 D+DH-5 Communication, Diagnosis Higher-level function
=
Anlage COM 354
Checked
Circuit diagrams

Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Kommunikation, Diagnose Einbauort + EBOX
647
EPE / 000 / 00
648
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/43.1
Circuit diagrams
CAN3- / =OPT+CAB/43.1
R26
1 2
120 Ω
R27
1 2
120 Ω
X4.A 14 17 X4.B 1 4 X5.E 1 2
+ARC +SEAT
X33 21 X33 22 X88 53 X88 33

X23 6 X23 7
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
CAN2_H CAN2_L
CANH CANL CAN + CAN -

CAN high CAN low CAN high CAN low CAN 3 high CAN 3 low
CAN + CAN low CAN + CAN low CAN 3 high CAN 3 low

0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 12.11.2015 BW 213-226 D+DH-5 Communication Higher-level function
=
Anlage COM 354
Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Kommunikation Einbauort + EBOX EPE / 000 / 00
16.8 / CAN2+ CAN2+ / =ENGI/20.1
16.8 / CAN2- CAN2- / =ENGI/20.1
16.8 / CAN1+ CAN1+ / =OPT/39.1
16.8 / CAN1- CAN1- / =OPT/39.1
15.1 / Gnd_PB Gnd_PB / =ENGI/20.1
15.9 / F148:2 F148:2 / =OPT/39.1
15.9 / M_CAN1+ CAN2+_TM / =OPT/40.1
15.9 / M_CAN1- CAN2-_TM / =OPT/40.1
R28
1 2
120 Ω
Resistors not equiped

Widerstände nicht bestückt
R29
1 2
120 Ω
X7.A 1 2 6 5 3 4 8 7 9 10

0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 12.11.2015 BW 213-226 D+DH-5 Communication Higher-level function
=
Anlage COM 354
Checked
Circuit diagrams

Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Kommunikation Einbauort + EBOX
649
EPE / 000 / 00
650
=SUPL/10.9 / F124:2
=SUPL/9.9 / F268:2
+MOT
=SUPL/8.6 / G02:B+
Circuit diagrams
F48 30
150A K209
Inline-Fuse
1
Fuse, heating-flange
Inlinesicherung
/20.4 87a 87
Sicherung Heizflansch Relay, fuel pump
Relais Kraftstoffpumpe
X1.A 3 6 X1.A 8 9
K14:1_4.1_6.1
22.8
K14:2_4.1_6.1
22.9
(85) (88a)
1 WH WH
4 1,5 mm² 1,5 mm²
K 14
K2 2 3
Splice
Fitted on the engine

Am Motor angebaut
(88) X78
(86) 84
Spleiss
WH 1
Relay, glow plug system 2,5 mm²
Relais Vorglühen K14:3_4.1_6.1

22.9 WH
2,5 mm²
X67 1
1 WH
R19 2,5 mm²
167A
R4 XR79 1
Heating flange 2
Heizflansch 31 1
Ground Engine
Masse Motor
R79
200W 2
Fuel-pre-heater
Kraftstoffvorheizung
XR79 2
BN
2,5 mm²
X67 2
BN
2,5 mm²

BN Splice
=SUPL/8.4 / 31_Eng 6 mm² Spleiss 31_Eng / =MON/25.0
74
4 3 /18.1
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 12.11.2015 BW 213-226 D+DH-5 Pre-heating, Fuel lift pump, Fuel-pre-heating Higher-level function
=
Anlage ENGI 354
Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Vorglühen, Kraftstoffförderpumpe, Kraftstoffvorwärmung Einbauort + EBOX EPE / 000 / 00
+ARC
=SUPL/14.2 / 15_Db VIB_TM / =OPT/40.1
13 23
low
eco
high
S127 X4.A 16
Switch, engine speed 14 24
Schalter Motordrehzahl
X33 9 X33 10 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

Switch, engine speed Sx. 1 Switch, engine speed Sx. 2 Switch, regeneration Sy. 1 Switch, regeneration Sy. 2 Vibration Telematik
Schalter Motordrehzahl Sx. 1 Schalter Motordrehzahl Sx. 2 Schalter Regeneration Sy. 1 Schalter Regeneration Sy. 2 Vibration Telematics

0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 12.11.2015 BW 213-226 D+DH-5 Engine speed, Regeneration mode Higher-level function
=
Anlage ENGI 354
Checked
Circuit diagrams

Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Motordrehzahl, Regenerationsmodus Einbauort + EBOX
651
EPE / 000 / 00
652
Circuit diagrams
X1.B:1 / 21.0
X1.B:2 / 21.0
X1.B:14 / 21.4
X1.B:9 / 21.4
X1.B:16 / 21.5
X1.B:12 / 21.5
X1.B:10 / 21.6
X1.B:13 / 21.6
X1.B:15 / 21.2
X1.B:18 / 21.3
X1.B 1 2 3 5 8 6 X1.B 14 9 17 16 X1.B 12 11 10 13 4 15 18 7
85 1
K38
D38
green
87 87a 85 2 86 1 12V/40A 86 2 87 87a 86 1

CN403
D41
green
green
green
87a 87
D209
D145
K41 K05
30 86 1 2 Relay, starter control 30 2
12V/25A K209 85 =DRIV+SEAT/30.8 K145 85
Relais Anlassteuerung
CN413 12V/25A 12V/40A
30
=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 K22 87 87a Relais Startstrom Relais Hubmagnet Starter
87 =DRIV/29.8 87
!!! There is still power supply even if the battery disconnector switch is turned off 87a 30 /18.6 Relay, shut off solenoid engine 30 87a 30 =SUPL/9.2
!!! Auch bei ausgeschaltetem Batterietrennschalter unter Spannung Relais Hubmagnet Abschaltung Motor
=SUPL/8.9 / S00:19
=SUPL/10.9 / F169:2
50a

=SUPL/14.9 / S01:22
=COM/17.8 / CAN2+
=COM/17.8 / CAN2- StU_TM / =OPT/40.1
=COM/17.8 / Gnd_PB Gnd_PB / =DRIV/26.0
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 12.11.2015 BW 213-226 D+DH-5 Engine - Machine-part Higher-level function
=
Anlage ENGI 354
Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Motor - Fahrzeugseite Einbauort + EBOX EPE / 000 / 00
A48
D2
Engine-controller EMR4 (EDC 17-CV52)
Motorsteuergerät EMR4 (EDC 17-CV52)
Plug, engine-controller motor-part Plug, engine-controller machine-part

Stecker Motorsteuergerät Motorseite = X44 D2.1 (A) D2.2 (K) X45 = Stecker Motorsteuergerät Maschinenseite
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 D2.2 D2.2 D2.2 D2.2 D2.2 D2.2 D2.2 D2.2 D2.2 D2.2
1 3 5 26 70 58 91 43 10 50 88 74 23 64 67 18 31 13 85 86 82 83 2 4 6
X45 1 3 5 26 70 58 91 43 10 50 88 74 23 64 67 18 31 13 85 86 82 83 2 4 6
D2.2 X41 X23
WH WH WH 32 BN BN BN
2,5 mm² 2,5 mm² 2,5 mm² 2,5 mm² 2,5 mm² 2,5 mm²
33
Splice
Spleiss 68
34
WH WH
2,5 mm² 2,5 mm²
Splice Splice
K22:87a / 24.0 Spleiss 11 Spleiss 12
X108 1 2 X108 3 4 5
Splice Splice
Splice
Spleiss 66
+MOT X73 1 2 +MOT
1
B218 1
1 X48 1 2 R30
2
B124 2120 Ω
2 Plug, engine stop
Stecker Motor Stop
R23
120 Ω 1
Sensor, water trap fuel B218 2

Sensor Wasserabscheider Kraftstoff
Ubat
CAN 2 high
CAN 2 low
CAN 1 high
CAN 1 low
31-GND
A M F H G B
X32

X22
20.2 / X1.B:1
20.2 / X1.B:2
20.5 / X1.B:9
20.7 / X1.B:15
20.7 / X1.B:10
20.7 / X1.B:13
20.8 / X1.B:18
20.4 / X1.B:14
20.5 / X1.B:16
20.6 / X1.B:12
CAN 1 = Diagnosis CAN

CAN 2 = Customer CAN
Diagnosis interface EMR

Diagnoseschnittstelle EMR
BN Splice
=SUPL/8.4 / 31_EMR 6 mm² Spleiss 31_AGR / 24.0
69
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 12.11.2015 BW 213-226 D+DH-5 Deutz TCD 3.6, 4.1 u. 6.1 Machine part Higher-level function
=
Anlage ENGI 354
Checked
Circuit diagrams

Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Deutz TCD 3.6, 4.1 a. 6.1 Fahrzeugseite Einbauort + EBOX
653
EPE / 000 / 00
654
A48
D2
Circuit diagrams
Harness EMR - Engine interface

Kabelbaum EMR - Motorschnittstelle

Harness Engine interface - Engine internal Stecker Motorsteuergerät Motorseite = X44 D2.1 (A) D2.2 (K) +EBOX-X45 = Stecker Motorsteuergerät Maschinenseite
Kabelbaum Motorschnittstelle - Motorintern
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 D2.1 D2.1 D2.1 D2.1 D2.1
85 64 22 43 65 86 23 44 66 87 24 45 85 45 64 66 23 24 100 99 75 102 101 94 95 63 88 58
X44 85 64 22 43 65 86 23 44 66 87 24 45 X44 85 45 64 66 23 24 100 99 75 102 101 94 95 63 88 58

D2.1 D2.1
+MOT
X46.1 34 35 38 36 32 37 33 39 X46.1 34 35 37 32 33 14 13 9 15 21 1 +EBOX

X17.1 X17.1
X41 1 3
X23
X47.1 1 2 3 4 X47.1 1 2 5 4 3
X41 2 6
X32.1 X32.1
X23
X47.2 2 3 4 1
1
X32.2
2
2 2 2 2 2 B114
B40.1
n
Y147 Y148 Y149 3
Y15.1 1 Y15.5 1 Y15.3 1 Y147 1 Y149 1 X46.1 3 2 6 7 8
Y15.1 Y15.2 X17.1
1
B130
B40.2
n
2
2 2 2 2 2
Y166 Y170 Y169

Y15.6 1 Y15.2 1 Y15.4 1 Y166 1 Y148 1
Y15.3 Y15.4
Injector A1 Injector A2 Injector A3 Injector A1 Injector A3

Injektor A1 Injektor A2 Injektor A3 Injektor A1 Injektor A3 EMR Sensor, engine speed 1
EMR Motordrehzahlsensor 1
K14:1_4.1_6.1
K14:2_4.1_6.1
K14:3_4.1_6.1
Injector A4 Injector A5 Injector A6 Injector A4 Injector A2

=SUPL/8.5 / K39:2
=SUPL/8.5 / K39:1
Injektor A4 Injektor A5 Injektor A6 Injektor A4 Injektor A2 Camshaft

EMR Sensor, engine speed 2
Nockenwelle
18.1 /
18.1 /
18.1 /
EMR Motordrehzahlsensor 2
at Deutz TCD 6.1 at Deutz TCD 4.1 Crankshaft
Kurbelwelle
bei Deutz TCD 6.1 bei Deutz TCD 4.1
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 12.11.2015 BW 213-226 D+DH-5 Deutz TCD 4.1/6.1 Higher-level function
=
Anlage ENGI 354
Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Deutz TCD 4.1/6.1 Einbauort + EBOX EPE / 000 / 00
A48
D2

Kabelbaum EMR - Motorschnittstelle

Harness Engine interface - Engine internal Stecker Motorsteuergerät Motorseite = X44 D2.1 (A) D2.2 (K) +EBOX-X45 = Stecker Motorsteuergerät Maschinenseite
Kabelbaum Motorschnittstelle - Motorintern
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
46 25 36 78 17 35 13 74 73 21 11 72 54 53 67 02 55 18 76 51 11
X44 46 25 36 78 17 35 13 74 73 21 11 72 54 53 67 02 55 18 76 51 08
D2.1
+MOT
X46.1 19 20 30 25 31 27 24 28 23 22 29 26 17
X17.1
X46.2 46 18 19 13 24 37 30 41
X17.2
1
2 1 1
2 4 2
Y137 B93 B133 B145 1
3 3
Y19 1 B49 B48 B51
3 2
2 4 B208
B61
3
1 1 Y261 1 4 5 3 2
2 2 2 Y35 1
B88 B238
3 3
B113 B6 B60 B209
B43 4 4 M ECU B64

1 2
EMR Actuator EMR Fuel pressure rail EMR Sensor, charging air pressure / -temperature EMR Low pressure Fuel EMR Sensor, delta p venturi
EMR Stellglied EMR Kraftstoffdruck Rail EMR Sensor Ladeluftdruck / -temperatur EMR Niederdruck Kraftstoff EMR Sensor Delta p Venturi
EMR Temperature sensor, coolant EMR engine oil pressure Pressure sensor, exhaust gas back DPF before turbine EMR Air intake throttle EMR Sensor, temperature EGR behind venturi
EMR Temperatursensor Kühlmittel EMR Motoröldruck Drucksensor Abgasgegendruck DPF vor Turbolader EMR Drosselklappe Ansaugluft EMR Sensor Temperatur EGR nach Venturi
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 12.11.2015 BW 213-226 D+DH-5 Deutz TCD 4.1/6.1 Higher-level function
=
Anlage ENGI 354
Checked
Circuit diagrams

Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Deutz TCD 4.1/6.1 Einbauort + EBOX
655
EPE / 000 / 00
656
A48
D2
Engine-controller EMR4
(EDC 17-CV52)
Motorsteuergerät EMR4
(EDC 17-CV52)

Plug,
1 Plug, engine-controller Kabelbaum EMR - Motorschnittstelle
Circuit diagrams
engine-controller machine-part 1
R32 motor-part
120Ω 2 Stecker Stecker R31
Motorsteuergerät Motorsteuergerät 120Ω 2
Motorseite = X44 D2.1 (A) D2.2 (K) +EBOX-X45 = Maschinenseite
Harness Engine interface - Engine internal
D2.1 D2.1 Kabelbaum Motorschnittstelle - Motorintern
98 77
X41 38 39 X41 36 35
X23 X23
X44 98 77
D2.1
21.9 / 31_AGR
21.6 / K22:87a
X41 28 29
X23
+MOT
X46.2 57 59 28 29 23 22
X17.2

Ub Gnd CAN L CAN H CAN L CAN H
Y174 1 2 6 3 4 5
Y20 OUT IN
EMR Exhaust gas recirculation
EMR Abgasrückführung
ECU
M
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 12.11.2015 BW 213-226 D+DH-5 Deutz TCD 4.1/6.1 - Exhaust aftertreatment Higher-level function
=
Anlage ENGI 354
Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Deutz TCD 4.1/6.1 - Abgasnachbehandlung Einbauort + EBOX EPE / 000 / 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 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
X101 1 2 3 X103 11
X5.A 10 X2.A 15
=SUPL/8.6 / D+ D+ / =OPT/40.1
+REFR
X11 1
1
+MOT +REFR
X72 1 X69 2
3 3 (1) 3 (1) + 1
B55 B03 P B21 P H07 R03

4 4 (2) 4 (2) 70mA - BW 211-216 = 66 Ω 2
BW 219-226 = 64,2 Ω
X72 2 X69 3
X11 2
=ENGI/18.8 / 31_Eng 31_Eng / =OPT+CAB/42.1
=SUPL/14.2 / 31_Db_2 31_Db_2 / =DRIV+SEAT/30.0

=DRIV/28.0 / 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
Function Page from
Erstellt 12.11.2015 BW 213-226 D+DH-5 Monitoring, Failure indicators Higher-level function
=
Anlage MON 354
Checked
Circuit diagrams

Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Überwachung, Störmeldungen Einbauort + EBOX
657
EPE / 000 / 00
658
=SUPL/13.9 / FM1
=SUPL/10.9 / F91:2 F91:2 / 27.0
=ENGI/20.8 / Gnd_PB Gnd_PB / 29.0
=SUPL/14.7 / 31_Ar 31_Ar / =VIB/32.1
=SUPL/11.9 / 31_DCtrl 31_DCtrl / 28.0

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
Slope sensor, speed range selection
Neigungssensor Stufenumschaltung V08 V010
S1M 2 S1M 2
X2.A 12 14 9 13 X5.A 2 16 1
B57
0,5-4,5V X106:1 / =VIB/31.1
Splice
1 2 3 Spleiss 41
- + S X106:5 / =VIB/31.1
X14 B +REFR X104 1 2 3 4 X105:11 / =VIB/34.1

-
+SEAT BU 5
4+
S06 B60
3 speed +DRUM
Switch, seat contact SW Speed sensor, axle
Sitzkontaktschalter Drehzahlsensor 2
Achsgeschwindigkeit dir Only at DH-Version
X14 A
Nur bei DH-Version
W3 3 4
7x1,0
-
5
+4
B59
speed 3
Speed sensor, drum
2 Drehzahlsensor
dir Bandagengeschwindigkeit
5 6 W3
X4.B 2 X2.A 1 X2.A 4 7x1,0
X5.B 10 X5.B 6 X5.B 5

X7.C 11 X7.C 10
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
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
Function Page from
Erstellt 12.11.2015 BW 213-226 D+DH-5 Slope sensor, Speed sensors Higher-level function
=
Anlage DRIV 354
Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Neigungssensor, Geschwindigkeitsaufnehmer Einbauort + EBOX EPE / 000 / 00
26.9 / F91:2 F91:2 / =MEAS/36.1
X2.A 10 at D Version
bei D Version
+REFR-X25 5
+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 B235 B236 B237

Pressure sensor, travel
P Pressure sensor, travel
P
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
+REFR-X25 1 2 3 4
bei DH Version
B234
B236 (X55)
(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
Function Page from
Erstellt 12.11.2015 BW 213-226 D+DH-5 Pressure sensors Higher-level function
=
Anlage DRIV 354
Checked
Circuit diagrams

Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Drucksensoren Einbauort + EBOX
659
EPE / 000 / 00
660
Travel pump axle forward Travel pump axle backward Travel pump drum forward Travel pump drum backward Travel motor axle Valve brake Travel motor drum
Fahrpumpe Achse vorwärts Fahrpumpe Achse rückwärts Fahrpumpe Bandage vorwärts Fahrpumpe Bandage rückwarts Fahrmotor Achse Ventil Bremse Fahrmotor Bandage
PWM_1 PWM_2 PWM_7 PWM_9 DO_2 PWM_5 DO_4
A34 A34 A34 A34 A34 A34 A34

OUT1 / 4A curr.-measur. OUT2 / 4A curr.-measur. OUT14 / 4A curr.-measur. OUT16 / 4A curr.-measur. OUT10 / 2,5A curr.-feedb. OUT5 / 4A curr.-measur. OUT12 / 2,5A curr.-feedb.
X35 46 X35 47 X35 20 X35 21 X35 2 X35 64 X35 3
X35 46 X35 47 X35 20 X35 21 X35 2 X35 64 X35 3

Circuit diagrams
X5.A 21
K48 30
+SEAT/30.9
Relay, travel lever 0-position
Relais, Fahrhebel 0-Stellung 87 87a
X4.A 21
WH
1,5 mm²
A1
Splice
+ARC-S01 Spleiss 61
=SUPL/9.4 A2
WH
1,5 mm²
X103 5 6 7 8 9 X4.A 7 X103 10 X104 7
X7.C 12 X2.A 7
at DH Version a.
BW 216-219 D
+REFR Splice Splice +DRUM bei DH Version u.
-X25 7 8 BW 216-219 D
1 W3
X11 3 X11 4
+PUMP 7x1,0
1 1 1 1 1 1 1 1
Y16 Y17 Y72 Y73 Y31 Y04 Y30 Y30
2,41A
Travel pump axle 2 Travel pump axle 2 Travel pump drum 2 Travel pump drum 2 1,05A 2 2 2,41A 2 2
Fahrpumpe Achse C1 Fahrpumpe Achse C2 Fahrpumpe Bandage C2 Fahrpumpe Bandage C1 1,05A
640...1580mA 640...1580mA 640...1580mA 640...1580mA at D Version 2 W3
bei D Version 7x1,0
Splice
Spleiss 75
Only at DH-Version
Nur bei DH-Version
31_RFr.2
=MON/25.0 -X25 6
X11 5 X104 8

BN
1,5 mm²
31_RFr BN Splice 31_RFr
10 mm² Spleiss
=SUPL/8.4 72 29.0
31_DCtrl 31_DCtrl
26.9 =VIB/31.1
Solenoid valve, travel direction forward Solenoid valve, travel direction forward Solenoid valve, speed range selection axle Solenoid valve, brake Solenoid valve, speed range selection drum
Magnetventil Fahrtrichtung vorwärts Magnetventil Fahrtrichtung vorwärts Magnetventil Fahrstufe Achse Magnetventil Bremse Magnetventil Fahrstufe Bandage
Solenoid valve, travel direction backward Solenoid valve, travel direction backward Solenoid valve, speed range selection drum
Magnetventil Fahrtrichtung rückwärts Magnetventil Fahrtrichtung rückwärts Magnetventil Fahrstufe Bandage
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 12.11.2015 BW 213-226 D+DH-5 Brake, Travel pumps, Speed ranges Higher-level function
=
Anlage DRIV 354
Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Bremse, Fahrpumpen, Fahrstufen Einbauort + EBOX EPE / 000 / 00
=SUPL/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
/29.8 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/43.1
X2.A 2
+REFR
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/25A 85 2 12V/25A 85 2
BN BN
1,5 mm² 1,5 mm²
X30 2
BN BN
1,5 mm² 1,5 mm²
=SUPL/14.2 / 31_Db 31_Db / =OPT/37.0
28.9 / 31_RFr 31_RFr / =VIB/31.1

26.9 / Gnd_PB Gnd_PB / +SEAT/30.8
87 87
87a 30 /29.3 87a 30 =ENGI/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
Function Page from
Erstellt 12.11.2015 BW 213-226 D+DH-5 Warning horns, Back up alarm, Higher-level function
=
Anlage DRIV 354
Checked
Circuit diagrams

Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Warnhörner, Rückfahralarm, Einbauort + EBOX
661
EPE / 000 / 00
662
+ARC +EBOX
at DH Version at D Version
bei DH Version bei D Version
+ARC
Switch, vibration front Switch, vibration low / high

Schalter Vibration vorne Schalter Vibration klein / gross
13 13 23
low
0
high
S09 S35
BTS brake
Circuit diagrams
14 14 24
Switch, speed range selector BTS Bremse
S42 Schalter Fahrstufen
DIN_6
12 Steps at DH, 5 Steps at D A34
12 Stufen bei DH, 5 Stufen bei D Only at BVC Not at BVC
4..20mA / 0-5V Nur bei BVC Nicht bei BVC DIN6 / 0..32V
X35 14
0V 9-30V 0-20mA 0,5-4,5V 0V +5V
X35 14
1 2 3 6 4 5
XS42 1 2 3 6 4 5
Relay, travel lever 0-position

X26 3 Relais, Fahrhebel 0-Stellung
X102 6 7 X5.A 14 Relay, starting current
Relais Startstrom 87
31_Db_2 31_Db_2
87 87a 30 +EBOX/28.7
=MON+EBOX/25.8 =OPT+EBOX/38.0
87a 30 =ENGI+EBOX/20.8
S139
Potentiometer, + 14 14
+EBOX X102 1 2 3 4 X102 5 frequency plates S36 S64 X4.B 9
Potentiometer 86 86
- S
Switch, vibration plates 13 Pushbutton, float 13 1 1
Frequenzverstellung position plates
K05 K48
D05
D48
Anbauplatten
green
green
15_Ar 15_Ar Schalter Vibration Taster Schwimmstellung

Anbauplatten Anbauplatten 12V/25A 85 2 12V/25A 85 2
=SUPL+EBOX/14.7 =VIB+EBOX/32.1 Splice
Spleiss 49
X26 1 2 Splice
Spleiss 50
Splice
Spleiss 47
Gnd_PB Gnd_PB
+EBOX/29.9 =VIB+EBOX/31.1
X23 11 X23 8 X23 5 X23 12 X24 4 X24 3 X24 1 X24 2 X23 3

X23 11 X23 8 X23 5 X23 12 X24 4 X24 3 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 3 Digital IN 1 Digital IN 2 BTS signal "Brake catch"
S55
AK Ext 1 AGND 1 Uext 1 AK Ext 2 DK Ext 4 DK Ext 3 DK Ext 1 DK Ext 2 BTS Brake
Switch, speed range selector 2 Ground analog selectors Supply analog selectors Frequency adjustment plates Vibration plates Floating position plates Switch, vibration low/off (on/off) Switch, vibration off/high BTS brake
Schalter Fahrstufen 2 Masse Analoge Wahlschalter Versorgung Analoge Wahlschalter Frequenzverstellung Anbauplatten Vibration Anbauplatten Schwimmstellung Anbauplatten Schalter Vibration klein/aus (an/aus) Schalter Vibration aus/groß BTS Bremse
At dozer blade At vibratory plate

Bei Planierschild Bei Vibrationsplatte

b c b c
e f e f
At vibratory plate or dozer blade

Bei Vibrationsplatte oder Planierschild
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 12.11.2015 BW 213-226 D+DH-5 Travel lever Higher-level function
=
Anlage DRIV 354
Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Fahrhebel Einbauort + SEAT EPE / 000 / 00
=DRIV/26.9 / X106:5
=DRIV/26.9 / X106:1
=DRIV/26.9 / AGND
Speed vibration drum Vibration pump off/high Vibration pump low/off

Drehzahl Vibration Bandage Vibrationspumpe aus/groß Vibrationspumpe klein/aus
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
30
K43
/31.4 87 87a
Relay, vibration
Relais Vibration
X5.B 9 3
not used today
wird zur Zeit nicht genutzt
X103 12 13
86 1 +PUMP 1 1
K43 Y07 Y08
D43
green
12V/25A 2 640...1580mA 2 640...1580mA 2
85
C1 C2
X106 6
=DRIV/28.9 / 31_DCtrl 31_DCtrl / 33.1
=DRIV/29.7 / 31_RFr 31_RFr / =OPT/38.0
=DRIV+SEAT/30.9 / Gnd_PB Gnd_PB / =OPT/37.0

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
Function Page from
Erstellt 12.11.2015 BW 213-226 D+DH-5 Vibration Higher-level function
=
Anlage VIB 354
Checked
Circuit diagrams

Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Vibration Einbauort + EBOX
663
EPE / 000 / 00
664
=SUPL/13.9 / FM2
+SEAT X5.E 11
=DRIV/26.9 / 31_Ar 31_Ar

=OPT+CAB/42.1
=DRIV+SEAT/30.2 / 15_Ar X107 7

Circuit diagrams
+DRUM
W1 X86:2 / =MEAS/36.1
12x0,75 9 10 Exciter up Exciter down Exciter priority
Erreger auf Erreger ab Erreger Priorität
X86 1
PWM_2 PWM_1 DO_5
A83 A83 A83
RD
2 (+) + X86 OUT2 / 4A curr.-measur. OUT1 / 4A curr.-measur. OUT6 / 4A
1 (-) - BK 2 X88 47 X88 46 X88 61
S107 B97
Switch, amplitude adjustment Sensor, adjustable motor X88 47 X88 46 61
3 (S) S
Schalter Amplitudenverstellung Sensor Verstellmotor
WH
12 steps
12 Stufen
4...20mA X86 3
W1
X107 9 10 11
12x0,75 11
X4.B 8
+DRUM
X5.E 14
W2
X107 8
7x1,0 1 3
1 1
X88 32 X88 9 Y140 Y141
400-1200mA 2 400-1200mA 2
X88 32 X88 9 b1 (v.r.) a1 (v.l.)
AIN8 / 10V 25mA AIN7 / 10V 25mA
A83 A83 -W2 2 4
AIN_8 AIN_7 7x1,0
Splice
Y140
Spleiss 8 Y141
Switch, amplitude adjustment Position exciter
Schalter Amplitudenverstellung Erregerposition
BN
1,5 mm²
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
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 12.11.2015 BW 213-226 D+DH-5 Variocontrol Higher-level function
=
Anlage VIB 354
Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Variocontrol Einbauort + EBOX EPE / 000 / 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 / +REFR/35.0
X5.A 7 X105:2 / +REFR/35.0
X105:3 / +REFR/35.0
Y379
X105:4 / +REFR/35.0
Y378 +DRUM X105:5 / +REFR/35.0
W4
X105:6 / +REFR/35.0
12x0,75 1 3 5 7
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 / +REFR/35.0
X105:10 / 34.1
X105:12 / 34.1

X105 7 10 12
BN BN BN
1,5 mm² 1,5 mm² 1,5 mm²
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
Function Page from
Erstellt 12.11.2015 BW 213-226 D+DH-5 Dozer blade Higher-level function
=
Anlage VIB 354
Checked
Circuit diagrams

Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Planierschild Einbauort + EBOX
665
EPE / 000 / 00
666
X105 11 Splice
=DRIV/26.9 / X105:11 Spleiss
22
Splice
33.8 / X105:12 Spleiss
23
+REFR
W8 X28 2 1 W7 X29 2 1
BINDER Sensorcable M12 90° BINDER Sensorcable M12 90°
4x0,5 BU (3) BN (1) 4x0,5 BU (3) BN (1)
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 (4) W7 BK (4)
4x0,5 4x0,5
X28 3 X29 3
X105 13 X105 14
Hour meter plates Plate pump enable Vibration pump plates

Stundenzähler Platten Freigabe Plattenpumpe Vibrationspumpe Platten
X35 31
+PLA DO_7 X35 8 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
X105 9 X105 15 X105 8
+REFR
X29 4 X29 5
X27
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
+
P43 3x0,75 BN
Operating hour meter

h plates
Betriebsstundenzähler X29 6
- Platten
BN Splice
33.8 / X105:10 1,5 mm² Spleiss
24
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 12.11.2015 BW 213-226 D+DH-5 Vibratory plate compactor Higher-level function
=
Anlage VIB 354
Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Anbauplatten Einbauort + EBOX EPE / 000 / 00
+EBOX
Floating position plates

Schwimmstellung Anbauplatten
DO_8
A34
OUT19 / 2,5A curr.-feedb.
X35 45
X35 45
X105 16
+EBOX/33.8 / X105:2
+EBOX/33.8 / X105:1
+EBOX/33.8 / X105:6
Y145
+EBOX/33.8 / X105:5
Y143
+EBOX/33.8 / X105:4
+EBOX/33.8 / 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
+EBOX/33.8 / 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
Function Page from
Erstellt 12.11.2015 BW 213-226 D+DH-5 Vibratory plate compactor Higher-level function
=
Anlage VIB 354
Checked
Circuit diagrams

Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Anbauplatten Einbauort + REFR
667
EPE / 000 / 00
668
=SUPL/13.6 / AGND_MC
=DRIV/27.9 / F91:2
X5.E 7
X107 1 2
Circuit diagrams
+DRUM WH WH
1,5 mm² 1,5 mm²
Splice
Spleiss 7
=VIB/32.5 / X86:2
Splice RxD Printer TxD Printer Power supply GPS
Spleiss 6
RxD Drucker TxD Drucker Spannungsversorgung GPS
W1
12x0,75 1 2 5 6
RxD TxD DO_3
A83 A83 A83
RxD_1 TxD_1 OUT11 / 2,5A curr.-feedb.
X88 4 X88 5 X88 25
X20 1 2 X21 1 2 X88 4 X88 5 X88 25
BK GNYE BK GNYE
+ +
- -
B62 B171
15g 15g
front 20g rear 20g

vorne hinten X5.E 5 3 8
BN BU BN BU
Transducer, acceleration
Transducer, acceleration
Aufnehmer Beschleunigung
Aufnehmer Beschleunigung
X20 4 3 X21 4 3
15_GPS / =OPT+CAB/43.1
W1
TxD / =OPT+CAB/43.1
12x0,75 4 3 8 7
RxD / =OPT+CAB/43.1
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
Function Page from
Erstellt 12.11.2015 BW 213-226 D+DH-5 Measurement equipment Higher-level function
=
Anlage MEAS 354
Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Messtechnik Einbauort + EBOX EPE / 000 / 00
=SUPL/9.9 / F22:2 +ARC
S26:13 / 38.0
=SUPL/9.9 / F19:2
=SUPL/10.9 / F05:2
+CAB/43.1
X4.E:9
13
S26
Switch, working lights 14
Schalter Arbeitsbeleuchtung
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 X7.C 6
Illumination
Beleuchtung
X22
2
X6.B 2 4
1 X22 1
+DPL +ROPS
WH WH
1,5 mm² 1,5 mm²
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/25A 2

- 85
BN
2,5 mm²
X22 2
Splice
Spleiss 87
BN
2,5 mm²
=DRIV/29.5 / 31_Db 31_Db / 38.0 X4.E 3 6
=VIB/31.8 / Gnd_PB Gnd_PB / 38.0

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
Function Page from
Erstellt 12.11.2015 BW 213-226 D+DH-5 Rops - Lighting, Socket Higher-level function
=
Anlage OPT 354
Checked
Circuit diagrams

Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Rops - Beleuchtung, Steckdose Einbauort + EBOX
669
EPE / 000 / 00
670
=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 13 23
Circuit diagrams
K16 S14 S37

WH Switch, hazard light Indicator lights
1,5 mm² /38.3 87a 87 14 24 Switch, indicator 14 24
31 11 23 Relay, headlights front Warnblinkschalter Blinker Schalter Blinker
01 2 DIN2
Relais Scheinwerfer vorne
S15
Switch, lighting StVZO 32 12 24
Schalter Beleuchtung StVZO A15
X4.D 5 2 8
Access without StvZO illumination

X4.A
Anschluss ohne StvZO Beleuchtung

11 EN_WL active high
37.9 / S26:13
WH +CAB/43.1 X33 8
1,5 mm² X1
H06 X33 8 Wb LE RE 30
X2
X4.D 7 A02
10 1 Flasher unit
X4.D Blinkgeber
LA RA 31
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
2 2
Schlussleuchte links Schlussleuchte rechts V06
Meldeleuchte Warnblinker
Indicator light, hazard light
WH
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
X80 3
+DPL X81 3
X79 3 X82 3
X80 1 X81 1
1 1 1 1 86 1 87a 87 5 5 2 2
X79 X82 X79 X82
E13 E12 E14 E15 K16
D16
green
LED 2 5W 2 5W 2 LED 2 12V/25A 85 2 30 1 1 1 1 1 1
E16 E17 E08 E09 E10 E11
/38.4
55W 2 55W 2 21W 2 21W 2 21W 2 21W 2
X80 4 X81 4
X79 6 6 2 2
X82 X80 X81
BN BN
1,5 mm² 1,5 mm²
37.1 / 31_Db 31_Db

+CAB/42.1
31_Db_2
+REFR
+REFR
=DRIV+SEAT/30.2 X11
31_RFr BN 11 BN Splice
1,5 mm² 1,5 mm² Spleiss

=VIB/31.8 Splice 64
8 BN Spleiss
1,5 mm²
63
37.9 / Gnd_PB Gnd_PB
39.1
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
Function Page from
Erstellt 12.11.2015 BW 213-226 D+DH-5 StVZO illumination Higher-level function
=
Anlage OPT 354
Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a StVZO Beleuchtung Einbauort + EBOX EPE / 000 / 00
=COM/17.8 / CAN1+ CAN1+ / +CAB/43.1
=COM/17.8 / CAN1- CAN1- / +CAB/43.1
38.9 / Gnd_PB Gnd_PB / 40.1
=COM/15.9 / F84:2
=COM/17.8 / F148:2
X7.B 3 2 1 4 6
+DPL
A67
Keyboard
Tastatur
X16
1

4
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 12.11.2015 BW 213-226 D+DH-5 Electronical Burglary protection Higher-level function
=
Anlage OPT 354
Checked
Circuit diagrams

Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Elektronische Diebstahlsicherung Einbauort + EBOX
671
EPE / 000 / 00
672
A124
Electronic system, BOMAG Telematics
Elektronik BOMAG Telematik
+ARC
A138
Antenna, BOMAG Telematics
Antenne BOMAG Telematik
Circuit diagrams
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
X6.D 8
=COM/17.8 / CAN2-_TM
7
=COM/17.8 / CAN2+_TM
4
=SUPL/10.9 / F243:2
1
=SUPL/10.9 / F244:2
2
=MON/25.1 / D+
D+ / +CAB/43.1 5
=ENGI/20.8 / StU_TM

6
=ENGI/19.8 / VIB_TM
3
39.9 / Gnd_PB
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 12.11.2015 BW 213-226 D+DH-5 BOMAG Telematics Higher-level function
=
Anlage OPT 354
Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a BOMAG Telematik Einbauort + EBOX EPE / 000 / 00
WH
=SUPL+EBOX/10.9 / F103:2 1,5 mm²
WH Splice WH
=SUPL+EBOX/9.9 / F68:2 2,5 mm² Spleiss 1,5 mm²
78
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 11 10 1
Power consumption Pot. 30 Pot. 15 Bel.
Energiebedarf [W] <100 8 16 30 40
-S28 11 10 1
E30 Timer
Heating unit Schaltuhr
Heizgerät
1
1
4
4
7
7
8
8
6
6
5
5
10
2 6 8 9 12 4
10 S+ Temp DIAG Gnd Gnd Gnd
SetVal Temp
SetVal
XS28 2 6 8 9 12 4
WH
2,5 mm²
1
X207 1
RD
1,5 mm²
4 YE 4
0,5 mm²
7 GRRD 7
0,5 mm²
8 BUYE 8
0,5 mm²
6 BNWH 6
0,5 mm²
5 GNRD 5
1 mm²
10 BN 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
Function Page from
Erstellt 12.11.2015 BW 213-226 D+DH-5 Cabin - Additional heater Higher-level function
=
Anlage OPT 354
Checked
Circuit diagrams

Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Kabine - Zusatzheizung Einbauort + DPL
673
EPE / 000 / 00
674
+EBOX
=SUPL+EBOX/10.9 / F29:2 WWF / 43.1
=SUPL+EBOX/10.9 / F40:2 WWR / 43.1
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 1
Heating climatic unit
X10
Heiz-Klima-Einheit Supply
WH X87, X99
1,5 mm² RD
+REFR
X68 1 3 2
/42.0
sw br BK/GN BK 1
B104 P
LP HP MP Out Gnd
Pressure switch, air conditioning sw/ge br/sw
Druckschalter Klimaanlage WH WH
X10 4 2 1,5 mm² 1,5 mm²
X68 2 4
/42.0 X87 1 X99 1
WH
1,5 mm²
WH Option
1,5 mm²
3 Option 3
+MOT X12 1 S29 S25
Switch, suspension seat 4 Switch, heating operators seat 4
WH BN Schalter Luftfedersitz Schalter Fahrersitzheizung
1 2 1,5 mm² 2,5 mm²
Y15 V04
3,5A 2 1 + +
1
BN 1 1
1,5 mm² X6.C 1
M10
M R06 M06 M07
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/25.8
Only at air conditioning 2 2

X87 X99
Nur bei Klimaanlage
BN BN
1,5 mm² 1,5 mm²
=VIB+EBOX/32.2 / 31_Ar

+EBOX/38.3 / 31_Db
Magnetic clutch, air conditioning compressor Compressor, suspension operators seat Motor, windscreen washer front
Magnetkupplung Klimakompressor Kompressor Luftfedersitz Scheibenwaschermotor vorne
Heating, operators seat Motor, windscreen washer rear
Heizung Fahrersitz Scheibenwaschermotor hinten
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 12.11.2015 BW 213-226 D+DH-5 Cabin - Heating, Air conditioning, Washer pumps Higher-level function
=
Anlage OPT 354
Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Kabine - Heizung, Klimaanlage, Wascherpumpen Einbauort + CAB EPE / 000 / 00
+EBOX
X4.E 14
=MEAS+EBOX/36.8 / RxD RxD / 48.6
4
=MEAS+EBOX/36.8 / TxD TxD / 48.6
8
WH
=MEAS+EBOX/36.8 / 15_GPS 1,5 mm² 15_GPS / 49.0
10
=COM+EBOX/16.8 / CAN3+ CAN3+ / 49.0
7
=COM+EBOX/16.8 / CAN3- CAN3- / 49.0
11
=DRIV+EBOX/29.7 / Rev Rev / 50.1
X202 -A178
1 9 Additional working lights left zusätzliche Arbeitsbeleuchtung links
Controller, console terminal cabin 1
+EBOX/39.9 / CAN1+
Controller Bedienkonsole Kabine
2 Illumination drum Bandagenbeleuchtung
2 10
+EBOX/39.9 / CAN1-
3 Start Start
17 6
+EBOX/40.1 / D+ 4 Stop Stop
Print Drucken
DIG In
5
5
High active
4
+EBOX/38.4 / EN_WL 6 Delete Löschen
Reserve Reserve
DIG In
9
7
High active
X7.C 7 WH 5
1,5 mm² 8 Additional working lights right zusätzliche Arbeitsbeleuchtung rechts
9 Windscreen wiper front Scheibenwischer vorne
DIG Out
+EBOX/37.2 / X4.E:9
10 Windscreen wiper rear Scheibenwischer hinten
15 8
WH
=SUPL+EBOX/8.9 / 15_CAB 1,5 mm² 15_PB_CAB / 44.1 11 Windscreen wascher front Scheibenwascher vorne
13 3
42.9 / WWF WWF_PB_CAB / 46.1 12 Rotary beacon Rundumkennleuchte
12 1 13 Working headlights front Arbeitsscheinwerfer vorne
42.9 / WWR WWR_PB_CAB / 46.1
14 Cabin inside light Kabineninnenbeleuchtung
15 Working headlights rear Arbeitsscheinwerfer hinten

X200
X8.A 30 30
RD Rear screen heating Heckscheibenheizung
=SUPL+EBOX/8.6 / X8.A 16 mm² 30_PB_CAB / 44.1 16
RADSOK® 8mm Amphenol RADSOK® 6mm
17 Windscreen wascher rear Scheibenwascher hinten
X201
X8.B 31 BN BN 31
=SUPL+EBOX/8.9 / X8.B 16 mm² 10 mm² GND_PB_CAB / 44.1
RADSOK® 6mm Amphenol RADSOK® 3,6mm
1 8
Optional
Optional
GND_CAB / 45.0
2 7
3 4 5 6
not used

31 31
Ground Cabin wird nicht genutzt
Masse Kabine
9 10
11 12 13 14 15 16 17
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 12.11.2015 BW 213-226 D+DH-5 Cabin - Supply Higher-level function
=
Anlage OPT 354
Checked
Circuit diagrams

Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Kabine - Versorgung Einbauort + CAB
675
EPE / 000 / 00
676
43.4 / 30_PB_CAB
43.4 / 15_PB_CAB
1 1 1
30 F17 F264 F271
5A 10A 10A
Circuit diagrams
K32 2 2 2
/44.1 87 87a
Relay, cabin
Relais Kabine
Fuse, radio
Fuse, BCM05
Fuse, BCM-Net
Sicherung Radio
Sicherung BCM05
Sicherung BCM-Net
F271:2 / 49.1
F264:2 / 49.1
F17:2 / 48.1
1 1 1 1 1 1 1
F272 F27 F28 F143 F266 F150 F279
5A 2 15A 2 15A 2 20A 2 10A 2 5A 2 15A 2
Fuse, reserve
terminal cabin
Sicherung Reserve
Fuse, GPS receiver
Sicherung Controller
Bedienkonsole Kabine
Fuse, controller console

Sicherung GPS Receiver
Fuse, radio / tachograph

86
D2.1
K32
Fuse, rear screen heating unit

Sicherung Radio / Tachograph
green
Sicherung Heckscheibenheizung
12V/25A 85 F279:2 / 46.1
Relay, cabin
Relais Kabine
Sicherung Wischer und Wascher vorne

Sicherung Wischer und Wascher hinten
F150:2 / 49.1
Fuse, windscreen wiper and washer rear
Fuse, windscreen wiper and washer front

F266:2 / 48.1
F143:2 / 47.1
F28:2 / 47.1
43.4 / GND_PB_CAB GND_PB_CAB / 45.0

F27:2 / 47.1
87
87a 30 /44.2 F272:2 / 45.0
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 12.11.2015 BW 213-226 D+DH-5 Cabin - Fuse protection Higher-level function
=
Anlage OPT 354
Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Kabine - Absicherung Einbauort + CAB EPE / 000 / 00
A178
/43.5
Controller, console 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
44.9 / 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
+ 1 1 1 1
E32 E27 E28 E23 E25
12V 70W - 12V 55W 2 12V 55W 2 12V 55W 2 12V 55W 2
43.3 / GND_CAB GND_CAB / 47.1

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
Function Page from
Erstellt 12.11.2015 BW 213-226 D+DH-5 Cabin - Lighting Higher-level function
=
Anlage OPT 354
Checked
Circuit diagrams

Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Kabine - Beleuchtung Einbauort + CAB
677
EPE / 000 / 00
678
A178
/43.5
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/25A 85 12V/25A 85 12V/25A 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
43.4 / WWF_PB_CAB Relay, heating rear screen Relay, windscreen wiper front Relay, windscreen wiper rear
Relais Heckscheibenheizung Relais Wischer vorne Relais Wischer hinten
43.4 / WWR_PB_CAB
44.9 / F279:2
max. 150 mA
X206 3 7 8

87 87 87
87a 30 /47.7 87a 30 /47.3 87a 30 /47.5
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 12.11.2015 BW 213-226 D+DH-5 Cabin - Cabin equipment Higher-level function
=
Anlage OPT 354
Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Kabine - Kabinenausrüstung Einbauort + CAB EPE / 000 / 00
44.9 / F143:2
44.9 / F28:2
44.9 / F27:2
87a 87 87a 87 30
K20 Relay, windscreen wiper front K21 Relay, windscreen wiper rear K141
/46.5 30 Relais Wischer vorne /46.6 30 Relais Wischer hinten /46.3 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
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
Function Page from
Erstellt 12.11.2015 BW 213-226 D+DH-5 Cabin - Cabin equipment Higher-level function
=
Anlage OPT 354
Checked
Circuit diagrams

Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Kabine - Kabinenausrüstung Einbauort + CAB
679
EPE / 000 / 00
680
44.9 / F266:2
44.9 / F17:2
46.8 / GND_PB_CAB
A178
Circuit diagrams
/43.5
PWM Out PWM Out PWM Out
X205 1 2 3 4 6 5 X202 2
X202:2 / 50.1
Splice
Spleiss 58
Splice
Spleiss 57
43.4 / TxD
Splice
Spleiss 56
43.4 / RxD
A1 Splice
Spleiss 59
P09
A2
A16 A3
3 2 1 3 2 1 2 1
31 15 30 Ctrl Ant
A5 -A12
Radio A8 A7 A4 A5 Ant
XB3 XS5 XS4 Radio
1 A6
2
C3 X94 1 2 5 4
A = white X83 1 2
3 4 RxD TxD Gnd Ub
B = yellow
4 3 B3 P11
C = red
5 2 B7 B8 B5 B6 B3 B4 B1 B2
XB2
XS3 1 B4 rl+ rl- fl+ fl- fr+ fr- rr+ rr-
Printer
Drucker
XS2 Tachograph
Tachograph B51.L B51.R
XS1 123456
+ -
- +
1 2 3 1 2

Speaker radio Speaker radio
Electronic system, tachograph Lautsprecher Radio Lautsprecher Radio
Elektronik Tachograph
Only at VM29-Printer
AGND Nur bei VM29-Drucker
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 12.11.2015 BW 213-226 D+DH-5 Cabin - Radio, Tachograph, Printer measurement Higher-level function
=
Anlage OPT 354
Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Kabine - Radio, Tachograph, Drucker Messtechnik Einbauort + CAB EPE / 000 / 00
44.9 / F271:2
44.9 / F150:2
44.9 / F264:2
X204 1 2 3 4

WH
43.4 / 15_GPS 1,5 mm²
BN BN
1,5 mm² 1,5 mm²
X85 1 X85 2 3
USB-CAN Interface BCM -A93
A87 USB-CAN Schnittstelle BCM GPS receiver
GPS Receiver
X85 X95.A X91
4 7 1
43.4 / CAN3+ 2
X85 3
4
5 2 1 SH
43.4 / CAN3-
12 6 7 2 11
X211 -X93 C B A -X97
Gnd2 4 A B C D E
RxD2 2
TxD2 3
P15 X96.A
BCM05 Ub 1 -X210 -X92
Supply
BCM05 Versorgung 1 A
AGnd 1 A
Gnd 2
Splice 2 2 B B
Spleiss 200
X90
Gnd1 5 3 3 C C
GPS receiver
GPS Receiver 2 4 D
RxD1 4 D

TxD1 3 5 5 E E
W10
7x1,0
X90 = Plug, access GPS - BCM

Female pin Stecker Anschluß GPS - BCM
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 12.11.2015 BW 213-226 D+DH-5 BOMAG Compaction Management BCM, GPS Higher-level function
=
Anlage OPT 354
Checked
Circuit diagrams

Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a BOMAG Verdichtungsmanagement BCM, GPS Einbauort + CAB
681
EPE / 000 / 00
682
48.8 / X202:2
49.7 / GND_CAB
43.4 / Rev
Circuit diagrams
P42
Display, back up monitoring
Monitor Rückraumüberwachung
Pin 5 - Trigger Cam 3

Pin 2 - Gnd
Pin 1 - 12/24V DC
P32 X50 1 RD
Camera, back up monitoring 2 BK

Plug, access display back up monitoring
Kamera Rückraumüberwachung 3 WH X50 = Stecker Anschluß Monitor Rückraumüberwachung
4 BU
5 BN
CA1 CA1
CA2
CA3

0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 12.11.2015 BW 213-226 D+DH-5 Back up monitoring Higher-level function
=
Anlage OPT 354
Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Rückraumüberwachung Einbauort + CAB EPE / 000 / 00
Device tag list
Betriebsmittelliste
Higher-level
Device tag Page Path Mounting location function characteristics
BMK Blatt Pfad Einbauort
Function text Funktionstext Techn.-Kenngrößen
Anlage
A02 38 8 +EBOX Flasher unit Blinkgeber

A12 48 4 +CAB Radio Radio
A15 14 2 +ARC Monitoring module Überwachungsmodul ---> Pin overview
A16 48 0 +CAB Electronic system, tachograph Elektronik Tachograph
A34 11 3 +EBOX Driving Controller Fahrsteuerung ---> Pin overview
A48 21 0 +EBOX Engine-controller EMR4 (EDC 17-CV52) Motorsteuergerät EMR4 (EDC 17-CV52)
A67 39 5 +DPL Keyboard Tastatur
A83 12 3 +EBOX Measurement controller Messtechnik Steuerung ---> Pin overview
A87 49 2 +CAB USB-CAN Interface BCM USB-CAN Schnittstelle BCM
A93 49 7 +CAB GPS receiver GPS Receiver
A108 42 2 +CAB Heating climatic unit Heiz-Klima-Einheit
A124 40 3 +EBOX Electronic system, BOMAG Telematics Elektronik BOMAG Telematik
A138 40 5 +ARC Antenna, BOMAG Telematics Antenne BOMAG Telematik
B03 25 4 +MOT Maintenance switch, air cleaner Wartungsschalter Luftfilter
B11.1 29 1 +REFR Warning horn Signalhorn max. 3,5A
B11.2 29 4 +REFR -"- -"- max. 3,5A
B11.3 29 1 +REFR -"- -"- max. 3,5A
B11.4 29 5 +REFR -"- -"- max. 3,5A
B21 25 5 +REFR Differential pressure switch, hydraulic oil filter Differenzdruckschalter Hydraulikölfilter
B51.L 48 4 +CAB Speaker radio Lautsprecher Radio
B51.R 48 5 +CAB -"- -"-
B55 25 2 +MOT Floating switch, coolant expansion tank Schwimmerschalter Kühlmittelausgleichsbehälter
B57 26 1 +EBOX Slope sensor, speed range selection Neigungssensor Stufenumschaltung 0,5-4,5V
B59 26 7 +DRUM Speed sensor, drum Drehzahlsensor Bandagengeschwindigkeit
B60 26 4 +REFR Speed sensor, axle Drehzahlsensor Achsgeschwindigkeit
B62 36 1 +DRUM Transducer, acceleration Aufnehmer Beschleunigung
B88 23 4 +MOT EMR engine oil pressure EMR Motoröldruck
B93 23 1 +MOT EMR Fuel pressure rail EMR Kraftstoffdruck Rail
B97 32 4 +DRUM Sensor, adjustable motor Sensor Verstellmotor
B104 42 1 +REFR Pressure switch, air conditioning Druckschalter Klimaanlage
B113 23 3 +MOT EMR Temperature sensor, coolant EMR Temperatursensor Kühlmittel

B114 22 6 +MOT EMR Sensor, engine speed 1 EMR Motordrehzahlsensor 1
B124 21 1 +MOT Sensor, water trap fuel Sensor Wasserabscheider Kraftstoff
B130 22 7 +MOT EMR Sensor, engine speed 2 EMR Motordrehzahlsensor 2
B133 23 3 +MOT EMR Sensor, charging air pressure / -temperature EMR Sensor Ladeluftdruck / -temperatur
B145 23 5 +MOT EMR Low pressure Fuel EMR Niederdruck Kraftstoff
B171 36 3 +DRUM Transducer, acceleration Aufnehmer Beschleunigung
0 1 2 3 4 5 6 7 8 9
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Erstellt MFS 12.11.2015 BW 213-226 D+DH-5 Device tag list Higher-level function
=
Anlage 354
Circuit diagrams

Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Betriebsmittelliste Einbauort + DTLE
683
EPE / 000 / 00
684
Device tag list
Betriebsmittelliste
Higher-level
Anlage
B208 23 8 +MOT EMR Sensor, delta p venturi EMR Sensor Delta p Venturi
Circuit diagrams
B209 23 9 +MOT EMR Sensor, temperature EGR behind venturi EMR Sensor Temperatur EGR nach Venturi
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
B238 23 6 +MOT Pressure sensor, exhaust gas back DPF before turbineDrucksensor Abgasgegendruck DPF vor Turbolader
B312 34 5 +REFR Sensor, height adjustment plates Sensor Höhenverstellung Platten 4...20mA
B313 34 6 +REFR Sensor, lateral adjustment plates Sensor Seitenverstellung Platten 4...20mA
D2.1 44 1 +CAB Indicator light, relay K32 Meldeleuchte Relais K32 green
D05 30 9 +EBOX Indicator light, relay K13 Meldeleuchte Relais K13 green
Dx 9 1 +EBOX Indicator light, fuse test Meldeleuchte Sicherungstest green
E08 38 7 +DPL Indicator, front left Blinkleuchte vorne links 21W
E09 38 8 +REFR Indicator, rear left Blinkleuchte hinten links 21W
E10 38 8 +DPL Indicator, front right Blinkleuchte vorne rechts 21W

E11 38 8 +REFR Indicator, rear right Blinkleuchte hinten rechts 21W
E12 38 1 +DPL Parking light, left Parkleuchte links 5W
E13 38 1 +REFR Tail light, left Schlussleuchte links LED
E14 38 2 +DPL Parking light, right Parkleuchte rechts 5W
E15 38 2 +REFR Tail light, right Schlussleuchte rechts LED
E16 38 4 +DPL Headlight, left Scheinwerfer links 55W
0 1 2 3 4 5 6 7 8 9
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=
Anlage 354
Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Betriebsmittelliste Einbauort + DTLE EPE / 000 / 00
Device tag list
Betriebsmittelliste
Higher-level
Anlage
E17 38 5 +DPL Headlight, right Scheinwerfer rechts 55W

E23 37 3 +ROPS Working headlight, front left Arbeitsscheinwerfer vorne links 12V 55W
E23 45 8 +CAB -"- -"- 12V 55W
E25 37 3 +ROPS Working headlight, front right Arbeitsscheinwerfer vorne rechts 12V 55W
E25 45 9 +CAB -"- -"- 12V 55W
E27 37 4 +ROPS Working headlight, rear left Arbeitsscheinwerfer hinten links 12V 55W
E27 45 7 +CAB -"- -"- 12V 55W
E28 37 4 +ROPS Working headlight, rear right Arbeitsscheinwerfer hinten rechts 12V 55W
E28 45 8 +CAB -"- -"- 12V 55W
E29 45 1 +CAB Inside light, cabin Innenleuchte Kabine
E30 41 0 +DPL Heating unit Heizgerät
E32 45 6 +CAB Rotary beacon Rundumkennleuchte 12V 70W
E72 45 2 +CAB Illumination, switches Beleuchtung Bedienschalter
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
F09 38 1 +EBOX Fuse, parking and tail light left Sicherung Park- und Schlussleuchte links 10A
F10 38 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 44 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 44 4 +CAB Fuse, windscreen wiper and washer front Sicherung Wischer und Wascher vorne 15A
F28 44 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 25A

F48 18 1 +MOT Fuse, heating-flange Sicherung Heizflansch 150A
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
F91 10 3 +EBOX Fuse, sensors Sicherung Sensoren 5A
F95 8 0 +REFR Fuse, engine controller Sicherung Motorsteuerung 30A
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Anlage 354
Circuit diagrams

685
EPE / 000 / 00
686
Device tag list
Betriebsmittelliste
Higher-level
Anlage
F103 10 1 +EBOX Fuse, potential 15 Sicherung Potential 15 15A

Circuit diagrams
F122 10 2 +EBOX Fuse, engine controller Sicherung Motorsteuerung 10A

F124 10 5 +EBOX Fuse, fuel-pre-heating Sicherung Kraftstoffvorheizung 25A
F143 44 5 +CAB Fuse, rear screen heating unit Sicherung Heckscheibenheizung 20A
F150 44 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 44 4 +CAB Fuse, BCM05 Sicherung BCM05 10A
F266 44 5 +CAB Fuse, radio / tachograph Sicherung Radio / Tachograph 10A
F268 9 8 +EBOX Fuse, fuel pump Sicherung Kraftstoffpumpe 20A
F271 44 5 +CAB Fuse, BCM-Net Sicherung BCM-Net 10A
F272 44 3 +CAB Fuse, controller console terminal cabin Sicherung Controller Bedienkonsole Kabine 5A
F279 44 6 +CAB Fuse, reserve Sicherung Reserve 15A
F320 41 7 +DPL Fuse, timer additional heater (potential 30) Sicherung Schaltuhr Zusatzheizung (Potential 30) 5A
F321 41 8 +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 / 88/110 Ah
G02 8 5 +MOT Generator Generator 14V / 150A
G03 8 1 +BAT Battery Batterie 12V / 88 Ah
H06 38 6 +ARC Indicator light, hazard light Meldeleuchte Warnblinker
H07 25 7 +ARC Warning buzzer, breakdown Warnsummer Betriebsstörung 70mA
H14 29 7 +REFR Back-up alarm buzzer Warnsummer Rückwärtsfahrt 300mA
K05 30 8 +EBOX Relay, starting current Relais Startstrom 12V/25A
K06 37 5 +EBOX Relay, headlights rear Relais Scheinwerfer hinten 12V/25A

K09 8 7 +EBOX Relay, air conditioning Relais Klimaanlage 12V/25A
K11 8 8 +EBOX Relay, potential 30 on 15 Relais Potential 30 auf 15 12V/70A
K13 29 8 +EBOX Relay, warning horn Relais Signalhorn 12V/25A
K14.1 18 1 +MOT Relay, glow plug system Relais Vorglühen
K16 38 3 +EBOX Relay, headlights front Relais Scheinwerfer vorne 12V/25A
K20 46 5 +CAB Relay, windscreen wiper front Relais Wischer vorne 12V/25A
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Anlage 354
Device tag list
Betriebsmittelliste
Higher-level
Anlage
K21 46 6 +CAB Relay, windscreen wiper rear Relais Wischer hinten 12V/25A
K22 29 8 +EBOX Relay, shut off solenoid engine Relais Hubmagnet Abschaltung Motor 12V/25A
K32 44 1 +CAB Relay, cabin Relais Kabine 12V/25A
K38 20 6 +EBOX Relay, starter control Relais Anlassteuerung 12V/40A
K39 8 5 +MOT Relay, starter Relais Anlasser
K41 20 3 +EBOX Relay, separation Trennrelais 12V/25A
K43 31 4 +EBOX Relay, vibration Relais Vibration 12V/25A
K48 30 9 +EBOX Relay, travel lever 0-position Relais, Fahrhebel 0-Stellung 12V/25A
K61 8 6 +EBOX Relay, charge control Relais Ladekontrolle 12V/25A
K141 46 3 +CAB Relay, heating rear screen Relais Heckscheibenheizung 12V/25A
K145 20 8 +EBOX Relay, solenoid starter Relais Hubmagnet Starter 12V/40A
K209 20 4 +EBOX Relay, fuel pump Relais Kraftstoffpumpe 12V/25A
M01 8 4 +MOT Starter Starter
M04 47 3 +CAB Motor, windscreen wiper front Scheibenwischermotor vorne 4,7A
M05 47 5 +CAB Motor, windscreen wiper rear Scheibenwischermotor hinten 4,7A
M06 42 8 +DPL Motor, windscreen washer front Scheibenwaschermotor vorne 3,5A
M07 42 9 +DPL Motor, windscreen washer rear Scheibenwaschermotor hinten 3,5A
M10 42 6 +SEAT Compressor, suspension operators seat Kompressor Luftfedersitz 12V / < 9A
M57 41 5 +MOT pump fuel heating unit Pumpe Kraftstoff Heizgerät
P09 48 3 +CAB Tachograph Tachograph
P11 48 6 +CAB Printer Drucker
P15 49 1 +CAB BCM05 BCM05
P32 50 1 +CAB Camera, back up monitoring Kamera Rückraumüberwachung
P42 50 5 +CAB Display, back up monitoring Monitor Rückraumüberwachung
P43 34 4 +PLA Operating hour meter plates Betriebsstundenzähler Platten
R03 25 8 +REFR Sender, level gauge Geber Tankanzeige 66 Ω / 64,2 Ω
R06 42 7 +SEAT Heating, operators seat Heizung Fahrersitz 12V / 6,85A
R10 8 6 +EBOX Parallel resistor Parallelwiderstand 82 Ω
R19 18 1 +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 8 +EBOX -"- -"- 120 Ω
R24 15 7 +EBOX -"- -"- 120 Ω
R25 15 7 +EBOX -"- -"- 120 Ω
R26 16 7 +EBOX -"- -"- 120 Ω
R27 16 7 +EBOX -"- -"- 120 Ω
0 1 2 3 4 5 6 7 8 9
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Anlage 354
Circuit diagrams

687
EPE / 000 / 00
688
Device tag list
Betriebsmittelliste
Higher-level
Anlage
R28 17 6 +EBOX Terminating resistor CAN Abschlußwiderstand CAN 120 Ω

Circuit diagrams
R29 17 6 +EBOX -"- -"- 120 Ω

R30 21 9 +EBOX -"- -"- 120 Ω
R31 24 8 +EBOX -"- -"- 120Ω
R32 24 1 +EBOX -"- -"- 120Ω
R79 18 8 +MOT Fuel-pre-heater Kraftstoffvorheizung 200W
R80 47 7 +CAB Rear window heater Heizung Heckscheibe ca. 11 A
S00 8 7 +ARC Ignition switch Startschalter
S01 9 4 +ARC Switch, emergency off Schalter NOT AUS
S06 26 3 +SEAT Switch, seat contact Sitzkontaktschalter
S09 30 5 +SEAT Switch, vibration front Schalter Vibration vorne
S14 38 5 +ARC Switch, hazard light Warnblinkschalter
S15 38 2 +ARC Switch, lighting StVZO Schalter Beleuchtung StVZO
S25 42 7 +SEAT Switch, heating operators seat Schalter Fahrersitzheizung
S26 37 5 +ARC Switch, working lights Schalter Arbeitsbeleuchtung
S28 41 6 +DPL Timer Schaltuhr
S29 42 6 +SEAT Switch, suspension seat Schalter Luftfedersitz
S30 8 3 +BAT Disconnect switch, battery Batterietrennschalter 250A
S35 30 7 +ARC Switch, vibration low / high Schalter Vibration klein / gross
S36 30 5 +SEAT Switch, vibration plates Schalter Vibration Anbauplatten
S37 38 8 +ARC Switch, indicator Schalter Blinker
S42 30 0 +ARC Switch, speed range selector Schalter Fahrstufen 4..20mA / 0-5V
S55 14 8 +SEAT Travel lever Fahrhebel
S64 30 6 +SEAT Pushbutton, float position plates Taster Schwimmstellung Anbauplatten
S107 32 2 +SEAT Switch, amplitude adjustment Schalter Amplitudenverstellung 4...20mA
S127 19 2 +ARC Switch, engine speed Schalter Motordrehzahl
S139 30 4 +SEAT Potentiometer, frequency plates Potentiometer Frequenzverstellung Anbauplatten
V01 8 6 +EBOX Diode Diode S5G-E3
V02 29 2 +REFR -"- -"- SF 64
V03 29 3 +REFR -"- -"- SF 64
V04 42 2 +MOT -"- -"- SF 64

V05 38 7 +ARC -"- -"- SF 64
V06 38 7 +ARC -"- -"- SF 64
V07 26 5 +EBOX -"- -"- S1M
V08 26 5 +EBOX -"- -"- S1M
V09 26 7 +EBOX -"- -"- S1M
V010 26 7 +EBOX -"- -"- S1M
0 1 2 3 4 5 6 7 8 9
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Anlage 354
Device tag list
Betriebsmittelliste
Higher-level
Anlage
Y04 28 7 +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 42 1 +MOT Magnetic clutch, air conditioning compressor Magnetkupplung Klimakompressor 3,5A
Y16 28 1 +PUMP Solenoid valve, travel direction forward Magnetventil Fahrtrichtung vorwärts 640...1580mA
Y17 28 2 +PUMP Solenoid valve, travel direction backward Magnetventil Fahrtrichtung rückwärts 640...1580mA
Y30 28 8 +REFR Solenoid valve, speed range selection drum Magnetventil Fahrstufe Bandage 2,41A
Y30 28 9 +DRUM -"- -"- 1,05A
Y31 28 5 +REFR Solenoid valve, speed range selection axle Magnetventil Fahrstufe Achse 1,05A
Y60 35 5 +REFR Solenoid valve, floating position Magnetventil Schwimmstellung
Y72 28 3 +PUMP Solenoid valve, travel direction forward Magnetventil Fahrtrichtung vorwärts 640...1580mA
Y73 28 4 +PUMP Solenoid valve, travel direction backward Magnetventil Fahrtrichtung rückwärts 640...1580mA
Y98 34 7 +MOT Solenoid valve, vibration pump plates Magnetventil Vibrationspumpe Platten 400-1200mA
Y102 33 4 +DRUM Solenoid valve, floating position Magnetventil Schwimmstellung
Y122 35 1 +REFR Solenoid valve, lift plates Magnetventil Platten heben
Y123 35 2 +REFR Solenoid valve, let down plates Magnetventil Platten senken
Y137 23 0 +MOT EMR Actuator EMR Stellglied
Y140 32 7 +DRUM Solenoid valve, exciter up Magnetventil Erreger auf 400-1200mA
Y141 32 8 +DRUM Solenoid valve, exciter down Magnetventil Erreger ab 400-1200mA
Y142 35 3 +REFR Solenoid valve, plate displace left Magnetventil Plattenverschieben links
Y143 35 3 +REFR Solenoid valve, plate displace right Magnetventil Plattenverschieben rechts
Y144 35 5 +REFR Solenoid valve, plate floating position Magnetventil Platten Schwimmstellung
Y145 35 4 +REFR Solenoid valve, plate (priority) Magnetventil Platten (Priorität)
Y147 22 1 +MOT Injector A1 Injektor A1
Y174 24 1 +MOT EMR Exhaust gas recirculation EMR Abgasrückführung
Y261 23 6 +MOT EMR Air intake throttle EMR Drosselklappe Ansaugluft

Y378 33 3 +DRUM Solenoid valve, dozer blade priority Magnetventil Planierschild Priorität
Y379 33 5 +DRUM Solenoid valve, lift dozer blade Magnetventil Planierschild heben
Y380 33 6 +DRUM Solenoid valve, lower dozer blade Magnetventil Planierschild senken
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Anlage 354
Circuit diagrams

689
EPE / 000 / 00
690
Pin overview
Pin Übersicht
Monitoring module
A15 Überwachungsmodul
Plug Pin Page Path Description
Signal Signal
Stecker Kontakt Blatt Pfad Beschreibung
Circuit diagrams
X33 2 25 8 0...140Ω Fuel level Tankfüllstand

X33 1 0...1500 Ω
X33 3 25 7 +UB, max 1,5A Warning buzzer, breakdown Warnsummer Betriebsstörung
X33 4 19 5 +UB, max 1,5A Vibration Telematik Vibration Telematics
X33 5 37 7 active high Illumination Beleuchtung
X33 6 configuration Pin RXD
X33 7 configuration Pin TXD
X33 8 38 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
X33 19 active low
X33 20 active low
X33 21 16 2 CAN high CAN high CAN +
X33 22 16 3 CAN low CAN low CAN low
X33 23 active low
X33 24 active high
X33 25 14 1 Ground Ground Masse
X33 26 14 1 Power supply Power supply Stromversorgung
(8...32V)

0 1 2 3 4 5 6 7 8 9
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Erstellt MFS 12.11.2015 BW 213-226 D+DH-5 Pin overview A15 Higher-level function
=
Anlage 354
Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Pin Übersicht A15 Einbauort + PINO EPE / 000 / 00
Pin overview
Pin Übersicht
Driving Controller
A34 Fahrsteuerung
Signal Signal
X35 1 13 2 AGND AGND Analogmasse
X35 2 28 5 OUT10 / 2,5A Travel motor axle Fahrmotor Achse
curr.-feedb.
X35 3 28 8 OUT12 / 2,5A Travel motor drum Fahrmotor Bandage
curr.-feedb.
X35 4 RxD_1
X35 5 TxD_1
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 34 5 AIN5 / 10V 25mA Sensor, height adjustment plates Sensor Höhenverstellung Platten
X35 9 25 1 AIN7 / 10V 25mA D+ Alternator D+ Generator
X35 10 34 6 DIN18 / 0..32V Plate pump enable Freigabe Plattenpumpe
X35 11 33 4 OUT20 / 2,5A Floating position dozer blade Schwimmstellung Planierschild
curr.-feedb.
X35 12 26 5 DIN2 / 0..32V, DRZ Speed axle Geschwindigkeit Achse
X35 13 26 4 DIN4 / 0..32V Direction axle Drehrichtung Achse
X35 14 30 8 DIN6 / 0..32V BTS brake BTS Bremse
X35 15 26 3 DIN8 / 0..32V Seat contact Sitzkontakt
X35 16 26 4 DIN10 / 0..32V, DRZ Proximity switch, arm rest right Näherungsinitiator Armlehne rechts
X35 17 26 7 DIN12 / 0..32V Direction drum Drehrichtung Bandage
X35 18 DIN14 / 0..32V, DRZ
X35 19 DIN16 / 0..32V, DRZ
X35 20 28 3 OUT14 / 4A Travel pump drum forward Fahrpumpe Bandage vorwärts
curr.-measur.
X35 21 28 4 OUT16 / 4A Travel pump drum backward Fahrpumpe Bandage rückwarts
curr.-measur.
X35 22 34 7 OUT18 / 4A Vibration pump plates Vibrationspumpe Platten
curr.-measur.
X35 23 13 2 8.5VEXT 8,5V Sensor Power 8,5V Sensor Spannung

X35 24 29 8 OUT9 / 2,5A Relay, shut off solenoid engine Relais Hubmagnet Abschaltung Motor
curr.-feedb.
X35 25 29 8 OUT11 / 2,5A Warning horn Signalhorn
curr.-feedb.
X35 26 15 3 CAN1_L CAN 1 low CAN 1 low
0 1 2 3 4 5 6 7 8 9
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Anlage 354
Circuit diagrams

Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Pin Übersicht A34 Einbauort + PINO
691
EPE / 000 / 00
692
Pin overview
Pin Übersicht
Driving Controller
A34 Fahrsteuerung
Signal Signal
Circuit diagrams
X35 27 15 2 CAN1_H CAN 1 high CAN 1 high

X35 28 11 1 +Ignition / 0..32V Ignition Zündung
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 34 6 AIN6 / 10V 25mA Sensor, lateral adjustment plates Sensor Seitenverstellung Platten
X35 32 26 2 AIN8 / 10V 25mA Slope sensor Neigungssensor
X35 34 31 3 DIN1 / 0..32V, DRZ Speed vibration drum Drehzahl Vibration Bandage
X35 35 26 6 DIN3 / 0..32V, DRZ Speed drum Geschwindigkeit Bandage
X35 36 25 3 DIN5 / 0..32V Water in Fuel Wasserabscheider
X35 37 25 5 DIN7 / 0..32V Hydraulic oil filter Hydraulikölfilter
X35 38 25 4 DIN9 / 0..32V Maintenance switch, air cleaner Wartungsschalter Luftfilter
X35 39 25 2 DIN11 / 0..32V Coolant level Kühlmittelfüllstand
X35 40 DIN13 / 0..32V, DRZ
X35 41 DIN15 / 0..32V, DRZ
X35 42 33 5 OUT13 / 4A Dozer blade up Planierschild anheben
curr.-measur.
X35 43 33 6 OUT15 / 4A Dozer blade down Planierschild absenken
curr.-measur.
X35 44 OUT17 / 4A
curr.-measur.
X35 45 35 5 OUT19 / 2,5A Floating position plates Schwimmstellung Anbauplatten
curr.-feedb.
X35 46 28 1 OUT1 / 4A Travel pump axle forward Fahrpumpe Achse vorwärts
curr.-measur.
X35 47 28 2 OUT2 / 4A Travel pump axle backward Fahrpumpe Achse rückwärts
curr.-measur.
X35 48 31 4 OUT3 / 4A Vibration pump off/high Vibrationspumpe aus/groß

curr.-measur.
X35 49 31 5 OUT4 / 4A Vibration pump low/off Vibrationspumpe klein/aus
curr.-measur.
X35 50 33 7 OUT21 / 5A Adjustment left plates Verschiebung links Platten
curr.-feedb.
0 1 2 3 4 5 6 7 8 9
Function Page from
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Anlage 354
Pin overview
Pin Übersicht
Driving Controller
A34 Fahrsteuerung
Signal Signal
X35 51 33 8 OUT22 / 5A Adjustment right plates Verschiebung rechts Platten
curr.-feedb.
X35 52 DIN17 / 0..32V
X35 54 11 2 +UE / 0..32V Power Supply (Electronic) Spannungsvers. (Elektronik)
X35 55 11 5 GND Ground Electronic Masse 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 61 29 7 OUT6 / 4A Back-up alarm buzzer Warnsummer Rückwärtsfahrt
X35 62 33 3 OUT7 / 2,5A Dozer blade priority Planierschild Priorität
curr.-feedb.
X35 63 34 4 OUT8 / 2,5A Hour meter plates Stundenzähler Platten
curr.-feedb.
X35 64 28 7 OUT5 / 4A Valve brake Ventil Bremse
curr.-measur.
X35 66 11 7 GND -"- -"-
X35 67 11 8 GND -"- -"-
X35 68 11 9 GND -"- -"-

0 1 2 3 4 5 6 7 8 9
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Anlage 354
Circuit diagrams

693
EPE / 000 / 00
694
Pin overview
Pin Übersicht
Measurement controller
A83 Messtechnik Steuerung
Signal Signal
Circuit diagrams
X88 1 13 6 AGND AGND Analogmasse

X88 2 OUT10 / 2,5A
curr.-feedb.
X88 3 OUT12 / 2,5A
curr.-feedb.
X88 4 36 6 RxD_1 RxD Printer RxD Drucker
X88 5 36 7 TxD_1 TxD Printer TxD Drucker
X88 6 AIN1 / 10V 25mA
X88 7 36 3 AIN3 / 10V 25mA Transducer Acceleration rear 20g Beschleunigungsaufn. hinten 20g
X88 8 AIN5 / 10V 25mA
X88 9 32 4 AIN7 / 10V 25mA Position exciter Erregerposition
X88 12 DIN2 / 0..32V, DRZ
X88 13 DIN4 / 0..32V
X88 14 DIN6 / 0..32V
X88 15 DIN8 / 0..32V
X88 16 DIN10 / 0..32V, DRZ
X88 17 DIN12 / 0..32V
X88 18 DIN14 / 0..32V, DRZ
X88 19 DIN16 / 0..32V, DRZ
X88 23 13 5 8.5VEXT 8,5V Sensor Power 8,5V Sensor Spannung
X88 24 OUT9 / 2,5A
curr.-feedb.
X88 25 36 8 OUT11 / 2,5A Power supply GPS Spannungsversorgung GPS
curr.-feedb.
X88 28 12 1 +Ignition / 0..32V Ignition Zündung
X88 29 36 2 AIN2 / 10V 25mA Transducer Acceleration front 15g Beschleunigungsaufn. vorne 15g
X88 30 36 4 AIN4 / 10V 25mA Transducer Acceleration rear 15g Beschleunigungsaufn. hinten 15g

X88 31 36 1 AIN6 / 10V 25mA Transducer Acceleration front 20g Beschleunigungsaufn. vorne 20g
X88 32 32 2 AIN8 / 10V 25mA Switch, amplitude adjustment Schalter Amplitudenverstellung
X88 34 DIN1 / 0..32V, DRZ
X88 35 DIN3 / 0..32V, DRZ
X88 36 DIN5 / 0..32V
0 1 2 3 4 5 6 7 8 9
Function Page from
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Anlage 354
Pin overview
Pin Übersicht
Measurement controller
A83 Messtechnik Steuerung
Signal Signal
X88 37 DIN7 / 0..32V
X88 38 DIN9 / 0..32V
X88 39 DIN11 / 0..32V
X88 40 DIN13 / 0..32V, DRZ
X88 41 DIN15 / 0..32V, DRZ
X88 46 32 8 OUT1 / 4A Exciter down Erreger ab
curr.-measur.
X88 47 32 7 OUT2 / 4A Exciter up Erreger auf
curr.-measur.
X88 48 OUT3 / 4A
curr.-measur.
X88 49 OUT4 / 4A
curr.-measur.
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 61 32 9 OUT6 / 4A Exciter priority Erreger Priorität
X88 64 OUT5 / 4A
curr.-measur.
X88 66 12 7 GND -"- -"-
X88 67 12 8 GND -"- -"-
X88 68 12 9 GND -"- -"-

0 1 2 3 4 5 6 7 8 9
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Anlage 354
Circuit diagrams

695
EPE / 000 / 00
696
Pin overview
Pin Übersicht
Travel lever
S55 Fahrhebel
Signal Signal
Circuit diagrams
X23 1 14 6 Power supply Power supply Stromversorgung

(8...32V)
X23 2 14 5 Ground Ground Masse
X23 3 30 9 BTS signal "Brake BTS brake BTS Bremse
catch"
X23 5 30 3 Output voltage Supply analog selectors Versorgung Analoge Wahlschalter
supply "+5V"
X23 6 16 4 CAN bus high CAN high CAN +
X23 7 16 5 CAN bus low CAN low CAN low
X23 8 30 2 Ground / 0V / Ground analog selectors Masse Analoge Wahlschalter
reference to PIN 5
X23 9 14 6 Adressing 1 Ground Masse
X23 10 14 7 Adressing 2 -"- -"-
X23 11 30 1 Analog IN 1 Switch, speed range selector 2 Schalter Fahrstufen 2
X23 12 30 4 Analog IN 2 Frequency adjustment plates Frequenzverstellung Anbauplatten
X23.1 4 BTS signal "warning
horn" (prepared)
X23.2 5 Digital IN 5
X23.2 6 Digital IN 6
X23.2 7 Output supply
voltage +Ub
X23.2 8 Output supply
voltage "ground" (0V)
X24 1 30 7 Digital IN 1 Switch, vibration low/off (on/off) Schalter Vibration klein/aus (an/aus)
X24 2 30 8 Digital IN 2 Switch, vibration off/high Schalter Vibration aus/groß
X24 3 30 6 Digital IN 3 Floating position plates Schwimmstellung Anbauplatten
X24 4 30 5 Digital IN 4 Vibration plates Vibration Anbauplatten

0 1 2 3 4 5 6 7 8 9
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Erstellt MFS 12.11.2015 BW 213-226 D+DH-5 Pin overview S55 Higher-level function
=
Anlage 354
Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Pin Übersicht S55 Einbauort + PINO EPE / 000 / 00
Plug overview
Steckerübersicht
Designation Mounting location Function text Designation Mounting location Function text
Bezeichnung Einbauort Funktionstext Bezeichnung Einbauort Funktionstext
Plug, supply potential 30 Plug, access harness rear frame
X0.A +EBOX Stecker Versorgung Potential 30 X2.A +EBOX Stecker Anschluß Kabelbaum Hinterrahmen
Contact Page Path Type Contact Page Path Type
Kontakt Blatt Pfad Typ Amphenol RADSOK® 8mm Kontakt Blatt Pfad Typ AMP Junior Power Timer 15 pole green
30 8 4 1 26 4
Plug, supply ground 2 29 7
X0.B +EBOX Stecker Versorgung Masse
4 26 5
Contact Page Path Type
Kontakt Blatt Pfad Typ Amphenol RADSOK® 6mm 7 28 7
31 8 6 9 26 5
Plug, supply potential 30 before battery disconnect switch 10 27 2
X0.C +EBOX Stecker Versorgung Potential 30 vor Batterietrennschalter 12 26 4
Kontakt Blatt Pfad Typ Amphenol RADSOK® 3,6mm
13 26 5
30 10 8 14 26 5
Plug, access harness engine 15 25 8
X1.A +EBOX Stecker Anschluß Kabelbaum Motor Plug, access harness StvZO illumination hinten
X2.B +EBOX Stecker Anschluß Kabelbaum StvZO Beleuchtung rear
Kontakt Blatt Pfad Typ AMP Junior Power Timer 9 pole blue Contact Page Path Type
Kontakt Blatt Pfad Typ AMP Junior Power Timer 6 pole green
1
2 1 38 8
3 2 38 1
4 3 38 2
5 42 1 4 38 8
Plug, access harness dashboard
6 X4.A +EBOX Stecker Anschluß Kabelbaum Bedienpult
7 8 6 Contact Page Path Type
8 18 8 Kontakt Blatt Pfad Typ AMP Junior Power Timer 21 pole grey
9 18 8 1 10 2
Plug, access harness engine controller 2 29 3
X1.B +EBOX Stecker Anschluß Kabelbaum Motorsteuergerät 3 8 8
Kontakt Blatt Pfad Typ AMP Junior Power Timer 18 pole blue
4 38 8
1 20 2 5 25 8
2 20 2 6 38 8
3 7 28 7
4 9 8 7
5 10 9 4
6 11 38 3
7 12 10 2
8 13 8 7
9 20 5 14 16 2
10 20 7 15 37 5
11 16 19 5

12 20 6 17 16 3
13 20 7 18 14 1
14 20 4 19 9 4
15 20 7 20 8 8
16 20 5 21 28 7
17
18 20 8
0 1 2 3 4 5 6 7 8 9
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Erstellt MFS 12.11.2015 BW 213-226 D+DH-5 Plug overview Higher-level function
=
Anlage 354
Circuit diagrams

Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Steckerübersicht Einbauort + PLGO
697
EPE / 000 / 00
698
Plug overview
Steckerübersicht
Plug, access harness console seat Plug, access cabin and rops
X4.B +EBOX Stecker Anschluß Kabelbaum Konsole Sitz X4.E +EBOX Stecker Anschluß Kabine und Rops
Circuit diagrams
Kontakt Blatt Pfad Typ AMP Junior Power Timer 9 pole grey Kontakt Blatt Pfad Typ AMP Junior Power Timer 18 pole grey
1 16 4 18 37 4
2 26 3 Plug, access harness driving controller 1
3 42 7
X5.A +EBOX Stecker Anschluß Kabelbaum Fahrsteuerung 1
4 16 5 Kontakt Blatt Pfad Typ AMP Junior Power Timer 21 pole brown
6 42 7 1 26 8
7 14 6 2 26 7
8 32 2 3 11 3
9 30 8 4 13 2
Plug, access harness StvZO illumination front
X4.D +EBOX Stecker Anschluß Kabelbaum StvZO Beleuchtung vorne
5 29 7
Contact Page Path Type 6 15 4
Kontakt Blatt Pfad Typ AMP Junior Power Timer 12 pole grey 7 33 2
1 38 2 9 15 5
2 38 8 10 25 1
3 38 7 12 15 2
5 38 8 13 13 2
6 38 8 14 30 8
7 38 4 15 15 3
8 38 9 16 26 7
9 38 2 17 29 8
10 38 2 18 11 2
11 38 8 19 11 1
12 38 1 20 29 8
Plug, access cabin and rops 21 28 7
X4.E +EBOX Stecker Anschluß Kabine und Rops Plug, access harness driving controller 2
Contact Page Path Type X5.B +EBOX Stecker Anschluß Kabelbaum Fahrsteuerung 2
Kontakt Blatt Pfad Typ AMP Junior Power Timer 18 pole grey Contact Page Path Type
2 43 1 1 31 6
3 37 3 3 31 6
4 43 1 5 26 5
5 43 1 6 26 4
6 37 4 8 31 4
7 43 1 9 31 5
8 43 1 10 26 3
9 43 1 Plug, access harness measurement controller
10 43 1
X5.E +EBOX Stecker Anschluß Kabelbaum Messtechnik Steuerung

12 43 1 1 16 7
13 43 1 2 16 8
14 43 1 3 36 7
15 43 1 4 12 1
16 37 3 5 36 6
17 43 1 6 12 3
0 1 2 3 4 5 6 7 8 9
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Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Steckerübersicht Einbauort + PLGO EPE / 000 / 00
Plug overview
Steckerübersicht
Plug, access harness measurement controller Plug, access CAN Gateways
X5.E +EBOX Stecker Anschluß Kabelbaum Messtechnik Steuerung X7.A +EBOX Stecker Anschluß CAN Gateways
Kontakt Blatt Pfad Typ AMP Junior Power Timer 15 pole brown Kontakt Blatt Pfad Typ AMP Junior Power Timer 12 pole yellow
7 36 1 7 17 6
8 36 8 8 17 5
9 13 5 9 17 6
10 33 2 10 17 7
11 32 4 11
12 15 7 12
13 12 2 Plug, access keyboard electronical burglary protection
14 32 2
X7.B +EBOX Stecker Anschluß Tastatur elektronische Diebstahlsicherung
15 15 6 Kontakt Blatt Pfad Typ AMP Junior Power Timer 6 pole yellow
Plug, access sockets
X6.B +EBOX Stecker Anschluß Bordsteckdosen
1 39 3
Kontakt Blatt Pfad Typ AMP Junior Power Timer 2 - 4 pole black 3 39 3
1 42 9 4 39 3
2 37 1 6 39 3
3 42 8 Plug, additional options
4 37 1
X7.C +EBOX Stecker Zusatzoptionen
Plug, access harness heating-climatic unit
X6.C +EBOX Kontakt Blatt Pfad Typ AMP Junior Power Timer 2 - 14 pole black
Stecker Anschluß Kabelbaum Heiz-Klimamodul
1 42 3 3 10 1
2 42 3 4 8 6
4 42 3 5 8 6
Plug, access telematics 6 37 6
X6.D +EBOX Stecker Anschluß Telematik
7 43 1
1 40 2 11 26 5
2 40 2 12 28 6
3 40 2 13 15 2
4 40 2 14 15 3
Plug, access diagnosis Interface Bomag
5 40 2 X7.D +EBOX Stecker Anschluß Diagnosesteckdose Bomag
7 40 2 Kontakt Blatt Pfad Typ AMP Junior Power Timer 15 pole yellow
8 40 2 2 15 1
Plug, access CAN Gateways 3 15 5
X7.A +EBOX Stecker Anschluß CAN Gateways
5 15 2

Kontakt Blatt Pfad Typ AMP Junior Power Timer 12 pole yellow 6 15 4
1 7 15 3
2 8 15 8
3 17 4 10 15 2
4 17 4 11 15 6
5 17 4 13 15 1
6 17 4 15 15 1
0 1 2 3 4 5 6 7 8 9
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Circuit diagrams

699
EPE / 000 / 00
700
Plug overview
Steckerübersicht
Plug, access supply cabin potential 30 Plug, keyboard electronical burglary protection
X8.A +EBOX Stecker Anschluß Kabine Potential 30 X16 +DPL Stecker Tastatur Elektronische Diebstahlsicherung
Circuit diagrams
Kontakt Blatt Pfad Typ Amphenol RADSOK® 8mm Kontakt Blatt Pfad Typ Deutsch DT 4 pole
30 43 2 3 39 5
Plug, access supply cabin potential 31 4 39 5
X8.B +EBOX Stecker Anschluß Kabine Potential 31 Plug, transducer acceleration front
Contact Page Path Type X20 +DRUM Stecker Beschleunigungsaufnehmer vorne
Kontakt Blatt Pfad Typ Amphenol RADSOK® 6mm Contact Page Path Type
43 2 Kontakt Blatt Pfad Typ Deutsch DT 4 pole
Plug, heating climatic unit 1 36 1
X10 +CAB Stecker Heiz-Klima-Einheit
2 36 2
Kontakt Blatt Pfad Typ AMP HDSCS 4 pole 3 36 2
1 42 3 4 36 1
Plug, transducer acceleration rear
2 42 4 X21 +DRUM Stecker Beschleunigungsaufnehmer hinten
Plug, connection rear frame - engine module Kontakt Blatt Pfad Typ Deutsch DT 4 pole
X11 +REFR Stecker Verbindung Hinterrahmen - Motormodul
1 36 3
Kontakt Blatt Pfad Typ Deutsch DT 12 pole 2 36 4
1 25 8 3 36 4
2 25 8 4 36 3
Plug, access rotary beacon ROPS
3 28 6 X22 +EBOX Stecker Anschluß Rundumkennleuchte ROPS
5 28 6 Kontakt Blatt Pfad Typ FASTIN-FASTON TAB housing 2 way
6 38 1 1 37 2
7 38 8 2 37 2
8 38 1 Plug, supply travel lever
9 38 2
X23 +SEAT Stecker Vorsorgung Fahrhebel
10 38 8 Kontakt Blatt Pfad Typ Deutsch DT 12 pole Code A
11 38 1 1 14 6
12 2 14 5
Plug, compressor air conditioning
X12 +MOT Stecker Kompressor Klimaanlage
3 30 9
Contact Page Path Type 4
Kontakt Blatt Pfad Typ 4,6RSH2,5 5 30 3
1 42 1 6 16 4
Plug, seat contact switch 7 16 5
X14 +SEAT Stecker Sitzkontaktschalter
8 30 2
A 26 3 10 14 7
B 26 3 11 30 1

C 12 30 4
Plug, keyboard electronical burglary protection Plug, IO´s travel lever
X16 +DPL Stecker Tastatur Elektronische Diebstahlsicherung
X24 +SEAT Stecker Ein-/Ausgänge Fahrhebel
Kontakt Blatt Pfad Typ Deutsch DT 4 pole Kontakt Blatt Pfad Typ Deutsch DT 8 pole
1 39 5 1 30 7
2 39 5 2 30 8
3 30 6
0 1 2 3 4 5 6 7 8 9
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Plug overview
Steckerübersicht
Plug, IO´s travel lever Plug, access lifting unit plates
X24 +SEAT Stecker Ein-/Ausgänge Fahrhebel X29 +REFR Stecker Anschluß Hubwerk Platten
Kontakt Blatt Pfad Typ Deutsch DT 8 pole Kontakt Blatt Pfad Typ Deutsch DTM 6 pole
4 30 5 6 34 6
5 Plug, backup alarm buzzer
6
X30 +REFR Stecker Rückfahrwarnsummer
7 Kontakt Blatt Pfad Typ Deutsch DT 2 pole
8 1 29 7
Plug, access double pump
X25 +REFR Stecker Anschluß Doppelpumpe
2 29 7
Diagnosis interface EMR
Contact Page Path Type X32 +EBOX Diagnoseschnittstelle EMR
Kontakt Blatt Pfad Typ Deutsch DTM 8 pole
1 27 2 Kontakt Blatt Pfad Typ ITT-Cannon 12 pole
2 27 3 A 21 7
3 27 4 B 21 9
4 27 4 C
5 27 2 D
6 28 3 E
7 28 3 F 21 8
8 28 4 G 21 8
Plug, potentiometer frequency plates
X26 +SEAT Stecker Potentiometer Frequenzverstellung Anbauplatten
H 21 8
Contact Page Path Type J
Kontakt Blatt Pfad Typ AMP Mate´n´loc 3 pole white K
1 30 4 L
2 30 4 M 21 8
3 30 4 Plug, monitoring module
Plug, quick connect coupling plates
X33 +ARC Stecker Überwachungsmodul
X27 +PLA Stecker Schnellverschlußkupplung Platten Contact Page Path Type
Contact Page Path Type Kontakt Blatt Pfad Typ AMP Superseal 26 pole
Kontakt Blatt Pfad Typ 1
1 34 5 2 25 8
2 34 5 3 25 7
3 34 4 4 19 5
Plug, sensor height adjustment plates 5 37 7
X28 +REFR Stecker Sensor Höhenverstellung Platten
6
Kontakt Blatt Pfad Typ Deutsch DTM 3 pole 7
1 34 5 8 38 7
2 34 5 9 19 1
3 34 5 10 19 2
Plug, access lifting unit plates 11

X29 +REFR Stecker Anschluß Hubwerk Platten 12
13
1 34 7 14
2 34 6 15
3 34 6 16
4 34 4 17
5 34 6 18
0 1 2 3 4 5 6 7 8 9
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Anlage 354
Circuit diagrams

701
EPE / 000 / 00
702
Plug overview
Steckerübersicht
Plug, monitoring module Plug, driving controller
X33 +ARC Stecker Überwachungsmodul X35 +EBOX Stecker Fahrsteuerung
Circuit diagrams
Kontakt Blatt Pfad Typ AMP Superseal 26 pole Kontakt Blatt Pfad Typ AMP 68 pole
19 10 34 6
20 11 33 4
21 16 2 12 26 5
22 16 3 13 26 4
23 14 30 8
24 15 26 3
25 14 1 16 26 4
26 14 1 17 26 7
Diagnosis interface BOMAG 18
X34 +EBOX Diagnosesteckdose BOMAG
19
Kontakt Blatt Pfad Typ Burndy 19 pole 20 28 3
A 15 2 21 28 4
B 15 3 22 34 7
C 15 4 23 13 2
D 15 5 24 29 8
E 15 6 25 29 8
F 15 8 26 15 3
G 27 15 2
H 28 11 1
J 15 2 29 27 4
K 30 27 4
L 31 34 6
M 32 26 2
N 15 1 33 15 5
P 15 1 34 31 3
R 15 1 35 26 6
S 36 25 3
T 37 25 5
U 38 25 4
V 39 25 2
Plug, driving controller 40
X35 +EBOX Stecker Fahrsteuerung 41
Kontakt Blatt Pfad Typ AMP 68 pole
42 33 5
1 13 2 43 33 6
2 28 5 44
45 35 5

3 28 8
4 46 28 1
5 47 28 2
6 27 2 48 31 4
7 27 3 49 31 5
8 34 5 50 33 7
9 25 1 51 33 8
52
0 1 2 3 4 5 6 7 8 9
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Anlage 354
Plug overview
Steckerübersicht
Plug, driving controller Plug, access external supply engine
X35 +EBOX Stecker Fahrsteuerung X41 +EBOX Stecker Anschluß externe Versorgung Motor
Kontakt Blatt Pfad Typ AMP 68 pole Kontakt Blatt Pfad Typ AMP MCP 2.8 39 pole
53 15 4 19
54 11 2 20
55 11 5 21
56 11 3 22
57 11 4 23
58 11 5 24
59 11 6 25
60 11 6 26
61 29 7 27
62 33 3 28 24 1
63 34 4 29 24 1
64 28 7 30
65 11 6 31
66 11 7 32 21 6
67 11 8 33 21 6
68 11 9 34 21 6
Plug, supply air intake throttle 35 24 8
X40 +MOT Stecker Versorgung Drosselklappe Ansaugluft
36 24 8
Kontakt Blatt Pfad Typ 37
2 38 24 1
3 39 24 1
Plug, access external supply engine Plug, engine-controller motor-part
X41 +EBOX Stecker Anschluß externe Versorgung Motor
X44 +EBOX Stecker Motorsteuergerät Motorseite
Kontakt Blatt Pfad Typ AMP MCP 2.8 39 pole Kontakt Blatt Pfad Typ Bosch 105 pole
1 22 8 02 23 7
2 22 8 08 23 9
3 22 8 11 23 4
4 13 23 3
5 17 23 2
6 22 8 18 23 8
7 21 23 4
8 22 22 1
9 23 22 2
10 23 22 5
11 24 22 3

12 24 22 5
13 25 23 1
14 35 23 2
15 36 23 1
16 43 22 1
17 44 22 2
18 45 22 3
0 1 2 3 4 5 6 7 8 9
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Circuit diagrams

703
EPE / 000 / 00
704
Plug overview
Steckerübersicht
X44 +EBOX Stecker Motorsteuergerät Motorseite X45 +EBOX Stecker Motorsteuergerät Maschinenseite
Circuit diagrams
Kontakt Blatt Pfad Typ Bosch 105 pole Kontakt Blatt Pfad Typ AMP 94 pole
45 22 4 10 21 3
46 23 0 13 21 5
51 23 9 18 21 5
53 23 6 23 21 4
54 23 5 26 21 1
55 23 7 31 21 5
58 22 9 43 21 3
63 22 8 50 21 3
64 22 1 58 21 2
64 22 4 64 21 5
65 22 1 67 21 5
66 22 2 70 21 1
66 22 4 74 21 4
67 23 7 82 21 8
72 23 4 83 21 8
73 23 4 85 21 8
74 23 3 86 21 8
75 22 6 88 21 4
76 23 8 91 21 2
77 24 3 Plug, engine EMR 1
78 23 1
X46.1 +MOT Stecker Motor EMR 1
85 22 0 Kontakt Blatt Pfad Typ AMP MCP 39 pole
85 22 4 1 22 7
86 22 2 2 22 8
87 22 2 3 22 8
88 22 9 6 22 8
94 22 8 7 22 9
95 22 8 8 22 9
98 24 3 9 22 6
99 22 6 13 22 6
100 22 6 14 22 6
101 22 7 15 22 7
102 22 7 17 23 5
Plug, engine-controller machine-part
X45 +EBOX Stecker Motorsteuergerät Maschinenseite
19 23 0
Kontakt Blatt Pfad Typ AMP 94 pole

21 22 7
1 21 0 22 23 4
2 21 9 23 23 4
3 21 0 24 23 3
4 21 9 25 23 1
5 21 0 26 23 4
6 21 9 27 23 2
0 1 2 3 4 5 6 7 8 9
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Anlage 354
Plug overview
Steckerübersicht
Plug, engine EMR 1 Plug, injectors 1
X46.1 +MOT Stecker Motor EMR 1 X47.1 +MOT Stecker Injektoren 1
Kontakt Blatt Pfad Typ AMP MCP 39 pole Kontakt Blatt Pfad Typ
28 23 3 3 22 5
29 23 4 4 22 2
30 23 1 4 22 5
31 23 2 5 22 4
32 22 2 Plug, injectors 2
32 22 5
X47.2 +MOT Stecker Injektoren 2
33 22 3 Kontakt Blatt Pfad Typ
33 22 5 1 22 3
34 22 0 2 22 1
34 22 4 3 22 2
35 22 1 4 22 3
35 22 4 Plug, engine stop
36 22 1 X48 +EBOX Stecker Motor Stop
37 22 2 Kontakt Blatt Pfad Typ Deutsch DTM 2 pole
37 22 4 1 21 2
38 22 1 2 21 2
39 22 3 Plug, access display back up monitoring
Plug, engine EMR 2 X50 +CAB Stecker Anschluß Monitor Rückraumüberwachung
X46.2 +MOT Stecker Motor EMR 2 Contact Page Path Type
Contact Page Path Type Kontakt Blatt Pfad Typ Deutsch DT 6 pole
Kontakt Blatt Pfad Typ AMP MCP 62 pole
1 50 5
13 23 7 2 50 5
18 23 7 3 50 5
19 23 7 4 50 5
22 24 2 5 50 5
23 24 2 6
24 23 8 Plug, pressure sensor travel pump axle MA
28 24 1 X55 +PUMP Stecker Drucksensor Fahrpumpe Achse MA
Kontakt Blatt Pfad Typ AMP Superseal 3pol
30 23 9
37 23 8 1 27 2
41 23 9 2 27 2
46 23 6 3
Plug, pressure sensor travel pump axle MB
57 24 1 X56 +PUMP Stecker Drucksensor Fahrpumpe Achse MB
Plug, injectors 1 Kontakt Blatt Pfad Typ AMP Superseal 3pol
X47.1 +MOT Stecker Injektoren 1 1 27 3

Kontakt Blatt Pfad Typ
2 27 3
1 22 0 3
Plug, pressure sensor travel pump drum MA
1 22 4 X57 +PUMP Stecker Drucksensor Fahrpumpe Bandage MA
2 22 4 Kontakt Blatt Pfad Typ AMP Superseal 3pol
3 22 1 1 27 4
0 1 2 3 4 5 6 7 8 9
Function Page from
=
Anlage 354
Circuit diagrams

705
EPE / 000 / 00
706
Plug overview
Steckerübersicht
Plug, pressure sensor travel pump drum MA Plug, sender level gauge
X57 +PUMP Stecker Drucksensor Fahrpumpe Bandage MA X69 +REFR Stecker Tauchrohrgeber
Circuit diagrams
Kontakt Blatt Pfad Typ AMP Superseal 3pol Kontakt Blatt Pfad Typ AMP Superseal 3pol
2 27 4 3 25 8
3 Plug, floating switch coolant expansion tank
Plug, pressure sensor travel pump drum MB
X72 +MOT Stecker Schwimmerschalter Kühlmittelausgleichsbehälter
X58 +PUMP Stecker Drucksensor Fahrpumpe Bandage MB Contact Page Path Type
Contact Page Path Type Kontakt Blatt Pfad Typ Deutsch DTM 2 pole
Kontakt Blatt Pfad Typ AMP Superseal 3pol 1 25 2
1 27 4 2 25 2
2 27 4 Plug, WaterInFuel Sensor
3
X73 +MOT Stecker Sensor Wasser im Kraftstoff
Plug, windscreen wiper motor rear
X65 +CAB Kontakt Blatt Pfad Typ AMP Junior Power Timer 2 pole
Stecker Scheibenwischermotor hinten
Kontakt Blatt Pfad Typ P4NAT 2 21 1
1 47 5 Plug, access fuel pump additional heater
2 47 5
X76 +MOT Stecker Anschluss Kraftstoffpumpe Zusatzheizung
4 47 5 1 41 5
Plug, windscreen wiper motor front
X66 +CAB Stecker Scheibenwischermotor vorne
2 41 5
Plug, access potential 15 Powerboard SCR-System
Contact Page Path Type X78 +MOT Stecker Anschluß Potential 15 Powerboard SCR-System
Kontakt Blatt Pfad Typ P6SNAT
1 47 3 Kontakt Blatt Pfad Typ Deutsch DT 2 pole
2 47 3 1 18 8
3 47 3 2
4 Plug, headlight front left
5 47 3 X79 +DPL Stecker Scheinwerfer vorne links
Plug, fuel pre heater
X67 +MOT Stecker Kraftstoffvorheizung 1
1 18 8 4
2 18 8 5 38 4
Plug, pressure switch air conditioning
X68 +REFR Stecker Druckschalter Klimaanlage
6 38 1
Plug, tail light rear left
Contact Page Path Type X80 +REFR Stecker Rückleuchte links
Kontakt Blatt Pfad Typ Deutsch DT 4 pole
1 42 1 Kontakt Blatt Pfad Typ Deutsch DT 4 pole
2 42 1 1 38 8
3 42 1

2 38 8
4 42 1 3 38 1
Plug, sender level gauge
X69 +REFR Stecker Tauchrohrgeber
4 38 1
Plug, tail light rear right
Contact Page Path Type X81 +REFR Stecker Rückleuchte rechts
Kontakt Blatt Pfad Typ AMP Superseal 3pol
2 25 8 1 38 8
0 1 2 3 4 5 6 7 8 9
Function Page from
=
Anlage 354
Plug overview
Steckerübersicht
Plug, tail light rear right Plug, measurement controller
X81 +REFR Stecker Rückleuchte rechts X88 +EBOX Stecker Messtechniksteuerung
Kontakt Blatt Pfad Typ Deutsch DT 4 pole Kontakt Blatt Pfad Typ AMP 68 pole
2 38 8 2
3 38 2 3
4 38 2 4 36 6
Plug, headlight front right 5 36 7
X82 +DPL Stecker Scheinwerfer vorne rechts
6
1 8
2 38 8 9 32 4
3 38 2 10
4 11
5 38 5 12
6 38 2 13
Plug, access additional blower 14
X83 +CAB Stecker Anschluß Zusatzlüfter 15
16
1 48 9 17
2 48 9 18
Plug, access BCM-system 19
X85 +CAB Stecker Anschluß BCM-System 20
22
1 49 5 23 13 5
2 49 5 24
3 49 6 25 36 8
4 49 1 26 15 7
5 49 1 27 15 6
6 28 12 1
Plug, sensor adjustable motor
X86 +DRUM Stecker Sensor Verstellmotor 29 36 2
Kontakt Blatt Pfad Typ Deutsch DTM 3 pole 31 36 1
1 32 4 32 32 2
2 32 5 33 16 8
3 32 4 34
Plug, suspension seat
X87 +SEAT Stecker Luftfedersitz
35
Kontakt Blatt Pfad Typ P2NAT 37

1 42 6 38
2 42 6 39
Plug, measurement controller 40
X88 +EBOX Stecker Messtechniksteuerung
41
Kontakt Blatt Pfad Typ AMP 68 pole 42
1 13 6 43
44
0 1 2 3 4 5 6 7 8 9
Function Page from
=
Anlage 354
Circuit diagrams

707
EPE / 000 / 00
708
Plug overview
Steckerübersicht
Plug, measurement controller Plug, USB BCM Dongle
X88 +EBOX Stecker Messtechniksteuerung X91 +CAB Stecker USB BCM Dongle
Circuit diagrams
Kontakt Blatt Pfad Typ AMP 68 pole Kontakt Blatt Pfad Typ USB
45 4 49 4
46 32 8 SH 49 4
47 32 7 Plug, access GPS-Receiver
48
X92 +CAB Stecker Anschluß GPS-Antenne
49 Kontakt Blatt Pfad Typ Burndy 12 pole
50 M
51 L
52 K
53 16 7 J
54 12 2 H
55 12 5 G
56 12 3 F
57 12 4 E 49 7
58 12 5 D 49 7
59 12 6 C 49 7
60 12 6 B 49 7
61 32 9 A 49 7
62 Plug, supply GPS System
63 X93 +CAB Stecker Spannungsversorgung GPS System
65 12 6 A 49 6
66 12 7 B 49 6
67 12 8 C 49 6
68 12 9 Plug, printer
Plug, access GPS - BCM X94 +CAB Stecker Drucker
X90 +CAB Stecker Anschluß GPS - BCM Contact Page Path Type
Contact Page Path Type Kontakt Blatt Pfad Typ AMP Mate´n´loc 6 pole white
Kontakt Blatt Pfad Typ SUB-D 9 pole
1 48 6
1 2 48 7
2 49 5 4 48 8
3 49 5 5 48 7
4 Plug, CAN BCM Dongle
5 49 5 X95.A +CAB Stecker CAN BCM Dongle
6 Contact Page Path Type
Kontakt Blatt Pfad Typ SUB-D 9 pole
7
8 1
2 49 2

9
Plug, USB BCM Dongle 3
X91 +CAB Stecker USB BCM Dongle 4
Kontakt Blatt Pfad Typ USB
6
1 49 4 7 49 2
2 49 4 8
3 49 4 9
0 1 2 3 4 5 6 7 8 9
Function Page from
=
Anlage 354
Plug overview
Steckerübersicht
Plug, supply BCM Plug, connection Armatures - Console seat
X96.A +CAB Stecker Versorgung BCM X102 +EBOX Stecker Verbindung Armaturen - Konsole Sitz
Kontakt Blatt Pfad Typ Kontakt Blatt Pfad Typ AMP Junior Power Timer 15 pole grey
1 49 5 3 30 1
2 49 5 4 30 1
Plug, GPS-Receiver StarFire 5 30 3
X97 +CAB Stecker GPS-Antenne StarFire
6 30 7
1 8
2 49 9 9
3 10
4 11
5 12
6 49 9 13
7 49 9 14
8 15
Plug, connection Driving controller - Rear frame
9 X103 +EBOX Stecker Verbindung Fahrsteuerung - Hinterrahmen
10 Contact Page Path Type
11 49 9 Kontakt Blatt Pfad Typ AMP Junior Power Timer 18 pole green
12 49 8 1 27 2
Plug, heating operators seat 2 27 3
X99 +SEAT Stecker Sitzheizung
3 27 4
Kontakt Blatt Pfad Typ P2NAT 4 27 4
1 42 7 5 28 1
2 42 7 6 28 2
Plug, connection Driving controller - Console seat 7 28 3
X100 +EBOX Stecker Verbindung Fahrsteuerung - Konsole Sitz 8 28 4
Kontakt Blatt Pfad Typ AMP Junior Power Timer 6 pole grey
9 28 5
1 26 4 10 28 8
2 11 25 5
3 12 31 5
4 13 31 6
5 14
6 15
Plug, connection Driving controller - Engine 16
X101 +EBOX Stecker Verbindung Fahrsteuerung - Motor 17
Kontakt Blatt Pfad Typ AMP Junior Power Timer 12 pole blue Plug, connection Driving controller - Front frame
1 25 2 X104 +EBOX Stecker Verbindung Fahrsteuerung - Vorderrahmen

Kontakt Blatt Pfad Typ AMP Junior Power Timer 9 pole purple
3 25 4
Plug, connection Armatures - Console seat 1 26 7
X102 +EBOX Stecker Verbindung Armaturen - Konsole Sitz 2 26 7
Kontakt Blatt Pfad Typ AMP Junior Power Timer 15 pole grey
4 26 8
1 30 1 5 26 6
2 30 1
0 1 2 3 4 5 6 7 8 9
Function Page from
=
Anlage 354
Circuit diagrams

709
EPE / 000 / 00
710
Plug overview
Steckerübersicht
Plug, connection Driving controller - Front frame Plug, connection Measurement controller - Front frame
X104 +EBOX Stecker Verbindung Fahrsteuerung - Vorderrahmen X107 +EBOX Stecker Verbindung Messrechner - Vorderrahmen
Circuit diagrams
Kontakt Blatt Pfad Typ AMP Junior Power Timer 9 pole purple Kontakt Blatt Pfad Typ AMP Junior Power Timer 12 pole purple
6 26 7 6 36 4
7 28 9 7 32 4
8 28 9 8 32 4
9 9 32 7
Plug, connection Driving controller - Front frame dozer blade 10 32 8
X105 +EBOX Stecker Verbindung Fahrsteuerung - Vorderrahmen Planierschild
11 32 9
Kontakt Blatt Pfad Typ AMP Junior Power Timer 18 pole purple 12 32 7
Plug, connection Engine - Engine Controller
1 33 3 X108 +EBOX Stecker Verbindung Motor - Motorsteuergerät
3 33 5 Kontakt Blatt Pfad Typ AMP Junior Power Timer 15 pole blue
4 33 6 1 21 1
5 33 7 2 21 1
6 33 8 3 21 3
7 33 3 4 21 3
8 34 7 5 21 4
9 34 4 6
10 33 4 7
11 34 1 8
12 33 4 9
13 34 5 10
14 34 6 11
15 34 6 12
16 35 5 13
17 14
18 15
Plug, connection Driving controller - Front frame sensor speed vibration Plug, supply potential 30
X106 +EBOX Stecker Verbindung Fahrsteuerung - Vorderrahmen Drehzahlaufnehmer Vibration X200 +CAB Stecker Versorgung Potential 30
Kontakt Blatt Pfad Typ AMP Junior Power Timer 6 pole purple Kontakt Blatt Pfad Typ Amphenol RADSOK® 6mm
1 31 2 30 43 3
2 31 1 Plug, supply ground
3 31 3
X201 +CAB Stecker Versorgung Masse
4 Kontakt Blatt Pfad Typ Amphenol RADSOK® 3,6mm
5 31 2 31 43 3
6 31 2 Plug, signals from/to central electric
Plug, connection Measurement controller - Front frame X202 +CAB Stecker, Signale von/zur Zentralelektrik
X107 +EBOX Stecker Verbindung Messrechner - Vorderrahmen Contact Page Path Type

Contact Page Path Type Kontakt Blatt Pfad Typ AMP Junior Power Timer 2 - 10 pole black
Kontakt Blatt Pfad Typ AMP Junior Power Timer 12 pole purple 1 43 3
1 36 1 2 48 8
2 36 2 3 43 3
3 36 1 4 43 3
4 36 2 5 43 3
5 36 3 6 43 3
0 1 2 3 4 5 6 7 8 9
Function Page from
=
Anlage 354
Plug overview
Steckerübersicht
Plug, signals from/to central electric Plug, access additional headlights, reserve funktions
X202 +CAB Stecker, Signale von/zur Zentralelektrik X206 +CAB Stecker Anschluß Zusatzscheinwerfer, Reservefunktionen
Kontakt Blatt Pfad Typ AMP Junior Power Timer 2 - 10 pole black Kontakt Blatt Pfad Typ AMP Junior Power Timer 9 pole grey
8 43 3 4 45 5
9 43 3 6 45 4
10 43 3 7 46 7
Plug, access cabin equipment 8 46 7
X203 +CAB Stecker Anschluß Kabinenausrüstung
9 45 5
Plug, heating unit additional heater
Kontakt Blatt Pfad Typ AMP Junior Power Timer 2 - 14 pole black X207 +DPL Stecker Heizgerät Zusatzheizung
2 45 6 Kontakt Blatt Pfad Typ AMP Junior Power Timer 16 pole
3 45 8 1 41 3
4 45 8 2
5 45 7 3
6 45 9 4 41 3
7 47 3 5 41 3
8 47 3 6 41 3
9 47 3 7 41 3
10 47 5 8 41 3
11 47 5 9
12 47 5 10 41 3
13 47 7 11
14 47 7 12
Plug, supply BCM System, printer 13
X204 +CAB Stecker Versorgung BCM System, Drucker
14
Kontakt Blatt Pfad Typ AMP Junior Power Timer 2 - 4 pole black 15
1 49 5 16
Plug, access GPS-Receiver
2 49 6 X210 +CAB Stecker Anschluß GPS-Antenne
Plug, access radio and tachograph 1 49 7
X205 +CAB Stecker Anschluß Radio und Tachograph
2 49 7
1 48 0 4 49 7
2 48 1 5 49 7
3 48 1 6
Plug, access temperature sensor asphalt
4 48 2 X211 +CAB Stecker Anschluß Asphalttemperatursensor

6 48 2 Kontakt Blatt Pfad Typ DTM 4 pole
Plug, access additional headlights, reserve funktions 1
X206 +CAB Stecker Anschluß Zusatzscheinwerfer, Reservefunktionen
2 49 5
Kontakt Blatt Pfad Typ AMP Junior Power Timer 9 pole grey 3 49 5
1 45 3 4 49 5
2 45 4
3 46 7
0 1 2 3 4 5 6 7 8 9
Function Page from
=
Anlage 354
Circuit diagrams

711
EPE / 000 / 00
712
Plug overview
Steckerübersicht
Plug, timer additional heater Plug, switch speed range selector
XS28 +DPL Stecker Schaltuhr Zusatzheizung XS42 +ARC Stecker Schalter Fahrstufen
Circuit diagrams
Kontakt Blatt Pfad Typ AMP Junior Power Timer 12 pole grey Kontakt Blatt Pfad Typ AMP GET 6 way
1 41 8 2 30 1
2 41 7 3 30 1
3 4 30 1
4 41 8 5 30 1
5 6 30 1
6 41 7
7
8 41 7
9 41 7
10 41 7
11 41 7
12 41 7
Plug, electronic system BOMAG Telematics
XA124 +EBOX Stecker Elektronik BOMAG Telematik
Kontakt Blatt Pfad Typ Deutsch DTM 12 pole Code A
1 40 4
2 40 3
3 40 3
4 40 3
5
6
7
8 40 4
9
10
11 40 4
12 40 3
Plug, fuel pre heater
XR79 +MOT Stecker Kraftstoffvorheizung
Kontakt Blatt Pfad Typ AMP 2,5mm 4 way black Code 1
1 18 8
2 18 8
3
4
Socket
XS +DPL Steckdose

37 1
Plug, switch speed range selector
XS42 +ARC Stecker Schalter Fahrstufen
Kontakt Blatt Pfad Typ AMP GET 6 way
1 30 0
0 1 2 3 4 5 6 7 8 9
Function Page from
=
Anlage 354
A48 S55
A15 A144 P15
+EBOX +SEAT +ARC +CAB +CAB
CAN 2
CAN 1
A87
+EBOX
A67
+DPL +CAB
CAN 3

A124
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt MFS 12.11.2015 BW 213-226 D+DH-5 Overview CAN Communication Higher-level function
=
Anlage 354
Circuit diagrams

Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Übersicht CAN Kommunkikation Einbauort + VIEW
713
EPE / 000 / 00
714
Circuit diagrams

0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt MFS 12.11.2015 BW 213-226 D+DH-5 Overview Central Electric Higher-level function
=
Anlage 354
Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Übersicht Zentralelektrik Einbauort + VIEW EPE / 000 / 00
Top view
Draufsicht

0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt MFS 12.11.2015 BW 213-226 D+DH-5 Overview plugs X100 - X109 Higher-level function
=
Anlage 354
Circuit diagrams

Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Übersicht Stecker X100 - X109 Einbauort + VIEW
715
EPE / 000 / 00
716
Circuit diagrams

0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt MFS 12.11.2015 BW 213-226 D+DH-5 Overview Powerboard Higher-level function
=
Anlage 354
Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Übersicht Powerboard Einbauort + VIEW EPE / 000 / 00
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt MFS 12.11.2015 BW 213-226 D+DH-5 Overview Powerboard Higher-level function
=
Anlage 354
Circuit diagrams

Geprüft 12.11.2015 Deutz TCD 4.1+6.1 Tier 3a Übersicht Powerboard Einbauort + VIEW
717
EPE / 000 / 00
Head Office/Hauptsitz
BOMAG
Hellerwald
D-56154 Boppard
Germany
Telefon: +49 6742 100-0
Fax: +49 6742 3090
e-mail: info@bomag.com
BOMAG BOMAG BOMAG

Niederlassung Berlin Niederlassung Boppard Niederlassung Chemnitz
Gewerbestraße 3 Hellerwald Querstraße 6
15366 Hoppegarten 56154 Boppard 09247 Chemnitz
GERMANY GERMANY GERMANY
Tel.: +49 3342 369410 Tel.: +49 6742 100360 Tel.: +49 3722 51590
Fax: +49 3342 369436 Fax: +49 6742 100392 Fax: +49 3722 515951
e-mail: nlberlin@bomag.com e-mail: nlboppard@bomag.com e-mail: nlchemnitz@bomag.com
BOMAG BOMAG BOMAG

Niederlassung Hannover Niederlassung München Niederlassung Stuttgart
Dieselstraße 44 Otto-Hahn-Ring 3 Uferstraße 22
30827 Garbsen-Berenbostel 85301 Schweitenkirchen 73630 Remshalden-Grunbach
GERMANY GERMANY GERMANY
Tel.: +49 5131 70060 Tel.: +49 8444 91840 Tel.: +49 7151 986293
Fax: +49 5131 6766 Fax: +49 8444 918420 Fax: +49 7151 9862959
e-mail: nlhannover@bomag.com e-mail: nlmuenchen@bomag.com e-mail: nlstuttgart@bomag.com
BOMAG Maschinenhandelsgesellschaft m.b.H. BOMAG MARINI EQUIPAMENTOS LTDA BOMAG (CANADA), INC.
Porschestraße 9 Rua Comendador Clemente Cifali, 530 3455 Semenyk Court
1230 Wien Distrito Industrial Ritter Missisauga, Ontario
AUSTRIA Cachoeirinha – RS L5C 4P9
BRAZIL CANADA
ZIP code 94935-225
Tel.: +43 1 69040-0 Tel.: +55 51 2125-6677 Tel.: +1 905 361 9961
Fax: +43 1 69040-20 Fax: +55 51 3470-6220 Fax: +1 905 361 9962
e-mail: austria@bomag.com e-mail: brasil@bomag.com e-mail: canada@bomag.com
BOMAG (China) Construction BOMAG France S.A.S. BOMAG (GREAT BRITAIN), LTD
Machinery Co. , Ltd 2, avenue du Général de Gaulle Sheldon Way, Larkfield
No. 2808, West Huancheng Road, 91170 VIRY-CHATILLON Aylesford
Shanghai Comprehensive Industrial FRANCE Kent ME20 6SE
Zone Fengxian Shanghai 201401 GREAT BRITAIN
CHINA
Tel.: +86 21 3365 5566 Tel.: +33 1 69578600 Tel.: +44 1622 716611
Fax: +86 21 3365 5508 Fax: +33 1 69962660 Fax: +44 1622 710233
e-mail: china@bomag.com e-mail: france@bomag.com e-mail: gb@bomag.com
BOMA Equipment Hong Kong LTD BOMAG Italia Srl. FAYAT BOMAG Polska Sp. z.o.o.
Room 1003, 10/F Charm Centre Via Roma 50 Ul. Szyszkowa 52
700, Castle Peak Road 48011 Alfonsine 02-285 Warzawa
Kowloon, ITALY POLAND
HONG KONG
Tel.: +852 2721 6363 Tel.: +39 0544 864235 Tel.: +48 22 4820400
Fax: +852 2721 3212 Fax: +39 0544 864367 Fax: +48 22 4820401
e-mail: bomahk@bomag.com e-mail: italy@bomag.com e-mail: poland@bomag.com
FAYAT BOMAG Rus OOO BOMAG GmbH, Singapore BOMAG Americas, Inc.
Klyazma block, h 1-g 300, Beach Road 125 Blue Granite Parkway
141400 Khimki, Moscow region The Concourse, ‚ 18-06 Ridgeway SC 29130
RUSSIA Singapore 199555 U.S.A.
SINGAPORE
Tel.: +7 (495) 2879290 Tel.: +65 294 1277 Tel.: +1 803 3370700
Fax: +7 (495) 2879291 Fax: +65 294 1377 Fax: +1 803 3370800
e-mail: russia@bomag.com e-mail: singapore@bomag.com e-mail: usa@bomag.com

ST BW219DH-5 101586341001-UP 00840097EN.f16

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Service Training

BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 /

Single drum roller

008 400 97 EN © 06/2016

BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 / BW 226 PDH-5 3

4.9 Telemecanique switch.............................................................................................................. 117

4 BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 / BW 226 PDH-5

6.5 Travel circuit.............................................................................................................................. 219

BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 / BW 226 PDH-5 5

10 Drive axle........................................................................................................................................... 319

6 BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 / BW 226 PDH-5

12.5.3 Trouble shooting axial piston motors..................................................................................... 545

BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 / BW 226 PDH-5 7

8 BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 / BW 226 PDH-5

BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 / BW 226 PDH-5 9

Genuine BOMAG spare parts

Copyright Information and illustrations in this manual must not be reproduced

10 BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 / BW 226 PDH-5

1.2 Concerning your safety

1.2.1.2 Explanation of warning signs:

BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 / BW 226 PDH-5 11

Sections marked accordingly indicate technical infor-

1.2.1.3 Personal protective equipment

Safety shoes To protect against heavy falling parts and slipping on

Protective gloves To protect the hands against excoriation, punctures or

12 BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 / BW 226 PDH-5

Hearing protection To protect the hearing against too loud noise.

1.2.1.4 Intended use

1.2.1.5 Improper use

BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 / BW 226 PDH-5 13

starting and operation of the machine in explosive environments

1.2.2 Definition of responsible persons

1.2.2.2 Expert / qualified person

1.2.2.3 Driver / operator

14 BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 / BW 226 PDH-5

The driver or operator must:

1.2.3 Fundamentals for safe operation

1.2.3.2 Regular safety inspections

1.2.3.3 Modifications and alterations to the machine

BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 / BW 226 PDH-5 15

The installation and/or use of such products may have an adverse

1.2.3.4 Damage, defects, misuse of safety devices

1.2.3.5 Roll Over Protective Structure (ROPS)

On machines with cab the ROPS is an integral part of

The frame of the machine must not be warped, bent or cracked in

1.2.4 Handling fuels and lubricants

16 BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 / BW 226 PDH-5

n Limitation and monitoring of exposure / personal protective

BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 / BW 226 PDH-5 17

AdBlue®/DEF has not been classified as environmen-

18 BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 / BW 226 PDH-5

Fig. 4 Should pressure fluid penetrate the skin, immediate

BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 / BW 226 PDH-5 19

20 BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 / BW 226 PDH-5

1.2.5 What to do in events of emergency

BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 / BW 226 PDH-5 21

In case of frequent use the wear on the multi-discs brakes will be

1.2.5.2 Disconnect the battery

1.2.5.3 Towing the machine

1.2.6 Park the machine in secured condition.

22 BW 219 DH-5 / BW 219 PDH-5 / BW 226 DH-5 / BW 226 PDH-5

3. Turn the ignition key to position “0” and pull it out.

5. Turn the main battery switch counter-clockwise and pull it

1.2.7 Maintenance and repair