Service Manual BW 219 - D5

Service Manual
BW 219 D-5 / BW 219 PD-5
S/N 101 587 32 1001> / S/N 101 586 31 1001> / S/N 101 586 35 1001> /
S/N 101 586 95 1001> / S/N 101 586 96 1001>
Single drum roller
008 401 20 EN © 02/2020

2
Table of contents
Table of contents
1 General information.............................................................................................................................. 9
1.1 Introduction................................................................................................................................. 10
1.2 Concerning your safety.............................................................................................................. 12
1.2.1 Basic prerequisites..................................................................................................................... 12
1.2.2 Definition of responsible persons............................................................................................... 15
1.2.3 Fundamentals for safe operation............................................................................................... 16
1.2.4 Handling fuels and lubricants..................................................................................................... 18
1.2.5 Load/transport the machine....................................................................................................... 23
1.2.6 Starting up the machine............................................................................................................. 24
1.2.7 Driving the machine; working operation..................................................................................... 25
1.2.8 Refuelling................................................................................................................................... 27
1.2.9 Topping up AdBlue®/DEF........................................................................................................... 28
1.2.10 Emergency procedures............................................................................................................ 28
1.2.11 Maintenance work.................................................................................................................... 29
1.2.12 Repair....................................................................................................................................... 32
1.2.13 Signage.................................................................................................................................... 32
1.2.14 Danger zones........................................................................................................................... 42
1.2.15 Safety components.................................................................................................................. 43
1.3 Maintenance and repair.............................................................................................................. 45
1.3.1 Notes on repair........................................................................................................................... 45
1.3.2 Preliminary remarks and safety notes........................................................................................ 61
1.3.3 Preparations / concluding work.................................................................................................. 62
1.3.4 Parking the machine in secured condition................................................................................. 64
2 Technical data...................................................................................................................................... 67
2.1 Technical data, BW 219 D-5........................................................................................................ 68
2.1.1 Technical data............................................................................................................................ 68
2.2 Technical data, BW 219 PD-5..................................................................................................... 72
2.2.1 Technical data............................................................................................................................ 72
2.3 Additional technical data............................................................................................................ 76
2.4 Terms and basis of calculation.................................................................................................. 80
2.5 Fuels and lubricants................................................................................................................... 81
2.5.1 Engine oil................................................................................................................................... 81
2.5.2 Fuel............................................................................................................................................ 82
2.5.3 AdBlue®/DEF.............................................................................................................................. 83
2.5.4 Coolant....................................................................................................................................... 85
2.5.5 Hydraulic oil................................................................................................................................ 88
2.5.6 Gear oil SAE 75W-90................................................................................................................. 88
2.5.7 Gear oil SAE 80W-140............................................................................................................... 88
2.6 List of fuels and lubricants........................................................................................................ 90
3 Overview of machine.......................................................................................................................... 93
3.1 General information.................................................................................................................... 94
3.1.1 BCM 05...................................................................................................................................... 99
3.1.2 BCM start................................................................................................................................. 101
3.1.3 BCM net................................................................................................................................... 102
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Table of contents
3.1.4 Economizer.............................................................................................................................. 103

3.1.5 Terrameter................................................................................................................................ 104
3.1.6 BOMAG Telematic.................................................................................................................... 106
3.2 Electric systems........................................................................................................................ 108
3.3 Hydraulic system....................................................................................................................... 110
3.4 Machine assemblies.................................................................................................................. 111
3.4.1 Diesel engine............................................................................................................................ 111
3.4.2 Drum......................................................................................................................................... 112
3.4.3 Air conditioning......................................................................................................................... 113
3.4.4 Auxiliary heating, AIRTRONIC................................................................................................. 114
4 Electric systems................................................................................................................................ 115
4.1 Basic principles......................................................................................................................... 116
4.1.1 Measuring technology.............................................................................................................. 117
4.1.2 Understanding circuit diagrams................................................................................................ 122
4.1.3 Telemecanique switch.............................................................................................................. 134
4.1.4 Deutsch connectors, DT and DTM series................................................................................ 136
4.2 Overview of electric system..................................................................................................... 141
4.2.1 Central electrics....................................................................................................................... 143
4.2.2 Operator’s stand...................................................................................................................... 145
4.2.3 Wiring....................................................................................................................................... 146
4.2.4 CAN BUS overview.................................................................................................................. 166
4.2.5 List of equipment...................................................................................................................... 169
4.3 Starting the engine with jump leads........................................................................................ 180
4.4 Fuse assignment....................................................................................................................... 181
4.4.1 Notes on safety........................................................................................................................ 181
4.4.2 Central electrics....................................................................................................................... 181
4.4.3 Main fuses................................................................................................................................ 182
4.4.4 Exhaust gas aftertreatment system.......................................................................................... 183
4.4.5 Control console cabin............................................................................................................... 183
4.4.6 Auxiliary heating....................................................................................................................... 184
4.5 Central electrics........................................................................................................................ 185
4.5.1 Power board............................................................................................................................. 188
4.6 Description of electrical components..................................................................................... 194
4.6.1 CPU control units and electrical modules................................................................................ 194
4.6.2 Power board for SCR-heating.................................................................................................. 199
4.6.3 Control console cabin............................................................................................................... 200
4.6.4 Sensors and actuators............................................................................................................. 202
4.7 Training of electric system....................................................................................................... 207
4.7.1 Electrics training machine control............................................................................................ 207
4.8 Inspection and maintenance work.......................................................................................... 333
4.8.1 Maintenance Table................................................................................................................... 333
4.8.2 Every 500 operating hours....................................................................................................... 333
4.8.3 As required............................................................................................................................... 334
5 Hydraulic system.............................................................................................................................. 337
5.1 Basic principles......................................................................................................................... 338
5.1.1 Open and closed hydraulic circuit............................................................................................ 339
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5.1.2 Swash plate principle, pump.................................................................................................... 341

5.1.3 Swash plate principle, motor.................................................................................................... 342
5.1.4 External gear pumps................................................................................................................ 344
5.2 Overview of hydraulics............................................................................................................. 347
5.3 Description of hydraulic components..................................................................................... 350
5.3.1 Travel / vibration pump, H1...................................................................................................... 350
5.3.2 Travel motor, H1....................................................................................................................... 354
5.3.3 Vibration motor A2FM.............................................................................................................. 356
5.3.4 Steering valve.......................................................................................................................... 358
5.4 Description of hydraulic circuits............................................................................................. 360
5.4.1 Charge circuit........................................................................................................................... 361
5.4.2 Travel circuit............................................................................................................................. 363
5.4.3 Vibration circuit......................................................................................................................... 368
5.4.4 Steering circuit......................................................................................................................... 375
5.5 Flushing and bleeding.............................................................................................................. 378
5.5.1 Flushing in general................................................................................................................... 378
5.5.2 Flushing the travel circuit......................................................................................................... 381
5.5.3 Flushing the vibration circuit..................................................................................................... 390
5.5.4 Bleeding................................................................................................................................... 395
5.6 Inspection and maintenance work.......................................................................................... 399
5.6.2 Checks prior to start up............................................................................................................ 399
5.6.4 Every 1000 operating hours..................................................................................................... 400
6 Machine assemblies......................................................................................................................... 405
6.1 Diesel engine............................................................................................................................. 407
6.1.1 Overviews................................................................................................................................ 408
6.1.2 Lubrication oil circuit TCD 4.1 / 6.1.......................................................................................... 416
6.1.3 Coolant circuit TCD 4.1 / 6.1.................................................................................................... 418
6.1.4 Common Rail System (CRS)................................................................................................... 419
6.1.5 Wastegate charge pressure controller..................................................................................... 426
6.1.6 Exhaust gas recirculation......................................................................................................... 428
6.1.7 EAT – Exhaust Aftertreatment System..................................................................................... 429
6.1.8 Engine electrics........................................................................................................................ 442
6.1.9 Inspection and maintenance work............................................................................................ 463
6.2 Drum........................................................................................................................................... 499
6.2.1 Repair overview for drum......................................................................................................... 500
6.2.2 Dismantling the drum............................................................................................................... 503
6.2.3 Dismantling and assembling the change-over weight.............................................................. 517
6.2.4 Assembling the drum............................................................................................................... 521
6.2.5 Changing the rubber buffers, adjusting the pretension............................................................ 543
6.2.6 Smooth drum scraper; installation and removal....................................................................... 548
6.2.7 Pad foot scraper; installation and removal............................................................................... 552
6.3 Padfoot shell.............................................................................................................................. 562
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6.3.1 Attaching the padfoot shells..................................................................................................... 562

6.3.2 Removing the padfoot shells.................................................................................................... 574
6.4 Oscillating articulated joint...................................................................................................... 582
6.4.1 Overview.................................................................................................................................. 582
6.4.2 Dismantling the oscillating articulated joint.............................................................................. 583
6.4.3 Assembly of oscillating articulated joint.................................................................................... 584
6.5 Drive axle................................................................................................................................... 588
6.5.2 Checks prior to start up............................................................................................................ 588
6.5.5 As required............................................................................................................................... 595
6.6 Air conditioning......................................................................................................................... 597
6.6.1 Overview of air conditioning system......................................................................................... 597
6.6.2 Physical principles.................................................................................................................... 600
6.6.3 Refrigerant R134a.................................................................................................................... 602
6.6.4 Compressor oil / refrigeration oil.............................................................................................. 604
6.6.5 Working principle of the air conditioning system...................................................................... 606
6.6.6 Monitoring devices................................................................................................................... 607
6.6.7 Description of components....................................................................................................... 608
6.6.8 Compressor.............................................................................................................................. 613
6.6.9 Emptying in case of repair........................................................................................................ 615
6.6.10 Drying and evacuation........................................................................................................... 616
6.6.11 Filling instructions................................................................................................................... 616
6.6.12 Steam table for R134a........................................................................................................... 619
6.6.13 Inspection and maintenance work.......................................................................................... 623
6.7 Auxiliary heating, AIRTRONIC................................................................................................. 631
6.7.1 Description of function.............................................................................................................. 632
6.7.2 Fuse assignment...................................................................................................................... 635
6.7.3 Control panel............................................................................................................................ 635
6.8 Cabin assembly......................................................................................................................... 640
6.8.1 Safety....................................................................................................................................... 640
6.8.2 Preparations............................................................................................................................. 641
6.8.3 Cabin assembly........................................................................................................................ 642
6.8.4 Final function tests and checks................................................................................................ 647
6.9 ROPS/FOPS assembly.............................................................................................................. 649
6.9.1 Safety....................................................................................................................................... 649
6.9.2 Preparations............................................................................................................................. 650
6.9.3 ROPS/FOPS assembly............................................................................................................ 651
6.9.4 Final work................................................................................................................................. 655
7 Troubleshooting................................................................................................................................ 657
7.1 Preliminary remarks.................................................................................................................. 659
7.2 Emergency procedures............................................................................................................ 660
7.2.1 Actuating the emergency stop switch....................................................................................... 660
7.2.2 Machine stops in case of faults................................................................................................ 661
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Table of contents
7.2.3 Disconnecting the battery......................................................................................................... 662

7.2.4 Emergency exit........................................................................................................................ 662
7.2.5 Towing the machine................................................................................................................. 662
7.2.6 After towing.............................................................................................................................. 667
7.3 Troubleshooting, electrical systems....................................................................................... 671
7.3.1 Preliminary remarks................................................................................................................. 671
7.3.2 Starting the engine with jump leads......................................................................................... 674
7.3.3 Servicing the battery, checking the main battery isolation....................................................... 675
7.3.4 Fuse assignment...................................................................................................................... 676
7.3.5 ESX, checking the electric power supply................................................................................. 680
7.3.6 Diagnostics concept................................................................................................................. 688
7.3.7 Fault code display.................................................................................................................... 691
7.4 Trouble shooting, diesel engine.............................................................................................. 692
7.4.1 Starting the engine with jump leads......................................................................................... 692
7.4.2 Engine malfunctions................................................................................................................. 692
7.4.3 SCR system warning strategy.................................................................................................. 696
7.4.4 Deutz DTC fault code list, EMR4............................................................................................. 699
7.5 Trouble shooting, hydraulics................................................................................................... 745
7.5.1 Preliminary remarks................................................................................................................. 745
7.5.2 Insufficient hydraulic power...................................................................................................... 746
7.5.3 Troubleshooting axial piston pumps......................................................................................... 749
7.5.4 Troubleshooting axial piston motors........................................................................................ 751
7.5.5 Troubleshooting table for hydraulic components..................................................................... 753
7.6 Troubleshooting the air conditioning system........................................................................ 761
7.6.1 Basic principles........................................................................................................................ 761
7.6.2 Troubleshooting....................................................................................................................... 768
7.6.3 Leak test................................................................................................................................... 781
7.6.4 Checking the magnetic clutch ................................................................................................. 782
7.7 Troubleshooting the auxiliary heating.................................................................................... 783
7.7.1 Fuse assignment...................................................................................................................... 783
7.7.2 Components............................................................................................................................. 784
7.7.3 Control and safety elements.................................................................................................... 785
7.7.4 Troubleshooting....................................................................................................................... 785
7.7.5 Diagnostics of control panel, old version.................................................................................. 786
7.7.6 Diagnostics of control panel, new version................................................................................ 794
7.7.7 Check the fuel supply............................................................................................................... 797
7.7.8 Circuit diagram, AIRTRONIC D2/D4........................................................................................ 799
8 Special tools...................................................................................................................................... 803
8.1 Special tools, electrics............................................................................................................. 804
8.2 Special tools for hydraulic system.......................................................................................... 805
8.2.1 Special tools, tests and adjustments........................................................................................ 805
8.2.2 Special tools for flushing.......................................................................................................... 807
8.3 Special tools for oscillating articulated joint.......................................................................... 808
8.4 Special tools, drum................................................................................................................... 810
8.5 List of special tools................................................................................................................... 812
9 Index................................................................................................................................................... 813
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Table of contents
Appendix............................................................................................................................................ 831
A Circuit diagrams............................................................................................ 833
A.1 Circuit diagram 518.................................................................................... 833
A.2 Circuit diagram 642.................................................................................... 932
A.3 Hydraulic diagram 477............................................................................. 1040
A.4 Hydraulic diagram 614............................................................................. 1050
8 BW 219 D-5 / BW 219 PD-5

General information
1 General information
BW 219 D-5 / BW 219 PD-5 9

General information – Introduction
1.1 Introduction............................................................... 10
1.2 Concerning your safety............................................ 12
1.2.1 Basic prerequisites.................................................. 12
1.2.2 Definition of responsible persons............................. 15
1.2.3 Fundamentals for safe operation............................. 16
1.2.4 Handling fuels and lubricants................................... 18
1.2.5 Load/transport the machine..................................... 23
1.2.6 Starting up the machine........................................... 24
1.2.7 Driving the machine; working operation................... 25
1.2.8 Refuelling................................................................. 27
1.2.9 Topping up AdBlue®/DEF......................................... 28
1.2.10 Emergency procedures.......................................... 28
1.2.11 Maintenance work.................................................. 29
1.2.12 Repair.................................................................... 32
1.2.13 Signage.................................................................. 32
1.2.14 Danger zones........................................................ 42
1.2.15 Safety components................................................ 43
1.3 Maintenance and repair............................................ 45
1.3.1 Notes on repair........................................................ 45
1.3.2 Preliminary remarks and safety notes..................... 61
1.3.3 Preparations / concluding work................................ 62
1.3.4 Parking the machine in secured condition............... 64
1.1 Introduction
General This manual:
n addresses the BOMAG Customer Service and professionally
trained personnel.
n provides support for repair work or maintenance procedures on
the machine.
This manual described the deinstallation, dismantling , assembly,
installation as well as the repair of components and assembly
groups as far as this makes sense with respect to tools and spare
parts supply.
Index The index is a reference register that will help you to find informa-
tion in this Service Manual. The index lists keywords in alphabet-
ical order. Cross references (keywords related to page numbers)
enable quick and convenient search/navigation.
Keywords concerning the following subjects are listed in the index:
n Electrical operating means
n Plug designations
n Overviews
n Fault codes
n Troubleshooting
n ...
10 BW 219 D-5 / BW 219 PD-5

General information – Introduction
Documentation For the BOMAG machines described in this manual the following
documentation is additionally available:
n Operating and maintenance instructions
n Spare parts catalogue
n Service information (if necessary)
Maintenance/parts service n Specialist teams are available for you in Germany, Europe and
overseas. This tight network ensures close customer contact
all over the world.
n Parts for maintenance, service and repair are available from
our branch offices and dealers at very short notice.
n BOMAG guarantees long-term availability of all common parts.
n Well-designed catalogues provide an easy guide to finding and
ordering the required parts.
n Only use genuine BOMAG parts. These have been specially
adapted to the corresponding machine. In this way, you will
prevent any problems arising and unnecessary downtimes of
your machine.
Updating service This manual is not subject of an updating service. For this reason
we would like to draw your attention to the additionally published
service informations.
In case of a new release all necessary changes will be included.
In the course of technical development we reserve the right for
technical modifications without prior notification.
Copyright Information and illustrations in this manual must not be reproduced

and distributed, nor must they be used for the purpose of competi-
tion without the consent of BOMAG. All rights according to the
copyright law remain expressly reserved.
BW 219 D-5 / BW 219 PD-5 11

General information – Concerning your safety
1.2 Concerning your safety

1.2.1 Basic prerequisites
1.2.1.1 General
This machine has been built in compliance with the latest technical
standard and complies with the applicable regulations and tech-
nical rules.
However, dangers for persons and property may arise from this
machine, if:
n it is used for purposes other than the ones it is intended for,
n it is operated by untrained personnel,
n it is changed or converted in an unprofessional way,
n the safety instructions are not observed.
Each person involved in the operation, maintenance and repair of
the machine must therefore read and comply with these safety reg-
ulations. If necessary, the operating company must obtain the rele-
vant signatures as confirmation.
Furthermore, the following obviously also applies:
n applicable accident prevention instructions,
n generally accepted safety and road traffic regulations,
n country/state specific safety regulations.
It is the duty of the operator to be acquainted with the safety regu-
lations and to apply these accordingly. This also applies for local
regulations and regulations concerning different types of handling
activities. Should the recommendations in these instructions be dif-
ferent from the regulations valid in your country, you must comply
with the safety regulations valid in your country.
1.2.1.2 Explanation of signal words used:
DANGER!
Danger to life if failing to comply!
Sections marked accordingly indicate an extremely
dangerous situation that could lead to fatal or
severe injuries, if this warning is disregarded.
WARNING!
Danger to life or danger of severe injuries if
failing to comply!
Sections marked accordingly indicate a dangerous
situation that could lead to fatal or severe injuries,
if this warning is disregarded.
12 BW 219 D-5 / BW 219 PD-5

CAUTION!
Danger of injury if failing to comply!
Sections marked accordingly indicate a dangerous
situation that could lead to fatal or severe injuries,
if this warning is disregarded.
NOTICE!
Danger of material damage if failing to comply!
Sections marked accordingly indicate possible
dangers for machines or components.
Sections marked accordingly indicate technical

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

Depending on the work to be carried out, personal protective equipment is required (to be provided
by the operating company):
Working clothes Tight fitting working clothes with low tear resistance, tight
sleeves and without any projecting parts protect against
being caught by moving components.
Safety shoes 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.
BW 219 D-5 / BW 219 PD-5 13

Safety goggles To protect the eyes against airborne particles and

squirting fluids.
Face protection To protect the face against airborne particles and

squirting fluids.
Hard hat To protect the head against falling parts and to protect
against injuries.
Hearing protection To protect hearing against excessive noise.
Respiratory protection To protect respiratory tracts against substances or parti-

cles.
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 with the machine if it is used other than for its
intended purpose.
Any danger caused by improper use is the sole responsibility of the
operating company or driver/operator; the manufacturer cannot be
held liable.
14 BW 219 D-5 / BW 219 PD-5

Examples of improper use are:

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

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

1.2.2.1 Operating company
The operating company is the natural or juridical person who uses
the machine or in who's name the machine is used.
The operating company must make sure that the machine is only
used for the purpose it is intended for and in strict compliance with
the safety regulations mentioned in these operating and mainte-
nance instructions.
The operating company must determine and assess the danger in
its company. It must then take appropriate action to ensure health
and safety at work for its employees and point out any remaining
dangers.
The operating company must determine whether there are special
operational hazards such as a toxic atmosphere or limiting soil
conditions. Such conditions require special, additional measures to
remove or reduce the hazard.
The operating company must make sure that all users read and
understand the information concerning safety.
The operating company is responsible for the planning and profes-
sional execution of regular safety inspections.
BW 219 D-5 / BW 219 PD-5 15

1.2.2.2 Expert / qualified person

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

This machine must only be operated by trained, instructed persons
entrusted by the operating company aged 18 or more.
Observe your local laws and regulations.
Rights, obligations and rules of conduct for driver or operator:
The driver or operator must:
n be instructed about his rights and obligations,
n wear protective equipment as appropriate for the application,
n have read and understood the operating instructions,
n have made himself familiar with the operation of the machine,
n be physically and psychologically able to drive and operate the
machine.
Persons under the influence of alcohol, medication or drugs are not
allowed to operate, service or repair the machine.
Maintenance and repair work requires specific knowledge and
must therefore only be performed by trained specialists.
1.2.3 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.
16 BW 219 D-5 / BW 219 PD-5

All persons remaining in the area of the machine must be informed

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

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

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

Machines which are not safe to operate or in traffic must be imme-
diately taken out of service and shall not be used, until these defi-
ciencies have been properly rectified.
Safety installations and switches must neither be removed nor
must they be made ineffective.
1.2.3.5 Roll Over 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.
BW 219 D-5 / BW 219 PD-5 17

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
18 BW 219 D-5 / BW 219 PD-5

1.2.4.2 Safety regulations and environmental protection regulations for handling diesel fuel
WARNING!
Danger of burning by ignited diesel fuel!
– Do not allow diesel fuel to come into contact
with hot components.
– Smoking and open fire is prohibited!
– Wear your personal protective equipment (pro-
tective gloves, protective clothing).
Fig. 1 CAUTION!
Health hazard caused by contact with diesel
fuel!
– Do not inhale any fuel fumes.
– Avoid contact.
CAUTION!
Danger of slipping on spilled diesel fuel!
– Immediately bind spilled diesel fuel with an oil-
binding agent.
ENVIRONMENT!
Diesel fuel is an environmentally hazardous
substance!
– Always keep diesel fuel in proper containers.
– Immediately bind spilled diesel fuel with an oil-
binding agent and dispose of properly.
– 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!
– Do not inhale ammonia vapours.
– Avoid contact and consumption.
AdBlue®/DEF has not been classified as environ-

Fig. 2 mentally harmful.
BW 219 D-5 / BW 219 PD-5 19

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
components.
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 regula-
tions.
20 BW 219 D-5 / BW 219 PD-5

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.
tective gloves, protective clothing, goggles).
Should pressure fluid penetrate the skin, imme-

Fig. 4 diate 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 regula-
tions.
BW 219 D-5 / BW 219 PD-5 21

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.
22 BW 219 D-5 / BW 219 PD-5

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 clean water.
Immediately call for medical advice in case of cau-
terization.
WARNING!
Danger of injury caused by exploding gas mix-
ture!
– Remove the plugs before starting to recharge
the battery.
– Ensure adequate ventilation.
– Do not lay any tools or other metal objects on
the battery.
– Do not wear jewellery (watch, bracelets, etc.)
when working on the battery.
ENVIRONMENT!
Battery acid is an environmentally hazardous
substance!
– Dispose of battery and battery acid according
to regulations.
1.2.5 Load/transport the machine

Use only stable loading ramps of sufficient load bearing capacity.
Loading ramps and transport vehicle must be free of grease, oil,
snow and ice.
The ramp inclination must be less than the gradability of the
machine.
Make sure that persons are not endangered by the machine tipping
or sliding off. The instructing person must stand within the view of
the operator, but outside the danger area.
BW 219 D-5 / BW 219 PD-5 23

Secure the machine with the articulation lock after driving it on the
transport vehicle or before loading it with a crane.
Do not use damaged or in any other way impaired lashing points.
Always use appropriate lifting and lashing means on the lifting and
lashing points.
Use lifting and lashing gear only in the prescribed direction of load
application.
Lifting tackle must not be damaged by machine components.
Secure the machine on the transport vehicle against rolling, slip-
ping and turning over.
Loads must only be attached and hoisted by an expert / capable
person.
Use only lifting gear and lifting tackle with sufficient load bearing
capacity for the weight to be loaded.
Fasten the lifting gear only at the specified lifting points.
Danger to the life of persons if they step or stand under a sus-
pended load.
When lifting the machine avoid uncontrolled movements of the
load. If necessary hold the load with guide ropes.
After the transport loosen the articulation lock again, as otherwise
the machine wouild not be steerable.
1.2.6 Starting up the machine

1.2.6.1 Prior to start-up
Only use machines which have been serviced at regular intervals.
Become acquainted with the equipment, the indicators and control
elements, the working principle of the machine and the working
area.
Use your personal protective equipment (hard hat, safety boots, if
necessary also goggles and ear protection).
Make sure that the machine is equipped with the required lighting
according to the requirements of the application.
Do not take any loose objects with you or fasten them to the
machine.
Before mounting the machine check whether:
n persons or obstructions are beside or under the machine,
n the machine is free of oily and combustible materials,
n all access steps, grips and platforms are free of obstacles,
grease, oils, fuel, dirt, snow and ice,
n all safety elements are in place,
n all maintenance flaps and doors are closed and locked.
Climb onto or off the machine only when the machine is standing.
Use the existing access steps and grips.
24 BW 219 D-5 / BW 219 PD-5

When climbing on and off the machine use the three-point support
method: Always keep two feet and one hand or one foot and two
hands on the machine.
Never jump off the machine.
Before start-up, carry out all required visual inspections and func-
tion tests.
If the tests reveal damages or other defects, the machine must not
be operated, until these deficiencies have been corrected.
Do not operate the machine with defective indicators and control
elements.
1.2.6.2 Starting the engine

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

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

1.2.7.1 Driving the machine
Always wear the seat belt when driving.
Only drive on load-bearing surfaces.
Do not drive on ice and snow.
BW 219 D-5 / BW 219 PD-5 25

If the machine has touched high-voltage power lines:

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

Do not drive on gradients or slopes exceeding the maximum gra-
deability of the machine Ä Chapter 2 ‘Technical data’ on page 67.
Drive extremely carefully on gradients and always directly up or
down the slope.
Soil conditions and weather influences impair the gradeability of
the machine.
Wet and loose soil considerably reduces traction of the machine on
inclinations and slopes. Increased danger of accident!
26 BW 219 D-5 / BW 219 PD-5

1.2.7.3 Cross-slope
The tipping angle was measured statically on level, hard ground
with the machine stopped and without steering.
The max. permissible inclination of the machine may be limited by
the max. permissible slanted position of the engine.
The specified angle must not be exceeded.
With loose soil, acceleration/deceleration, running vibration,
steering or attached accessories the tipping angle may be consid-
erably lower.
Driving across slopes should therefore be strictly avoided, because
of the high risk of tipping over and the related risk of severe or
Fig. 7: Maximum cross-slope even fatal accidents.
1.2.7.4 Working with vibration

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

Park the machine on horizontal, level, firm ground.
Before leaving the machine:
n shift all control levers to “Neutral position”, “Off” or “0”,
n apply the parking brake,
n shut down the engine, pull off the ignition key,
n pull off the main battery switch,
n secure the machine against unauthorized use.
Do not jump off the machine, but use hand grips and access steps.
Mark machines, which could be in the way, with a clearly visible
sign.
When parking on ascents or descents use appropriate means to
secure the machine against rolling.
1.2.8 Refuelling
Do not inhale any fuel fumes.
Refuel only with the engine shut down.
Do not refuel in closed rooms.
No open fire, do not smoke.
BW 219 D-5 / BW 219 PD-5 27

Static charges may be generated in the fuel as it passes through

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

If AdBlue®/DEF heats up to a temperature in excess of 50 °C
(122 °F) over a longer period of time, e.g. caused by direct insola-
tion, AdBlue®/DEF may disintegrate. This results in ammonia
vapours.
If you open the AdBlue®/DEF tank lid at high temperatures,
ammonia vapours may escape.
Ammonia vapours have a pungent smell and irritate, above all,
skin, mucous membranes and eyes. This can cause burning sen-
sations in eyes, nose and throat and also cause coughing and
watering eyes.
Do not inhale escaping ammonia vapours.
1.2.10 Emergency procedures

1.2.10.1 Actuating the emergency stop switch
In events of emergency and in case of danger actuate the emer-
gency stop switch immediately.
The machine is braked immediately, the engine is shut down.
Restart the machine only after the danger that caused the actua-
tion of the emergency stop switch has been eliminated.
In case of frequent use the wear on the multi-discs brakes will be
very high, you should therefore never use the emergency stop
switch as a service brake.
28 BW 219 D-5 / BW 219 PD-5

1.2.10.2 Disconnecting the battery

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

Tow the machine only in a case of emergency or to avoid an acci-
dent.
Before releasing the parking brake apply suitable measures to
secure the machine against unintended rolling.
Use a tractor vehicle with sufficient traction and braking power for
the unbraked towed load.
If no tow bar is used, towing is only permitted uphill.
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.
1.2.11 Maintenance work

1.2.11.1 Preliminary remarks
Always carry out the prescribed maintenance work and mainte-
nance measures on time in order to maintain the safety, opera-
tional readiness and long service life of the machine.
The machine must only be serviced by qualified personnel author-
ised by the operating company.
1.2.11.2 Working 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 assistance if
injured by hydraulic oil.
Do not step in front of or behind the machine when performing
adjustment work in the hydraulic system.
Do not change the setting of pressure relief valves.
Drain the hydraulic oil at operating temperature – danger of
scalding!
Any hydraulic oil must be collected and disposed of in an environ-
mentally friendly way.
Always collect and dispose of hydraulic oils separately.
BW 219 D-5 / BW 219 PD-5 29

Do not start the engine after draining off the hydraulic oil. Once all
work is completed (with the system still depressurized!) check all
connections and fittings for leaks.
Hydraulic hoses must be visually inspected at regular intervals.
Do not mix up hoses by mistake.
Only genuine replacement hydraulic hoses ensure that the correct
hose type (pressure range) is used at the right location.
1.2.11.3 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 approx. another 15
minutes.
Keep out of the danger zone during the initial test run.
In case of leaks return to the workshop immediately.
Drain the engine oil at operating temperature – danger of scalding!
Wipe off spilled oil, collect leaking oil and dispose of it in an envi-
ronmentally friendly way.
Store used filters and other oil contaminated materials in a sepa-
rate, specially marked container and dispose of them in an environ-
mentally friendly way.
The settings for idle speed and highest speed must not be
changed, since this would affect the exhaust gas values and cause
damage to engine and power train.
Engine and exhaust system work at high temperatures. Keep com-
bustible materials away and do not touch any hot surfaces.
Check and change coolant only when the engine is cold. Collect
coolant and dispose of it in an environmentally friendly way.
1.2.11.4 Exhaust gas aftertreatment system, regeneration at standstill

During regeneration at standstill the exhaust gas reaches very high
temperatures and the exhaust gas quantity increases - fire hazard!
When performing regeneration at standstill park the machine out-
doors at a safe distance from any combustible or explosive mate-
rials.
Components of the exhaust gas aftertreatment system get very
hot.
Do not touch hot components or exhaust gases.
Should there be an endangerment caused by high exhaust gas
temperatures and quantities, the operator needs to suppress the
regeneration at standstill.
30 BW 219 D-5 / BW 219 PD-5

1.2.11.5 Maintenance work on electric components and battery

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

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

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

Do not perform cleaning work while the motor is running.
Allow the engine to cool down before starting cleaning work on
engine and exhaust system.
Never use gasoline or other easily inflammable substances for
cleaning.
BW 219 D-5 / BW 219 PD-5 31

When cleaning with a high pressure cleaner, do not subject elec-

trical parts and insulation material to the direct jet of water, or cover
them beforehand.
Do not guide the water jet into the exhaust pipe and into the air
filter.
1.2.11.9 Measures for longer shut-down periods

If the machine is taken out of operation for a longer period of time,
various conditions must be met and maintenance work must be
carried out both before and after shut-down Ä Chapter 6.1.9.8.3
‘Measures prior to extended shut-down period’ on page 490.
It is not necessary to define a maximum storage period if these
measures have been performed.
1.2.11.10 After maintenance work

Reassemble all guards and protective devices.
Close all maintenance flaps and maintenance doors again.
1.2.12 Repair
Identify a defective machine with a warning sign.
Only operate the machine after it has been repaired.
Repairs must only be performed by an expert/qualified person.
When replacing safety relevant components, only original spare
parts must be used.
1.2.13 Signage
Keep stickers and signage in good and legible condition and
comply with their meaning.
Replace damaged and illegible stickers or signage immediately.
32 BW 219 D-5 / BW 219 PD-5

AdBlue® /DEF
WARNING
California Proposition 65 Warning
This product contains chemicals

that cause cancer + chemicals
that are reproductive toxicants
B-586-0473
Fig. 8
BW 219 D-5 / BW 219 PD-5 33

AdBlue® /DEF
WARNING

B-586-0474
Fig. 9
34 BW 219 D-5 / BW 219 PD-5

B-586-0359
Fig. 10
BW 219 D-5 / BW 219 PD-5 35

B-586-0400
Fig. 11
Warning sticker - Danger of crushing
Fig. 12
Warning sticker - Follow operating instructions
Fig. 13
36 BW 219 D-5 / BW 219 PD-5

Warning sticker – California Proposition 65
WARNING

B-DEC-0316
Fig. 14
Prohibition sticker - High pressure cleaning
Fig. 15
Instruction sticker - Always wear your seat belt
Fig. 16
Information sticker - Emergency exit
Fig. 17
BW 219 D-5 / BW 219 PD-5 37

Information sticker - Lashing point
Fig. 18
Information sticker - Lifting point
Fig. 19
Information sticker - Filler opening for AdBlue®/DEF

AdBlue® /DEF
Fig. 20
Information sticker - Minimum topping up quantity AdBlue®/DEF
Fig. 21
38 BW 219 D-5 / BW 219 PD-5

Information sticker - Engine oil drain
Fig. 22
Information sticker - Coolant drain
Fig. 23
Information sticker - Hydraulic oil drain
Fig. 24
Information sticker - Ultra-low sulphur fuel
Fig. 25
BW 219 D-5 / BW 219 PD-5 39

Information sticker - Filler opening for diesel
Diesel
Fig. 26
Information sticker - Disconnecting the battery
Fig. 27
Information sticker - Main battery switch plus side
Fig. 28
Information sticker - Vehicle voltage 12 V
Fig. 29
40 BW 219 D-5 / BW 219 PD-5

Information sticker - Filler opening for hydraulic oil
Hydraulic Oil
Fig. 30
Information sticker - Guaranteed sound capacity level
Fig. 31
Information sticker - Coolant
B-DEC-0221
Fig. 32
Information sticker - Low ash engine oil
Fig. 33
BW 219 D-5 / BW 219 PD-5 41

Machine type plate (example)
Fig. 34
1.2.14 Danger zones
3m 3m
B-586-0456
Fig. 35
The area around the machine is a danger zone.

Before starting the machine and during operation, the driver / oper-
ator must ensure that nobody is in the danger zone.
Give warning signals, if necessary. Stop work immediately if per-
sons are in the danger zone.
42 BW 219 D-5 / BW 219 PD-5

1.2.15 Safety components
3
2 2
12
11
7
10
8
9
B-586-0472
Fig. 36
1 ROPS/FOPS (optional equipment)
2 Exhaust gas aftertreatment system
3 Engine hood
4 Backup alarm system (optional equipment)
5 Main battery switch
6 Fan protection (optional equipment)
7 Safety belt
8 Control system
BW 219 D-5 / BW 219 PD-5 43

9 Articulation lock
10 Operator detection system
11 Emergency stop switch
12 ROPS cabin (optional equipment)
44 BW 219 D-5 / BW 219 PD-5

General information – Maintenance and repair
1.3 Maintenance and repair

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

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

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

before the plus pole. When installing the battery connect the
minus pole after the plus pole to avoid short circuits.
n Assemble the battery terminal clamps without force.
BW 219 D-5 / BW 219 PD-5 45

n Always keep battery poles and terminal clams clean to avoid

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

without the battery connected is dangerous. When discon-
necting the cables from the poles high inductivities (arcs,
voltage peaks) may occur and destroy the electrical installa-
tion.
n For purposes like e.g. purging the fuel systems, starters may
be operated for maximum 1 minute without interruption. Then
you should wait for at least 30 minutes (cooling down) until
trying again. During the 1 minute starting period this process
should not be interrupted.
n Starter motors must not be cleaned with high pressure steam
cleaning equipment.
n The contacts on starter terminals 30, 45, 50 must be protected
against unintended shorting (jump protection).
n When replacing the starter the ring gear on the engine flywheel
must be checked for damage and its number of teeth - if nec-
essary replace the ring gear.
n Always disconnect the battery before starting assembly work in
the starter area of the engine or on the starter itself.
46 BW 219 D-5 / BW 219 PD-5

1.3.1.1.2 Repair notes for hydraulics

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

immediate surrounding areas must be cleaned before removal.
n Before loosening hoses, pipe lines etc. relieve all pressure
from the system.
n During repair work keep all openings closed with clean plastic
plugs and caps.
n Never run pumps, motors and engine without oil or hydraulic
oil.
n When cleaning hydraulic components take care not to damage
any fine machined surfaces.
n Chemical and rubber dissolving cleansing agents may only be
used to clean metal parts. Do not let such substances come in
contact with rubber parts.
n Rinse of cleaned parts thoroughly, dry them with compressed
air and apply anti-corrosion oil immediately. Do not install parts
that show traces of corrosion.
n Avoid the formation of rust on fine machined parts caused by
hand sweat.
n Use new O-rings or seal rings for reassembly.
n Use only hydraulic oil as sliding agent when reassembling. Do
not use any grease!
n Use only the specified pressure gauges. Risk of damaging the
pressure gauges under too high pressure.
n Check the hydraulic oil level before and after the work.
n Use only clean hydraulic oil in strict compliance with the speci-
fication in the operating and maintenance instructions to fill the
hydraulic system.
n Check the hydraulic system for leaks, if necessary find and rec-
tify the cause.
n Before taking new hydraulic components into operation fill
these with hydraulic oil as specified in the operating and main-
tenance instructions.
n After changing a hydraulic component thoroughly flush, refill
and bleed the complete hydraulic system.
n Perform pressure tests at operating temperature of the
hydraulic oil (approx. 40 °C).
n After the completion of all tests perform a test run and then
check all connections and fittings for leaks with the engine still
stopped and the hydraulic system depressurized.
Before commissioning n Fill the housings of hydraulic pumps and motors with hydraulic
oil. Use only hydraulic oils according to the specification in the
maintenance instructions.
n After changing a component flush the hydraulic system as
described in the flushing instructions.
BW 219 D-5 / BW 219 PD-5 47

Taking into operation n Bleed the hydraulic circuits.

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

Special requirements with respect to cleanliness in the fuel system
do apply for commissioning, maintenance and repair work, particu-
larly for engines with the Common Rail System. Contamination like
dirt, welding residues or similar can lead to the failure of individual
components and adversely affect engine operation.
Spare parts should be left in their original packaging as long as
possible and should only be unpacked just before use.
When parts are unpacked any connections must be closed with
suitable plugs or caps, in order to prevent contamination of hose
connections. If e.g. fuel hoses are connected to one side, while the
second side cannot yet be connected, there is a danger of dirt
entering into the system. The free connection must in this case
also be appropriately closed.
Fig. 37: Example
Notes and measures to be applied n The fuel system must be closed. Visual examination for leaks /
before starting work in the fuel damage in the fuel system.
system n Before starting work in the fuel system clean the complete
engine and the engine compartment with the system still
closed.
n The engine should be dry before work is started in the fuel
system.
n Blow drying with compressed air is only permitted while the fuel
system is still closed.
48 BW 219 D-5 / BW 219 PD-5

n When using steam cleaning equipment cover control unit,

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

during work in the fuel system n Use only lint-free cleaning cloths for work in the fuel system.
any means of extraction. Vacuum cleaning equipment must
generally be used for cleaning when the fuel system is open.
n Do not use any previously used cleaning or testing fluids for
cleaning.
n The use of compressed air for cleaning is prohibited when the
fuel system is open.
n Work on disassembled components must only be carried out at
a specially furnished work place.
n When removing or assembling components you should not use
any materials from which particles or fibres could flake off
(cardboard, wood, towels).
n Dismantled parts must only be wiped off with clean, lint-free
cloths if required. No dirt particles must be wiped into the com-
ponents.
BW 219 D-5 / BW 219 PD-5 49

n Close openings on components and engine immediately with

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

Leaking sealing faces can mostly be traced back to incorrect
assembly of seals and gaskets.
n Before assembling a new seal or gasket make sure that the
sealing surface is free of pitting, flutes, corrosion or other
damage.
n Inappropriately stored or handled seals (e.g. hanging from
hooks or nails) must under no circumstances be used.
n Install seals and gaskets only with sealing compound, grease
or oil, if this is specifically specified in the repair instructions.
n If necessary remove any old sealing compound before assem-
bling. For this purpose do not use any tools that could damage
the sealing surfaces.
50 BW 219 D-5 / BW 219 PD-5

n Sealing compound must be applied thin and evenly on the cor-

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

1. Lubricate sealing lips (2) with clean grease; in case of double
seals fill the space between the sealing lips with a generous
amount of grease.
2. Slide the seal over the shaft, with the lip facing towards the
fluid to be sealed.
NOTICE!
Use an assembly sleeve.
If possible, use an assembly sleeve (1) to
protect the lip from being damaged by
Fig. 38 sharp edges, threads or splines. If no
assembly sleeve is available, you should use
a plastic tube or adhesive tape to prevent the
sealing lip from being damaged.
3. Lubricate the outer rim of the seal (3) and press it flat on the
housing seat.
4. Press or knock the seal into the housing, until it is flush with
the housing surface.
NOTICE!
Use an assembly bell.
If possible, use an "assembly bell" (1 ), to
make sure that the seal will not skew. In
some cases it may be advisable to assemble
the seal into the housing first, before sliding it
over the shaft. Under no circumstances
should the full weight of the shaft rest on the
Fig. 39 seal.
If you have no proper service tools at hand,
use a suitable drift punch with a diameter
which is about 0.4 mm smaller than the outer
diameter of the seal. Use VERY LIGHT
blows with the hammer if no press is avail-
able.
BW 219 D-5 / BW 219 PD-5 51

1.3.1.1.5 Repair notes for ball and roller bearings

n If one bearing of a pair of bearings shows defects, we highly
recommend the replacement of both bearings.
n Remove any lubricant residues from the bearing to be exam-
ined by washing it with a suitable degreasing agent.
n Check balls or rollers, running surfaces, outer faces of outer
races and inner faces of inner races for visible damage. If nec-
essary, replace the bearing.
n Check the bearing for clearance and resistance between the
inner and outer races, replace if necessary.
n Lubricate the bearing with the recommended type of grease
before assembly or reassembly.
n On greased bearings (e.g. wheel bearings) fill the space
between the bearing and the outer seal with the recommended
type of grease before assembling the seal.
n Check shaft and bearing housing for discolouration or other
signs of movement between bearing and seats.
n Make sure that shaft and housing are free of burrs before
Fig. 40 assembling the bearing.
n Always mark the individual parts of separable bearings (e.g.
taper roller bearings) to enable correct reassembling. Never
assemble the rollers to an outer race that has already been
used, replace the complete bearing instead.
NOTICE!
When assembling the ball or roller bearing to the
shaft load must only be applied to the inner race
(1).
When fitting the bearing into the housing load must
only be applied to the outer race (2).
Fig. 41
1.3.1.1.6 Feather keys and keyways

1. Clean the feather key, examine it and only use it again if it
had not been damaged.
2. Deburr and clean the edges of keyways thoroughly before
reassembling the feather key.
Fig. 42
52 BW 219 D-5 / BW 219 PD-5

1.3.1.1.7 Repair notes for cotter pins

Cotter pins
In places where cotter pins are used, these must be reassembled.
Cotter pins must generally be renewed after disassembly.
Cotter pins must be assembled as shown in the illustration, unless
specified differently.
Fig. 43
1.3.1.1.8 Repair notes for screws and nuts
NOTICE!
Tighten screws and nuts in accordance with the
values in the following tables. Tightening torques
deviating from the ones in the table are specially
mentioned in the repair instructions.
Damaged screws must not be used again.
Recutting threads with thread cutters or taps
adversely affects the strength and leak tightness of
the screw joint. Damaged or corroded thread
pitches can cause incorrect torque value readings.
Self-locking nuts must generally be replaced after
disassembly.
The use of screws with too high strength can
cause damage!
n Nuts of a higher strength can generally be used instead of nuts

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

Strength classes, metric screws The strength classes (from 3.6 to 12.9) are specified for all strength
classes from a nominal diameter of 5 mm. The corresponding iden-
tification can be found where the shape of the screw permits it.
BW 219 D-5 / BW 219 PD-5 53

Example: A screw is marked with 12.9.
Fig. 44: Identification of screws
Strength classes of metric nuts Nuts are differentiated by three load groups. Each load group has
a special designation system for the strength class assigned, so
that the load group can be clearly identified.
Nuts (1) for screw connections with full load capacity
In a connection with a screw, these nuts (1) must be able to bear
the full pre-load at the yield point.
Nut height above 0.8 d (d = nominal dimension).
Fig. 45: Identification of nuts

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

The preceding "0" indicates that, due to their low height, nuts 2
Ä Fig. 45 in this group are only able to withstand the force of a
screw to a limited extent.
Nut height below 0,8 d (d = nominal dimension).
Nuts (3) for screw connections without specified load capacity
This standard contains strength classes (hardness classes) for
nuts 3 Ä Fig. 45, for which no load values can be specified, e.g.
because of their shape and dimensions, but which can only be
classified by their hardness.
54 BW 219 D-5 / BW 219 PD-5

Nut height below 0,5 d (d = nominal dimension).
Identification in clock system

For small nuts Ä Fig. 46 the clock system can be used for identifi-
cation.
n The 12 o'clock position is identified by a dot or the manufactur-
er's symbol.
n The strength class is identified by a dash (b).
Fig. 46: Identification of nuts in clock
system
1.3.1.1.10 Identification of UNF-threads

Identification of UNF-threads
Studs (1)
At the outmost end a short end of the component is reduced to its
core diameter.
Nuts (2).
An uninterrupted series of stamped in circles parallel to the axis of
the nut on a hexagon area.
Screws (3)
The screw head is marked with a stamped in, round cavity.
Fig. 47
1.3.1.2 Tightening torques

The values specified in the table apply for screws:
n black oiled
n with surface protection A4C
n with surface protection DACROMET
DACROMET is a surface protection that mainly

consists of zinc and aluminium in a chromium
oxide matrix. DACROMETIZATION provides excel-
lent corrosion protection for metal surfaces by
applying a mineral coating with metallic-silver
appearance.
The difference between Withworth and UNF/UNC
threads is the fact that UNF and UNC threads have
60° flanks, as the metric ISO-thread, whereas
Withworth has a flank of only 55°.
BW 219 D-5 / BW 219 PD-5 55

Tightening torques for screws with metric unified thread

Tightening torques Nm (Coefficient of friction µ tot. = 0.14)
Screw dimension
8.8 10.9 12.9
M4 3 5 5
M5 6 9 10
M6 10 15 18
M8 25 35 45
M10 50 75 83
M12 88 123 147
M14 137 196 235
M16 211 300 358
M18 290 412 490
M20 412 578 696
M22 560 785 942
M24 711 1000 1200
M27 1050 1480 1774
M30 1420 2010 2400
Tightening torques for screws with metric unified fine thread

Screw dimension
8.8 10.9 12.9
M8 x 1 26 37 48
M10 x 1.25 52 76 88
M12 x 1.25 98 137 162
M12 x 1.5 93 127 152
M14 x 1.5 152 216 255
M16 x 1.5 225 318 383
M18 x 1.5 324 466 554
M20 x 1.5 461 628 775
M22 x 1.5 618 863 1058
M24 x 2 780 1098 1294
M27 x 2 1147 1578 1920
M30 x 2 1568 2254 2695
56 BW 219 D-5 / BW 219 PD-5

Tightening torques for screws treated with anti-seizure paste OKS 240 (copper paste)
Tightening torques Nm
Screw dimension
8.8 10.9 12.9
M16 169 240 287
M16 x 1.5 180 255 307
M18 232 330 392
M18 x 1.5 260 373 444
M20 330 463 557
M20 x 1.5 369 502 620
M22 448 628 754
M22 x 1.5 495 691 847
M24 569 800 960
M24 x 2 624 879 1036
M27 840 1184 1520
M27 x 2 918 1263 1536
M30 1136 1608 1920
M30 x 2 1255 1804 2156
4² 276 388 464

3/ - 10 UNC
4² 308 432 520

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

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

Tightening torques Nm (Coefficient of friction µ
Thread diameter tot. = 0.14)
10.9
M12 x 1.5 100
M14 x 1.5 150
M18 x 1.5 300 - 350
M20 x 1.5 400 - 500
M22 x 1.5 500 - 600
BW 219 D-5 / BW 219 PD-5 57

Tightening torques for screws with UNC thread, UNC Unified Coarse Thread Series, American Unified
Coarse Thread
Screw dimension
8.8 10.9 12.9
4² 11 15 19
1/ - 20
16² 23 32 39
5/ - 18
8² 39 55 66
3/ - 16
16² 62 87 105
7/ - 14
2² 96 135 160
1/ - 13
16² 140 200 235

9/ - 12
8² 195 275 330

5/ - 11
4² 345 485 580

3/ - 10
8² 560 770 940

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

7/ - 20
2² 110 155 185

1/ - 20
16² 155 220 260

9/ - 18
8² 220 310 370

5/ - 18
4² 385 540 650

3/ - 16
8² 620 870 1050

7/ - 14
1² - 12 930 1300 1600
58 BW 219 D-5 / BW 219 PD-5


Screw dimension
8.8 10.9 12.9
1 1/8² - 12 1350 1900 2300
1 1/4² - 12 1900 2700 3200
1 3/8² - 12 2600 3700 4400
1 1/2² - 12 3300 4600 5600
BW 219 D-5 / BW 219 PD-5 59

Tightening torques for hydraulic fittings with metric thread - series “L” (pressures up to 250 bar)
Thread Spanner width Tightening torque [Nm]
M12 x 1.5 14 15
M14 x 1.5 17 20
M16 x 1.5 19 30
M18 x 1.5 22 35
M22 x 1.5 27 65
M26 x 1.5 32 80
M30 x 2 36 130
M36 x 2 41 160
M45 x 2 50 200
M52 x 2 60 250
Tightening torques for hydraulic fittings with metric thread - series “S” (pressures up to 400 bar)
M14 x 1.5 17 14
M16 x 1.5 19 25
M18 x 1.5 22 27
M20 x 1.5 24 48
M22 x 1.5 27 55
M24 x 1.5 30 65
M30 x 2 36 110
M36 x 2 46 140
M42 x 2 50 180
M52 x 2 60 220
Tightening torques for hydraulic fittings with UNF-thread (Unified Fine Thread)
16² 14 15
7/ - 20
2² 17 20
1/ - 20
16² 19 27
9/ - 18
4² 22 55
3/ - 16
8² 27 80
7/ - 14
1 1/16² - 12 32 110
60 BW 219 D-5 / BW 219 PD-5


1 3/16² - 12 36 125
1 5/16² - 12 41 160
1 5/8² - 12 220
1 7/8² - 12 270
1.3.2 Preliminary remarks and safety notes
DANGER!
Danger to life caused by an operationally
unsafe machine!
– The machine must only be serviced by quali-
fied and authorized personnel.
– Follow the safety regulations for maintenance
work Ä Chapter 1.2.11 ‘Maintenance work’
on page 29.
WARNING!
Health hazard caused by fuels and lubricants!
– Safety regulations and environmental protec-
tion regulations must be followed when han-
dling fuels and lubricants Ä Chapter 1.2.4
‘Handling fuels and lubricants’ on page 18.
CAUTION!
Danger of being injured by the engine hood
dropping down!
– Always secure an opened engine hood.
Wear your personal protective equipment.

Park the machine on horizontal, level, firm ground.
Keep unauthorised persons away from the machine.
Perform maintenance work only with the engine shut down.
Make sure that the engine cannot be accidentally started during
maintenance work.
Do not touch hot components.
Thoroughly clean the machine and engine before starting mainte-
nance work.
Before mounting the machine, check whether all access steps,
grips and platforms are free of obstacles, grease, oils, fuel, dirt,
snow and ice.
BW 219 D-5 / BW 219 PD-5 61

Use only the intended access steps and grips to mount the
machine.
For overhead maintenance work use the access steps and working
platforms provided or other secure means.
Do not step on machine parts which are not intended for this pur-
pose.
Always attach the articulation lock when working in the area of the
articulated joint.
Do not leave any tools or other objects, that could cause damage,
in or on the machine.
After maintenance work has been completed, dispose of fuels and
lubricants, filters, sealing elements and cleaning cloths in line with
environmental regulations.
After maintenance work is completed reinstall all protective
devices.
Close all maintenance flaps and doors after maintenance work has
been completed.
The terms right/left are always in relation to the

travel direction.
1.3.3 Preparations / concluding work

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

Open the engine hood
1. Unlock the lock.
2. Press the button.
Fig. 48
62 BW 219 D-5 / BW 219 PD-5

Bottom position
1. Pull the support out of the bracket and support the hood.
Fig. 49
Top position
1. Push the hood to top position.
2. Secure the locking bolt with the split pin (1).
Fig. 50
1.3.3.2 Engaging / releasing the articulation lock

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

2. Shut down the engine, pull off the ignition key.
3. Engage the articulation lock and secure the bolt with the
spring pin.
Fig. 51
BW 219 D-5 / BW 219 PD-5 63

1.3.3.2.2 Disengaging the articulation lock
WARNING!
Danger of crushing by the articulating
machine!
– Do not step into the articulation area of the
machine while the engine is running.
1. Loosen the articulation lock again, fix it in its receptacle and

lock the bolt with the spring plug.
Fig. 52
1.3.4 Parking 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.
NOTICE!
Danger of engine damage!
– Do not shut down the engine all of a sudden
from full load speed, but let it idle for about two
minutes.
Fig. 53
3. Turn the ignition key to position “0” and pull it out.

4. Open and secure the engine hood Ä Chapter 1.3.3.1 ‘Open
and secure the engine hood’ on page 62.
Fig. 54
64 BW 219 D-5 / BW 219 PD-5

5. Turn the main battery switch counter-clockwise and pull it

out.
6. Close the engine hood and lock it if necessary.
Fig. 55
BW 219 D-5 / BW 219 PD-5 65

66 BW 219 D-5 / BW 219 PD-5

Technical data
2 Technical data
BW 219 D-5 / BW 219 PD-5 67

Technical data – Technical data, BW 219 D-5
2.1 Technical data, BW 219 D-5..................................... 68

2.1.1 Technical data.......................................................... 68
2.2 Technical data, BW 219 PD-5................................... 72
2.2.1 Technical data.......................................................... 72
2.3 Additional technical data......................................... 76
2.4 Terms and basis of calculation................................ 80
2.5 Fuels and lubricants................................................. 81
2.5.1 Engine oil................................................................. 81
2.5.2 Fuel.......................................................................... 82
2.5.3 AdBlue®/DEF........................................................... 83
2.5.4 Coolant.................................................................... 85
2.5.5 Hydraulic oil............................................................. 88
2.5.6 Gear oil SAE 75W-90............................................... 88
2.5.7 Gear oil SAE 80W-140............................................. 88
2.6 List of fuels and lubricants...................................... 90
2.1 Technical data, BW 219 D-5

2.1.1 Technical data
Dimensions
Fig. 56
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)
68 BW 219 D-5 / BW 219 PD-5

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 (1) 0–4 km/h
(0 – 2.5) (mph)
(0 – 3.1) (mph)
(0 – 3.7) (mph)
Travel speed (4) 0 - 10 km/h
(0 – 6.2) (mph)
Max. gradability without/with vibration (soil dependent) 50/48 %
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
BW 219 D-5 / BW 219 PD-5 69

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)
70 BW 219 D-5 / BW 219 PD-5

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 EU Machine Directive edition 2006/42/EU
n Noise Emission Directive 2000/14/EU, Noise Protection Direc-
tive 2003/10/EU
n Vibration Protection Directive 2002/44/EU
During operation these values may vary because of the prevailing
operating conditions.
2.1.1.1.1 Noise data

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

Vibration of the entire body (driv- The weighted effective acceleration value determined according to
er’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.
BW 219 D-5 / BW 219 PD-5 71

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

2.2.1 Technical data
Dimensions
Fig. 57
A B D H H2 K L O1/2 S W
3255 2300 1500 2295 3034 495 6500 85 35 2130
(128) (91) (59) (90) (119) (19.5) (256) (3.3) (1.4) (84)
Dimensions in millimetres
(Dimensions in inch)
Weights
Max. operating weight 21000 kg
(46297) (lbs)
Operating weight with ROPS cabin (CECE) 20000 kg
(44092) (lbs)
Axle load, drum (CECE) 13200 kg
(29101) (lbs)
Axle load, wheels (CECE) 6800 kg
(14991) (lbs)
72 BW 219 D-5 / BW 219 PD-5

Travel characteristics
(0 – 2.5) (mph)
(0 – 3.1) (mph)
(0 – 3.7) (mph)
Travel speed (4) 0 - 10 km/h
(0 – 6.2) (mph)
Max. gradability without/with vibration (soil dependent) 52/50 %
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
Padfoot drum
Padfeet, quantity 150
Area of one padfoot 137 cm2
21.2 (in2)
Height of padfeet 100 mm
(3.9) (in)
Tyres
Tyre size 23.1-26 12TL
Air pressure, nominal value 1.4 bar
(20) (psi)
BW 219 D-5 / BW 219 PD-5 73

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) 1.90/1.00 mm
(0,075/0,039) (in)
Centrifugal force (1/2) 328/245 kN
(73737/55078) (lbf)
Filling capacities
Fuel (diesel) 280 l
(74) (gal us)
2.2.1.1 Noise and vibration data

The following noise and vibration data were determined in accord-
ance with the following guidelines under equipment specific condi-
tions and by using harmonized standards:
n EU Machine Directive edition 2006/42/EU
n Noise Emission Directive 2000/14/EU, Noise Protection Direc-
tive 2003/10/EU
n Vibration Protection Directive 2002/44/EU
During operation these values may vary because of the prevailing
operating conditions.
74 BW 219 D-5 / BW 219 PD-5

2.2.1.1.1 Noise data

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

Vibration of the entire body (driv- The weighted effective acceleration value determined according to
er’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.
BW 219 D-5 / BW 219 PD-5 75

Technical data – Additional technical data
2.3 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
Exhaust gas aftertreatment CSF (Catalyzed Soot Filter)
module + SCR (Selective Cata-
lytic Reduction) module
Low idle speed rpm 800
High idle speed rpm 2100
ECO rpm 1800
Valve clearance intake ° 75° ± 15°
Valve clearance exhaust ° 120° ± 15°
Travel pump
Manufacturer Sauer
Type H1 P078 RA (EP)
System Axial piston/swash plate
Max. displacement cm3/rev 78
High pressure limitation bar 450
Charge pressure relief valve for high idle speed, travel pump bar 25
1
Charge pressure relief valve, travel pump 2 against block
Pressure override valve bar 400
Travel pump, improvement of gradeability of BW 219 D-5

Manufacturer Sauer
Type H1 P089 RA (EP)
Charge pressure relief valve for high idle speed, travel pump bar 25
1
Charge pressure relief valve, travel pump 2 against block
76 BW 219 D-5 / BW 219 PD-5

Drum reduction gear

Manufacturer Bonfiglioli
Type 711C2
Transmission ratio 55.9
Drum reduction gear, improvement of gradeability of BW

219 D-5
Manufacturer Bonfiglioli
Type 711C3
Transmission ratio 93.7
Axle motor / drum drive motor

Manufacturer Sauer
Type H1 B110
System Axial piston – bent axle
Max. displacement (stage 1) cm3/rev 110
Min. displacement (stage 2) cm3/rev 35
Perm. leak oil rate l/min 2
Flushing rate l/min 5
Flushing pressure limitation bar 16
Drum drive motor, improvement of gradeability of BW

219 D-5
Manufacturer Sauer
Type H1 B110
Axle motor, improvement of gradeability of BW 219 D-5
BW 219 D-5 / BW 219 PD-5 77

Manufacturer Sauer
Type H1 B110
Vibration pump
Manufacturer Sauer
Type H1 P0 78 RA (EP)
Starting pressure bar 365 ± 65
Operating pressure (soil dependent) bar approx. 100
Charge pressure relief valve against block
Auxiliary pump cm3/rev 17
Vibration motor
Manufacturer Bosch-Rexroth
Type A2FM 63
System Axial piston/bent axle
Displacement cm3/rev 63
Steering/charge pump
System Gear pump
Displacement cm3/rev 16
Max. steering pressure bar 175 + 25
78 BW 219 D-5 / BW 219 PD-5

Steering valve
Manufacturer Danfoss
Type OSPC 500 ON
System Rotary spool valve
Rear axle
Manufacturer Dana
Type CHC 193/98
Differential No-spin
Degree of locking % 100
Reduction ratio 65.7
BW 219 D-5 / BW 219 PD-5 79

Technical data – Terms and basis of calculation
2.4 Terms and basis of calculation

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

1 Dimensions mm n All dimensions given in mm
2 Axle load kg n Specification of the static weight in (kg) affecting each axle
3 Drive system - n Mechanically from the diesel/petrol engine via V-belt, toothed
belt or chain, gears, or cardan shaft
n Hydrostatically from the diesel/petrol engine via hydraulic
pump and hydraulic motor(s)
4 Amplitude mm n Half the excursion in millimetres (mm) covered by the com-
paction body (plate or drum) per revolution of the exciter shaft
5 Working speed m/min n Path covered by the machine in metres (m) in a minute (min)
6 Operating kg n Static weight of the machine, including
weight CECE - fuels and lubricants - 50% fuel tank content x 0.84 specific
weight
- 50% water tank content
- 75 kg for the driver (only in the case of sit-on machines)
7 Rated speed min-1 n Number of revolutions per minute of the diesel/petrol engine
8 Basic weight kg n Static weight of the machine without fuels and lubricants
9 Travel speed km/h n Path covered by the machine in kilometres (km) in an hour (h)
10 Frequency Hz min-1 n Number of revolutions made by the exciter shaft per second
(Hz) ore minute (min-1)
For example: 50 Hz = 50 rev./sec = 50 x 60 = 3000 rev./min (•/
min)
11 Fuel consump- l/h n Average engine fuel consumption at 70% capacity utilisation
tion
12 Rated power kW n Effective output at the engine flywheel in kilowatts (kW) at the
SAE J 1349/ISO set nominal speed
3046
13 Track radius mm n Radius in mm which the machine achieves at full steering
angle; measured from the theoretical circle midpoint to the
inner edge of the drums/wheel
14 Static surface kg/m2 n Relates to the machine operating weight in kg divided by the
load base plate contact area
15 Static linear kg/cm or n Axle load in kg divided by the working width of the drums in
load kg/m cm or m
16 Centrifugal kN n Force generated by the exciter shaft in kilonewton (kN) which
force makes the compaction body (drum or plate) oscillate. It
depends on the vibrating mass of the compaction body and
the frequency.
Attention: Specification of a greater centrifugal force is no
guarantee of high compaction power.
80 BW 219 D-5 / BW 219 PD-5

Technical data – Fuels and lubricants
2.5 Fuels and lubricants

2.5.1 Engine oil
2.5.1.1 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:
n Low-ash engine oils complying with DQC III-LA or DQC IV-LA.
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
BW 219 D-5 / BW 219 PD-5 81

2.5.1.2 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. 58: Oil viscosity diagram
2.5.1.3 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).
2.5.2 Fuel
2.5.2.1 Fuel quality
In order to fulfil the regulations of the exhaust gas legislation,
diesel engines equipped with an exhaust gas aftertreatment
system, must only be operated with sulphur-free diesel fuel.
The following fuel specifications are permitted:
n EN 590
n ASTM D975 Grade-No. 1-D S15 and 2-D S15
82 BW 219 D-5 / BW 219 PD-5

2.5.2.2 Winter fuel

For winter operation use only winter diesel fuel, to avoid clogging
because of paraffin separation.
At very low temperatures disturbing paraffin separation can also be
expected when using winter diesel fuel.
Diesel fuels suitable for temperatures down to -44 °C (-47 °F) are
available for Arctic climates.
NOTICE!
– The admixture of petroleum and the addition of
“flow enhancing additives” (fuel additives) is
not permitted.
2.5.2.3 Storage
Even traces of zinc, lead and copper can cause deposits in the
injection nozzles, especially in modern Common-Rail injection sys-
tems.
Zinc and lead coatings in refuelling systems and fuel lines are not
permitted.
Copper containing materials (copper lines, brass items) should be
avoided, because they can cause catalytic reactions in the fuel with
subsequent depositing in the injection system.
2.5.3 AdBlue®/DEF
2.5.3.1 AdBlue®/DEF quality
AdBlue® is a non-inflammable, non-toxic, colour and odourless as
well as water soluble fluid.
It consists of a 32.5% urea solution.
The following terms are used as alternatives to AdBlue®:
n DEF (Diesel Exhaust Fluid)
n AUS 32 (Aqueous Urea Solution)
n ARLA 32 (Agente Redutor Liquido de Óxido de Nitrogênio
Automotivo)
The following specifications are permitted:
n ISO 22241-1
n DIN 70070
n ASTM D 7821
BW 219 D-5 / BW 219 PD-5 83

NOTICE!
Filling the AdBlue®/DEF tank with cleaning
agent or other operating media or fuels, mixing
in additives or diluting AdBlue®/DEF will
damage the exhaust gas aftertreatment system.
– Use only AdBlue®/DEF of the permitted specifi-
cation Ä Chapter 2.5.3 ‘AdBlue®/DEF’
on page 83.
– In case of incorrect filling inform our service
immediately.
2.5.3.2 Low outside temperatures

AdBlue®/DEF freezes at a temperature of approx. -11 °C (12 °F).
Winter operation is also guaranteed at temperatures below -11 °C
(12 °F).
At low temperatures crystals may form on the wound hose
between engine and exhaust silencer. Such crystallization does not
impair the function of the exhaust gas aftertreatment. If necessary
just remove the crystals with clear water.
2.5.3.3 Storage
Use only tanks made of the following material to store AdBlue®/
DEF:
n Cr-Ni steels acc. to DIN EN 10 088-1/2/3
n Mo-Cr-Ni steels acc. to DIN EN 10 088-1/2/3
n Polypropylene
n Polyethylene
NOTICE!
Damage to the exhaust gas aftertreatment
system!
Containers made of the following materials are not
suitable for storing AdBlue®/DEF, because compo-
nents of these materials may dissolve and thus
damage the exhaust gas aftertreatment system:
– aluminium
– copper
– copper containing alloys
– non-alloyed steel
– galvanized steel
The service life of AdBlue®/DEF without any loss of quality is influ-

enced by the storage conditions.
Exposure of stored containers to direct insolation and UV-radiation
must be strictly avoided.
84 BW 219 D-5 / BW 219 PD-5

constant storage temperature Minimum shelf life (months)

< 10 °C (50 °F) 36
< 25 °C (77 °F) 18
< 30 °C (86 °F) 12
< 35 °C (95 °F) 6
> 35 °C (95 °F) Check the product before use
AdBlue®/DEF should remain in the tank for max. four months.
2.5.3.4 Cleanliness
NOTICE!
Damage to the exhaust gas aftertreatment
system!
Contaminated AdBlue®/DEF, e.g. caused by other
operating fluids, cleaning agents or dust leads to:
– increased emission values
– damage to catalytic converters
– engine damage
– malfunction of the exhaust gas aftertreatment
system.
Always ensure strict cleanliness of the AdBlue®/DEF in order to

avoid malfunction of the exhaust gas aftertreatment system.
If AdBlue®/DEF is pumped out of the tank, the pumped liquid must
not be returned to the tank.
2.5.4 Coolant
2.5.4.1 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.
2.5.4.2 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.
BW 219 D-5 / BW 219 PD-5 85

Analysis values
pH-value at 20 °C (68 °F) 6.5 - 8.5
Chlorine-ion content max. 100 mg/l
Sulphate ion content max. 100 mg/l
Water hardness (ion content of max. 3.56 mmol/l
calcium and magnesium )
max: 356 mg/l (ppm)
Germ degree: max. 20 °dH
English degree: max: 25 °eH
French degree: max: 35.6 °fH
Bacteria, fungi, yeasts not permitted
Information concerning the water quality can be obtained from the

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

As a protection against frost, corrosion and boiling, anti-freeze
agents must be used in any climatic conditions.
Coolant is prepared by adding an ethylene-glycol based anti-freeze
agent with corrosion inhibiting properties to the cooling water.
We therefore highly recommend using our BOMAG cooling system
protection agent.
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.
86 BW 219 D-5 / BW 219 PD-5

The list of approved lubrication oils is also available on the

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

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

value:
Cooling system Fresh water Protection against
protection agent cold down to
min. 35% 65% -22 °C (-8 °F)
40% 60% -28 °C (-18 °F)
45% 55% -35 °C (-31 °F)
max. 50% 50% -41 °C (-42 °F)
NOTICE!
– A proportion of more than 50% of cooling
system protection agent results in reduced
cooling power.
– The use of corrosion protection oils as cooling
system protection agents is not permitted.
BW 219 D-5 / BW 219 PD-5 87

2.5.5 Hydraulic oil

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

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

Use a fully synthetic gear oil in accordance with SAE 75W-90,
API GL5 with a kinematic viscosity of at least 16 mm2/s at 100 °C
(212 °F).
2.5.7 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).
88 BW 219 D-5 / BW 219 PD-5

It is a hypoid lubricant of highest quality class for transmissions

under extreme strain.
BW 219 D-5 / BW 219 PD-5 89

Technical data – List of fuels and lubricants
2.6 List of fuels and lubricants

Assembly group Fuel or lubricant Spare parts Filling quantity
number
Summer Winter Observe the
level mark!
Engine oil SAE 15W-40 009 920 09 15.5 l
Specification: Ä Chapter 2.5.1 ‘Engine oil’ 20 l (4.1 gal us)
on page 81
SAE 10W-40
SAE 10W-30
SAE 30 SAE 10W
Fuel Diesel Winter diesel fuel 280 l
Specification: Ä Chapter 2.5.2 ‘Fuel’ (74 gal us)
on page 82
AdBlue®/DEF Specification: Ä Chapter 2.5.3 ‘AdBlue®/DEF’ 20 l
on page 83
(5.3 gal us)
Coolant Mixture of water and anti-freeze agent 009 940 03 26 l
Specification: Ä Chapter 2.5.4 ‘Coolant’ 20 l (6.9 gal us)
on page 85
Hydraulic system Hydraulic oil (ISO), HVLP 46 009 930 09 75 l
Specification: Ä Chapter 2.5.5.1 ‘Mineral oil 20 l (20 gal us)
based hydraulic oil’ on page 88
or ester based biodegradable hydraulic oil
Specification: Ä Chapter 2.5.5.2 ‘Bio-degrad-
able hydraulic oil’ on page 88
Exciter housing Gear oil SAE 75W-90 009 925 05 1.6 l each
Specification: Ä Chapter 2.5.6 ‘Gear oil SAE 20 l (0.4 gal us)
75W-90’ on page 88
Drum drive reduction Gear oil SAE 80W-140 009 925 07 5l
gear
80W-140’ on page 88
Drive axle Gear oil SAE 80W-140 009 925 07 11 l
80W-140’ on page 88
Axle reduction gear Gear oil SAE 80W-140 009 925 07 1.9 l
80W-140’ on page 88
Wheel hubs Gear oil SAE 80W-140 009 925 07 1.4 l each
80W-140’ on page 88
90 BW 219 D-5 / BW 219 PD-5

Assembly group Fuel or lubricant Spare parts Filling quantity

number
Summer Winter Observe the
level mark!
Tyres 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)
BW 219 D-5 / BW 219 PD-5 91

92 BW 219 D-5 / BW 219 PD-5

Overview of machine
3 Overview of machine
BW 219 D-5 / BW 219 PD-5 93

Overview of machine – General information
3.1 General information.................................................. 94

3.1.1 BCM 05.................................................................... 99
3.1.2 BCM start............................................................... 101
3.1.3 BCM net................................................................. 102
3.1.4 Economizer............................................................ 103
3.1.5 Terrameter............................................................. 104
3.1.6 BOMAG Telematic................................................. 106
3.2 Electric systems..................................................... 108
3.3 Hydraulic system.................................................... 110
3.4 Machine assemblies............................................... 111
3.4.1 Diesel engine.......................................................... 111
3.4.2 Drum...................................................................... 112
3.4.3 Air conditioning....................................................... 113
3.4.4 Auxiliary heating, AIRTRONIC............................... 114
3.1 General information
2
1
4 3
S-586-0455
Fig. 59: with attachment plates

1 Drum
2 Diesel engine
3 Central electrics
4 Articulated joint
94 BW 219 D-5 / BW 219 PD-5

Simple servicing due to excellent

accessibility
Fig. 60
Smooth drum: BVC, D and DH

machines
Fig. 61
n Compaction of sand, gravel and crushed rock
n Tapered drum edges
n Optimum surface quality
BW 219 D-5 / BW 219 PD-5 95

Padfoot drum: PD and PDH

machines
Fig. 62
n Use on cohesive soils
n Surface enlargement for faster drying
n Flexing and kneading effect
Padfoot shell optional equipment
Fig. 63
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.
96 BW 219 D-5 / BW 219 PD-5

ECOMODE
The standard BOMAG "ECOMODE” ensures a clean result. Active
engine management provides power to the roller operator when
needed and reduces power when the application allows. Intelligent
sensors combined with a sophisticated control immediately detect
the actual power requirement and the engine speed is automati-
cally adjusted.
With conventional rollers, the hydrostatic drive of the vibration unit
depends on the diesel engine speed. As a result, the diesel engine
must be driven at “full load” to maintain the corresponding speed of
the exciter shaft. This is independent of whether the engine power
is actually needed at maximum speed or not. “ECOMODE”
reduces the speed of the diesel engine towards the optimum
engine torque. The drive pump of the vibration unit hydrostatic
drive now regulates the volume flow so that the speed of the
exciter shaft is not affected by it. The pump and engine always pro-
vide the “correct” speed of the vibration shaft for the closed circuit
of the vibration drive. If the diesel engine is actuated by increasing
the driving pressure, the engine speed will increase with simulta-
neous adjustment of the exciter shaft speed.
To summarise: “ECOMODE” allows the engine speed to be
reduced while full power is still available in the hydraulic system.
Fuel consumption and noise levels are reduced, vibration frequen-
cies and centrifugal forces remain unaffected.
ECOSTOP
With the optional ECOSTOP the engine is shut down automatically
after a defined period of idle speed. This also reduces fuel con-
sumption and wear.
BW 219 D-5 / BW 219 PD-5 97

Additional modules
Fig. 64: BCM05, example of a single drum roller

1 PC or laptop
2 Printer
3 Print-outs
4 BCM 05mobile
5 CAN-USB communication
6 Output of measuring data in file format on any type of data
storage medium for transfer to third parties (e.g. client, con-
struction supervision, etc.)
Furthermore, the machine can also be extended with additional
modules. The technical requirements for surface covering compac-
tion control are achieved with BOMAG COMPACTION METER
(BCM) and GPS, the satellite-assisted location system.
98 BW 219 D-5 / BW 219 PD-5

3.1.1 BCM 05
‘BCM 05’ is used for continuous and area covering compaction
control. The system documents the stiffness of the soil in MN/m2
(EVIB-value) in earth or asphalt compaction.
The EVIB-value is a physical measured value that correlates directly
with the plate-load test used in earth and road construction. It
expresses the correlation between the ground contact force and
the indentation of the roller drum.
Fig. 65
1 Office PC with BCM 05 office software
2 USB-stick for data transfer
3 Tablet-PC with touchscreen and BCM 05 mobile software
The machine is equipped with a tablet-PC (3) with ‘BCM 05
mobile’ software. During compaction, the display on the tablet-PC
informs the operator about the current position of the machine and
the number of passes that have already been driven.
With a USB-stick (2) the measured data can be transferred to an
Office-PC (1) for analysis and documentation with the software
‘BCM 05 office’ .
A report of the recorde3d measured data can be saved as a PDF
file or directly printed out.
BW 219 D-5 / BW 219 PD-5 99

3.1.1.1 Network structure
Fig. 66
If more than one machines are working on a project, the measuring
data are recorded by various tablet-PCs (3) and then transferred to
the Office-PC (1). This PC is the Master-PC of the project.
When using further Office-PCs (2) one must make absolutely sure
that the measured data of a project are only transmitted to the
Master-PC.
3.1.1.2 Position detection

During a measurement, the measured data are assigned to the
corresponding measuring positions on the construction site.
‘BCM 05’ works with two different kinds of position detection.
This fundamental difference influences the representation and
evaluation of measured data.
Manual position detection for track Manual position detection requires a track bound working mode.
bound fields The construction site is in this case divided into fixed tracks.
The assignment of measured data and measuring positions is
accomplished by a distance transducer, which determines the posi-
tion of the machine within a track.
100 BW 219 D-5 / BW 219 PD-5

Automatic position detection for In automatic position detection the assignment of measured data to
GPS fields measuring positions takes place with the help of an automatic posi-
tion detection system (e.g. a GPS-system).
In this case the machine is equipped with e.g. a GPS antenna.
Fig. 67
n To exactly 22 cm
n No local referencing station
The assignment of the individual measuring values to the meas-
uring position is accomplished with the help of an automatic posi-
tion acquisition system.
3.1.2 BCM start

‘BCM start’ documents the number of passes when compacting
soil or asphalt.
When compacting asphalt, the passes are not only documented
but also the compaction temperature if the machine is equipped
with a corresponding temperature sensor.
By means of a GPS receiver the system determines the machine's
position.
During compaction, the display on the tablet PC shows the oper-
ator the machine's current position and the number of performed
passes.
The resulting log of the recorded data can be saved as a PDF file
on a USB stick.
BW 219 D-5 / BW 219 PD-5 101

3.1.3 BCM net

‘BCM net’ links up all rollers on a construction site involved in the
compaction process.
The individual measuring data and the position of the roller are
made available to all participants in the ‘BCM net’ group. The
tablet PC keeps each driver informed about his compaction work
and the work performed by other participants.
Fig. 68
1 BCM net Server
2 BCM net Client
The complete communication runs through a central node, the
‘BCM net’ server (1). Each group contains exactly one server. The
tablet PCs (2) with the ‘BCM 05 mobile’ or the ‘BCM start’ soft-
ware of the individual machines serve as clients.
Each machine sends its current position data as well as the deter-
mined measuring values to the server, which in turn distributes
these to all other machines. The server may, in addition to a client,
be located on a machine in the group.
The exchange of data can only take place when the client is within
the reach of the server. The reach is approximately 150 meters
around the server. It depends on both the environment and pos-
sibly existing interfering influences.
Should client and server become too far apart, the client can con-
tinue work separated from the group. In this time it is unable to
receive data from other clients and cannot transfer data to the
server.
Once the connection to the server has been restored, the saved
measuring values will be transmitted.
102 BW 219 D-5 / BW 219 PD-5

3.1.4 Economizer
Fig. 69
The BOMAG ECONOMIZER, which is integrated in the central dis-
play, informs the driver about the optimal compaction results. Oper-
ation is very simple, because no set-up or calibration is required.
The ECONOMIZER automatically determines the compaction pro-
gress. A light strip informs the driver about the end of compaction,
in order to avoid over-compaction. A warning light also indicates
when there is a risk of overcompaction developing. Moreover, the
driver is also informed about the optimal speed.
BW 219 D-5 / BW 219 PD-5 103

3.1.5 Terrameter
BOMAG TERRAMETER TERRAMETER is
available for all single drum rollers -5 and as
standard in single drum rollers with VARIOCON-
TROL.
Fig. 70
In earthworks, the stiffness of the material, measured with a pres-
sure plate, is often used as a criterion. However, load plates only
measure specific points and are expensive to use. TERRAMETER
has the technology to do far more. This measuring system allows
BOMAG single drum rollers to become rolling pressure plates: sur-
face covering, in real time.
TERRAMETER measures the level of stiffness E in MN/m². EVIB
correlates directly with the EV1 and EV2 values of the plate load
test. This means the driver not only sees the trend, but also a spe-
cific, absolute measuring value. The driver can directly work
towards the required stiffness level specified in the contract. .
The standard set values for DIN V2 of 45, 80, 100 and 120 MN/m²
are shown on the display as a compression ratio. This allows the
target achieved to be quickly displayed. Additionally, the driver is
notified by a red LED that compaction has not increased between
two passes.
HOW EXACTLY IS THE EVIB VALUE EVIB uses the interaction of the acceleration of the vibrating drum
CREATED? and the stiffness of the soil. In general, the soil stiffness will
increase as compaction increases. The principle corresponds with
a dynamic load plate.
104 BW 219 D-5 / BW 219 PD-5

S-921-0388
Fig. 71
If the soil becomes stiffer, the drum acceleration will also increase.
The measuring sensors record this acceleration and from this
determine the effective contact force between the soil and drum
and, at the same time, the vibration amplitude of the drum. If the
contact force is then laid on top of the vibration amplitude of the
drum, this results in a loading and unloading curve for every revo-
lution of the exciter. The EVIB value corresponds with the increase
in load curve, as this correlates with the stiffness of the soil.
BW 219 D-5 / BW 219 PD-5 105

3.1.6 BOMAG Telematic
S-921-0390
Fig. 72
BOMAG TELEMATIC is a fleet management system for the effi-
cient deployment of all machines. With BOMAG TELEMATIC the
machine operator can localise machines and record and save
operating states. The actual operating hours are documented.
BOMAG TELEMATIC is able to detect unauthorised use and theft
and simplify maintenance of the machine. The system consists of
machine-integrated hardware and an internet application. All data
is stored in a database. Access is individually determined for each
user and password protected on the internet.
BOMAG TELEMATIC START TELEMATIC START is available as an optional extra for self-pro-
pelled BOMAG machines – and BOMAG TELEMATIC START can
even be integrated into machines from other manufacturers! This
enables convenient management of mixed fleets.
The basic package offers the following functions
n Location tracking
n Geo-fence (an alarm signals when the machine leaves defined
areas)
n Monitoring of standing time (an alarm signals if the machine is
operated outside of defined times)
n Recording of operating hours
n Service and maintenance plan
106 BW 219 D-5 / BW 219 PD-5

BOMAG TELEMATIC POWER TELEMATIC POWER is available as an optional extra for self-pro-
pelled BOMAG machines with electronic control, e.g. DH-4 single
drum rollers, pavers, planers, refuse compactors or MPH recyclers/
stabilizers. BOMAG TELEMATIC can also be installed in machines
from other manufacturers.
The POWER solution offers the following features in addition to
those from the basic package
n Calculation of total and average fuel consumption for any time
period
n Reports on utilisation of capacities and efficiency
n Idle running control
n Alarms in certain operational conditions (oil pressure, cooling
water, etc.)
BW 219 D-5 / BW 219 PD-5 107

Overview of machine – Electric systems
3.2 Electric systems
4 5 6 7 8 9 10 11
3 12
13
14
2 15
16
1 17
18
19
20
31 30 29 28 27 26 25 24 23 22 21
S-586-0454
Fig. 73
1 Operating console and monitoring module, A15
2 Monitor for reversing monitoring, P42
3 Working head lights, front left, E23
4 Tachograph (P09) and tachograph electronics (A16)
5 Front windscreen wiper motor, M04
6 Radio (A12) and printer (P11)
7 Working head lights, rear left, E27
8 Working head lights, front right, E25
9 Rear windscreen wiper motor, M05
10 Camera for reversing monitoring, P32
11 Working head lights, rear right, E28
12 Travel lever, S55
13 Control elements of driver’s seat
14 Air filter maintenance switch (B03) and ambient temperature sensor (B218)
15 Float switch for coolant compensation tank, B55
16 Fuse box for exhaust gas aftertreatment system; only for machines with exhaust classification Tier4f and
STAGE V
17 Warning buzzer for reverse travel, H14
18 Differential pressure switch for hydraulic oil filter, B21
108 BW 219 D-5 / BW 219 PD-5

Overview of machine – Electric systems
20 Pressure sensor for travel pump, B234, B235, B236 and B237
21 Battery disconnecting switch, S30
22 Power board for SCR heating, only machines with exhaust classification Tier4f and STAGE V
23 Fluid level sensor, R03
24 Battery, G01
25 Solenoid valve for brake, Y04
26 Warning horn, B11
27 Front windscreen washer motor, M06 and rear windscreen washer motor, M07
28 Central electrics, travel control (A34), engine control unit (A48), measuring technology control (A83), Tel-
ematic module (A124), cross-slope sensor (B57), diagnostics interfaces (X32) and (X34), Powerboard
and connector strip (X100 to X109)
29 Keyboard for anti-theft protection, A76
31 Wiring loom, cabin
BW 219 D-5 / BW 219 PD-5 109

Overview of machine – Hydraulic system
3.3 Hydraulic system
Fig. 74
1 Travel motor of drum
2 Steering valve
3 Hydraulic oil tank
4 Travel pump
5 Vibration pump
6 Charge oil filter
7 Brake valve (Y04)
8 Steering/charge pump
9 Travel motor of axle
10 Manifold block with thermostat
11 Steering cylinder
12 Vibration motor
110 BW 219 D-5 / BW 219 PD-5

Overview of machine – Machine assemblies
3.4 Machine assemblies

3.4.1 Diesel engine.......................................................... 111
3.4.2 Drum...................................................................... 112
3.4.3 Air conditioning....................................................... 113
3.4.4 Auxiliary heating, AIRTRONIC............................... 114
3.4.1 Diesel engine
1
2
7 6 5 4 3
S-586-0461
Fig. 75
1 Diesel engine
2 Fuel pre-filter with water level sensor (B124)
3 Main fuses
4 Power board for SCR heating
5 AdBlue tank and solenoid valve for tank heating
6 AdBlue feed module
7 Central electrics, engine control unit (A48)
BW 219 D-5 / BW 219 PD-5 111

3.4.2 Drum
Fig. 76: Sectional drawing of drum, BW216

1 Vibration motor
2 Exciter unit
3 Clutch
4 Travel gear
5 Travel motor
6 Drum shell
7 Rubber buffer
8 Rectangular rubber buffers
9 Travel bearings
112 BW 219 D-5 / BW 219 PD-5

3.4.3 Air conditioning
3 2 1
S-586-0456
Fig. 77
1 Compressor
2 Condenser
3 Drier / collector
4 HKL module
Optional equipment
BW 219 D-5 / BW 219 PD-5 113

3.4.4 Auxiliary heating, AIRTRONIC
2 3
1
S-586-0459
Fig. 78
1 Heater unit, E30
2 Air filter
3 Timer (S28) and fuses (F320 and F321)
4 Fuel filter and pump for heating unit, Y14/M57
Optional equipment
114 BW 219 D-5 / BW 219 PD-5

Electric systems
4 Electric systems
BW 219 D-5 / BW 219 PD-5 115

Electric systems – Basic principles
4.1 Basic principles...................................................... 116

4.1.1 Measuring technology............................................ 117
4.1.2 Understanding circuit diagrams............................. 122
4.1.3 Telemecanique switch............................................ 134
4.1.4 Deutsch connectors, DT and DTM series.............. 136
4.2 Overview of electric system.................................. 141
4.2.1 Central electrics..................................................... 143
4.2.2 Operator’s stand.................................................... 145
4.2.3 Wiring..................................................................... 146
4.2.4 CAN BUS overview................................................ 166
4.2.5 List of equipment................................................... 169
4.3 Starting the engine with jump leads..................... 180
4.4 Fuse assignment.................................................... 181
4.4.1 Notes on safety...................................................... 181
4.4.3 Main fuses............................................................. 182
4.4.4 Exhaust gas aftertreatment system....................... 183
4.4.5 Control console cabin............................................ 183
4.4.6 Auxiliary heating.................................................... 184
4.5 Central electrics...................................................... 185
4.5.1 Power board.......................................................... 188
4.6 Description of electrical components................... 194
4.6.1 CPU control units and electrical modules.............. 194
4.6.2 Power board for SCR-heating................................ 199
4.6.4 Sensors and actuators........................................... 202
4.7 Training of electric system.................................... 207
4.7.1 Electrics training machine control.......................... 207
4.8 Inspection and maintenance work........................ 333
4.8.1 Maintenance Table................................................. 333
4.8.2 Every 500 operating hours..................................... 333
4.8.3 As required............................................................ 334
4.1 Basic principles

4.1.1 Measuring technology............................................ 117
4.1.2 Understanding circuit diagrams............................. 122
4.1.3 Telemecanique switch............................................ 134
4.1.4 Deutsch connectors, DT and DTM series.............. 136
116 BW 219 D-5 / BW 219 PD-5

4.1.1 Measuring technology

Test lamp
NOTICE!
This type of tester must not be used for testing on
electronic components. The high power consump-
tion of the test lamp may destroy electronic compo-
nents in the control units.
Fig. 79: Test lamp
Voltage tester
It is used to perform simple voltage measurements. The tester con-
sists of two probes. The negative measuring line is connected to
ground; the positive measuring line is connected to the relevant
measuring point.
When voltage is applied, the corresponding LED lights up.
S-ELE-0044
Fig. 80: Voltage tester
BW 219 D-5 / BW 219 PD-5 117

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. 81: 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. 82
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. 83
118 BW 219 D-5 / BW 219 PD-5

Voltage and voltage drop measurement with multimeter

n Measurement at the voltage source measures the currently
available voltage.
n The meter is always connected parallel to consumer, compo-
nent or power source.
Fig. 84: Measuring voltage
n A measurement at the consumer measures the voltage drop at

this component.
Fig. 85: 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. 86: Measuring current
BW 219 D-5 / BW 219 PD-5 119

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. 87: Current measurement
Clip-on measuring instrument

The clip-on measuring instrument can be used to measure current,
voltage and resistance.
Fig. 88: Clip-on measuring instrument
n For measuring current the individual conductor must be fully

enclosed by the measuring tongs, the actual measurement
takes place without contact.
Fig. 89
120 BW 219 D-5 / BW 219 PD-5

Magnet tester
The magnet tester is used to test solenoid valves and magnetic
coils.
The test lamp responds to the magnetic fields of A.C-voltage, D.C.-
voltage and permanent magnets.
n The component to be tested does not need to be removed.
n The magnetic coil can also be tested under a protective cap.
Fig. 90: 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. 91
BW 219 D-5 / BW 219 PD-5 121

4.1.2 Understanding circuit diagrams

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

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

trouble shooting in the vehicle wiring system. This diagram pro-
vides the following information:
n Number and type of individual elements in the examined elec-
tric circuit, such as plug connectors, fuses, switches, con-
sumers, relays, etc.
n The sequence in which current flows through the individual ele-
ments in the electric circuit.
n Connections between the examined electric circuit and other
circuits in the vehicle wiring system.
n Pin assignment of plug-in connections.
Structure of circuit diagram The circuit diagram consists of following individual parts:
n Cover sheet (with general information) Ä ‘Cover sheet’
on page 122
n Table of contents Ä ‘Table of contents’ on page 123
n Overview of structural symbols (only if the structural view is
used) Ä ‘Overview of structural symbols’ on page 123
n Overview of installation locations (only if the structural view is
used) Ä ‘Overview of installation locations’ on page 124
n Electric circuit documents for electrical engineering (functional
diagrams) Ä ‘Functional diagrams’ on page 125
n List of components for electrical engineering (without terminals
and plugs) Ä ‘List of components’ on page 126
n Overview of terminal strips (form type: terminal diagram)
Ä ‘Overview of terminal strips’ on page 127
n Overview of pins (form type: PLC diagram) Ä ‘Overview of
pins’ on page 128
n Overview of plugs (form type: plug diagram) Ä ‘Overview of
plugs’ on page 128
n Additional graphical information (e.g. CAN structure, overview
of central electrics and control boxes).
Cover sheet The cover sheet contains general information.
122 BW 219 D-5 / BW 219 PD-5

S-ELE-0026
Fig. 92: Cover sheet
Table of contents The table of contents lists the individual functions.
S-ELE-0027
Fig. 93: Table of contents
Overview of structural symbols

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

machine with respect to equipment, functions and installation loca-
tions as a summary. Structural symbols are mainly abbreviations
for machine parts/machines, functions and installation locations,
which were derived from designations in English.
BW 219 D-5 / BW 219 PD-5 123

S-ELE-0028
Fig. 94: Overview of structural symbols

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

Overview of installation locations (only if the struc-
tural view is used).
124 BW 219 D-5 / BW 219 PD-5

+FRFR
+DRUM +REFR
+PLA
+CAB
+ROPS
+DPL
+SEAT
+MOT
+ARC +PUMP
+BAT
+EBOX
0 1 2 3 4 5 6 7 8 9
Function Page from
Created == 7 98
Erstellt Layout mounting locations Funktion Blatt von
Checked
Geprüft
Übersicht Einbauorte S-ELE-0025 Higher-level function
Anlage
Mounting location
Einbauort
=
+ VIEW EPE / 000 / 00
Fig. 95: Installation locations with structural symbols

Overview of structural symbols Ä Fig. 94
Functional diagrams n The main reading direction is sheet by sheet, from top to
bottom and from left to right.
n All sheets are numbered successively.
n BOMAG uses the resolved type of representation. In this case
parts and components with different functions, which belong to
the same components (e.g. relay coil and relay contact), can
be represented on different sheets. Cross-references, which
refer to the sheet and current path, connect these partial com-
ponents.
BW 219 D-5 / BW 219 PD-5 125

2 S15:11/=OPT/41.0
K61
4
3
5
5 6 7 8
S-ELE-0029
Fig. 96: Functional diagrams

1 Relay cross references are used to track signals, which need to be tracked for components with outgoing
contacts. A contact overview with information about the contact types of a relay and their positions in the
circuit diagram is additionally attached to the bottom of each relay coil. Example: (K61/9.6) indicates that
the relay coil on page 9 is found in current path 6.
2 Structural symbols example: +REFR Ä Fig. 94.
3 Potential cross references serve the purpose of tracking signals, which are transmitted from one func-
tional diagram to another. Potential cross-references may additionally have structural symbols assigned
to them. Example: → S15:11/=OPT/41.0 is continued to the right to page 41, current path 0. OPT stands
for option.
4 Contact overview of relay
5 Current paths are numbered successively from 0 to 9.
List of components The list of components is the first evaluation list that follows the
functional diagrams. This list contains all components used in the
circuit diagram, except terminal strips and plugs.
126 BW 219 D-5 / BW 219 PD-5

S-ELE-0030
Fig. 97: List of components

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

electrical and the hydraulic documentation and are
identical.
Overview of terminal strips The overview of terminal strips contains all terminal strips used in
the machine. Each terminal strip starts on a new page and can be
localized via the cross-reference in the circuit diagram.
BW 219 D-5 / BW 219 PD-5 127

Terminal strip overview

Klemmleistenübersicht
WAGO
X1 WAGO
Mounting location
Einbauort
Device tag Page Path X1: 19-1 6 4 X1: 50 32 7 X1: 113 28 5 X1: 152 19 2 X1: 183 14 9
BMK Blatt Pfad
X1: 19-2 6 4 X1: 51 6 6 X1: 114 27 2 X1: 153 19 2 X1: 184 14 8
X1: 1-1 4 5 X1: 20-1 28 2 X1: 52 10 4 X1: 115 27 3 X1: 153 21 3 X1: 185 12 8
X1: 1-2 4 5 X1: 20-2 28 2 X1: 53 32 6 X1: 116 20 4 X1: 154 14 3 X1: 186 12 8
X1: 2-1 27 7 X1: 21-1 27 6 X1: 54 4 5 X1: 117 27 7 X1: 154 14 5 X1: 187 12 5
X1: 2-2 27 7 X1: 21-2 27 6 X1: 54 34 0 X1: 118 6 8 X1: 154 19 3 X1: 188 12 6
X1: 3-1 26 5 X1: 22-1 6 3 X1: 55 10 8 X1: 119 27 7 X1: 155 19 4 X1: 189 20 2
X1: 3-2 26 5 X1: 22-2 6 3 X1: 55 33 4 X1: 121 15 6 X1: 156 7 9 X1: 190 20 1
X1: 4-1 28 1 X1: 23-1 30 6 X1: 61-1 15 9 X1: 122 15 6 X1: 156 12 5 X1: 191 21 3
X1: 4-2 28 1 X1: 23-2 30 6 X1: 61-2 15 9 X1: 123 15 6 X1: 156 20 1 X1: 192 21 4
X1: 5-1 27 0 X1: 24-1 6 6 X1: 62-1 15 8 X1: 124 17 2 X1: 157 12 8 X1: 193 21 5
X1: 5-2 27 0 X1: 24-2 6 6 X1: 62-2 15 8 X1: 125 21 0 X1: 157 28 0 X1: 195 18 2
X1: 6-1 6 8 X1: 25-1 6 5 X1: 63-1 15 8 X1: 126 27 8 X1: 157 28 8 X1: 196 14 4
X1: 6-2 6 8 X1: 25-2 6 5 X1: 63-2 15 8 X1: 127 20 5 X1: 159 17 6 X1: 197 14 3
X1: 7-1 26 4 X1: 26-1 6 1 X1: 64-1 15 8 X1: 128 13 3 X1: 160 17 7 X1: 205 12 2
X1: 7-2 26 4 X1: 26-2 6 1 X1: 64-2 15 8 X1: 128 27 8 X1: 161 14 6 X1: 206 12 1
X1: 8-1 26 3 X1: 27-1 6 2 X1: 65-1 15 7 X1: 129 17 2 X1: 162 7 8 X1: 207 12 2
X1: 8-2 26 3 X1: 27-2 6 2 X1: 65-2 15 7 X1: 130 20 5 X1: 163 7 8 X1: 208 12 1
X1: 9-1 5 4 X1: 31 4 4 X1: 71-1 4 3 X1: 131 27 6 X1: 164 11 3 X1: 209 12 0
X1: 9-2 5 4 X1: 32 4 4 X1: 71-2 4 3 X1: 132 27 6 X1: 165 11 3 X1: 210 12 1
X1: 10-1 5 3 X1: 33 11 5 X1: 72-1 6 9 X1: 133 28 4 X1: 166 4 3 X1: 211 26 3
X1: 10-2 5 3 X1: 34 11 6 X1: 72-2 6 9 X1: 134 28 5 X1: 167 30 7 X1: 212 26 4
X1: 11-1 5 4 X1: 35 11 3 X1: 73-1 4 8 X1: 135 27 2 X1: 168 7 6 X1: 213 26 3
X1: 11-2 5 4 X1: 36 11 4 X1: 73-2 4 8 X1: 136 27 3 X1: 169 4 7 X1: 214 26 4
X1: 12-1 5 1 X1: 37 28 2 X1: 76-1 30 6 X1: 137 18 4 X1: 170 4 8 X1: 215 17 2
X1: 12-2 5 1 X1: 38 28 2 X1: 76-2 30 6 X1: 138 18 5 X1: 171 15 6 X1: 215 18 7
X1: 13-1 4 8 X1: 39 15 8 X1: 103 15 5 X1: 139 27 6 X1: 172 15 5 X1: 216 18 6
X1: 13-2 4 8 X1: 40 15 4 X1: 104 15 6 X1: 139 37 4 X1: 173 15 4 X1: 216 21 9
X1: 14-1 5 5 X1: 41 6 3 X1: 105 15 5 X1: 140 27 6 X1: 174 15 2 X1: 217 17 2
X1: 14-2 5 5 X1: 42 6 3 X1: 106 18 3 X1: 141 13 1 X1: 175 14 8 X1: 219 17 1
X1: 15-1 21 1 X1: 43 13 1 X1: 107 18 3 X1: 142 13 2 X1: 176 14 9 X1: 219 17 3
X1: 15-2 21 1 X1: 44 14 9 X1: 109 6 8 X1: 144 13 1 X1: 177 13 5 X1: 220 21 9
X1: 16-1 27 2 X1: 45 14 8 X1: 109 20 4 X1: 149 5 1 X1: 178 13 5 X1: 221 21 7
X1: 16-2 27 2 X1: 46 24 2 X1: 109 27 0 X1: 151 19 1 X1: 179 15 6 X1: 222 21 7
X1: 17-1 27 3 X1: 47 12 8 X1: 110 27 0 X1: 151 21 5 X1: 180 15 5 X1: 231 27 6
X1: 17-2 27 3 X1: 48 12 8 X1: 111 27 1 X1: 152 14 4 X1: 181 15 4 X1: 232 27 6
X1: 18-1 6 5 X1: 49 27 1 X1: 112 28 3 X1: 152 18 2 X1: 182 15 2 X1: 233 28 2
X1: 18-2 6 5
0 1 2 3 4 5 6 7 8 9
Higher-level function Page from
Created = 46 65
Erstellt Terminal strip overview X1 Anlage
Function
==
Blatt von
Funktion
Checked
Geprüft Klemmleistenübersicht X1 S-ELE-0031 Mounting location
Einbauort + EPE/ 000 / 00
Fig. 98: Overview of terminal strips
Overview of pins The overview of pins Ä Fig. 99 informs about the type of inputs
and outputs of the components used in the machine Ä Fig. 97, as
well as their signals and potentials.
Pin overview
Pin Übersicht
Travel lever
S55 Fahrhebel
Plug Pin Page Path Description
Stecker Kontakt Blatt Pfad Beschreibung Signal Signal
X23 1 14 6 Power supply (8...32V) Power supply Stromversorgung

X23 2 14 5 Ground Ground Masse
X23 3 29 9 BTS signal "Brake catch" BTS brake BTS Bremse
X23 4 BTS signal "warning horn"
(prepared)
X23 5 29 3 Output voltage supply Supply analog selectors Versorgung Analoge Wahlschalter
"+5V"
X23 6 16 4 CAN bus high
X23 7 16 5 CAN bus low CAN low CAN low
X23 8 29 2 Ground / 0V / reference Ground analog selectors Masse Analoge Wahlschalter
to PIN 5
X23 9 14 6 Adressing 1 Ground Masse
X23 10 14 7 Adressing 2 -"- -"-
X23 11 29 1 Analog IN 1 Switch, speed range selector 2 Schalter Fahrstufen 2
X23 12 29 4 Analog IN 2 Frequency adjustment plates Frequenzverstellung Anbauplatten
X24 1 29 7 Digital IN 1 Switch, vibration low/off (on/off) Schalter Vibration klein/aus (an/aus)
X24 2 29 8 Digital IN 2 Switch, vibration off/high Schalter Vibration aus/groß
X24 3 29 6 Digital IN 3 Floating position plates Schwimmstellung Anbauplatten
X24 4 29 5 Digital IN 4 Vibration plates Vibration Anbauplatten
X24 5 Digital IN 5
X24 6 Digital IN 6
X24 7 Output supply voltage
+Ub
"ground" (0V)
0 1 2 3 4 5 6 7 8 9
Function Page from
Created == 74 98
Erstellt Pin overview S55 Funktion
Higher-level function
=
Blatt von
Checked
Geprüft
Pin Übersicht S55 S-ELE-0032 Anlage
Mounting location
Einbauort + PINO EPE / 000 / 00
Fig. 99: Overview of pins, S55
Overview of plugs The plug diagram is at the end of the list evaluations. The plug dia-
gram contains all plugs used in the machine. The list is sorted in
numerical order. Behind each connector designation is a reference
to the installation location, a function text and information about the
plug type used. For each individual connector pin used, a note is
given where the PIN is shown in the circuit diagram.
128 BW 219 D-5 / BW 219 PD-5

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

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

Blatt Pfad Blatt Pfad 12 20 6 12 28 4
1 8 5 1 13 20 7 13
2 14 20 4 14 28 5
Plug Mounting location 3 15 20 7 15 27 8
Stecker -X0.B Einbauort +EBOX 4 16 20 5
Function text Plug, supply ground 5 48 1 17 Plug Mounting location
Funktionstext Stecker Versorgung Masse 18 20 8 Stecker -X2.A Einbauort +EBOX
6
Function text Plug, access harness rear frame
Plug type
7 8 6
Steckertyp Plug Mounting location Funktionstext Stecker Anschluß Kabelbaum Hinterrahmen
8 18 8 -X1.B +EBOX
Stecker Einbauort Plug type
Wire harness 9 18 8 AMP Junior Power Timer 15 pole green
Function text Plug, access harness engine controller Steckertyp
Kabelbaum
Contact
Kontakt
Funktionstext Stecker Anschluß Kabelbaum Motorsteuergerät Wire harness
Page Path Plug Mounting location
-X1.A +EBOX Plug type Kabelbaum
Contact
Kontakt
Blatt Pfad Stecker Einbauort AMP Junior Power Timer 18 pole blue
Steckertyp Page Path
Function text Plug, access harness engine
31 8 6 Wire harness Blatt Pfad
Funktionstext Stecker Anschluß Kabelbaum Motor
Kabelbaum
Contact
Kontakt
Plug Mounting location Plug type
1 28 4
Stecker -X0.B Einbauort +EBOX Steckertyp Page Path 2 32 6
Wire harness Blatt Pfad 3
Function text Plug, supply ground
Kabelbaum 1 20 2 4 28 5
Contact
Kontakt
Funktionstext Stecker Versorgung Masse
Plug type Page Path 2 20 2 5
Amphenol RADSOK® 6mm Blatt Pfad 3 20 2 6
Steckertyp
Wire harness 1 9 2 4 20 7 7 31 7
Kabelbaum 2 9 2 5 20 2 8
Contact
Kontakt
Page Path 3 18 6 6 20 3 9 28 5
Blatt Pfad 4 20 5 7 20 8 10 30 2
5 48 1 8 20 3 11
1 8 6 9 20 5 12 28 4
6 18 6
7 8 6 10 20 7 13 28 5
Plug Mounting location
Stecker -X0.C +EBOX 8 18 8 11 20 6 14 28 5
Einbauort
9 18 8 12 20 6 15 27 8
Function text Plug, supply potential 30 before battery disconnect switch
Funktionstext Stecker Versorgung Potential 30 vor Batterietrennschalter
13 20 7
14 20 4
Plug type
Steckertyp
Amphenol RADSOK® 3,6mm 15 20 7
16 20 5
Wire harness
17 20 5
Kabelbaum
Contact
Kontakt
18 20 8
Page Path
Blatt Pfad
30 10 8
0 1 2 3 4 5 6 7 8 9
Function Page from
Created == 75 98
Erstellt Plug overview Funktion
=
Blatt von
Anlage
Checked
Geprüft
Steckerübersicht Mounting location
Einbauort + PLGO EPE / 000 / 00
Fig. 100: Overview of plugs
4.1.2.2 Circuit symbols in E-Plan

Circuit symbol Circuit symbols are standardized representations for electrical
appliances. They serve the purpose of a simplified representation
of complete systems, from which, however, the function can be
clearly identified. This standardization is in compliance with the
globally valid regulations of the IEC (International Electrical Com-
mission). The standardization serves the purpose of global under-
standing and fault free connection of appliances, especially in
vehicle repairs. Since the wiring diagram is intended to show only
the most essential aspects, the circuit symbol only shows as much
of the function, as is needed for easy recognition and for the avoid-
ance of mistakes.
Fig. 101: For example: Circuit symbol

1 Current source
2 Conductor
3 Switches
4 Ground
5 Filament lamp
6 Filament lamp with two luminous elements
7 Voltmeter
8 Ammeter
9 Resistance
BW 219 D-5 / BW 219 PD-5 129

10 Fuse
11 Terminal strip
12 Plugs
Different symbols are used to simplify the differentiation of terminal
strips 11 Ä Fig. 101 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. 102: 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.
130 BW 219 D-5 / BW 219 PD-5

Identification of externally supplied

documentation
Fig. 103: 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. 104: PLC box representation

The PLC box representation of connecting pins uses a table with
associated connecting plugs, which are used in connection with the
machine functions. The table symbols can be arranged in a line, if
necessary. Connections which are not used do not need to be rep-
resented. The PLC box representation enables the representation
of further reaching functional descriptions to the individual compo-
nent connections.
The PLC box representation is mainly used for controls with
BOMAG software, or for electronic devices which were specified
accordingly, and where information on the assignment of signals is
available.
Identification of similar, adjacent circuit symbols
In circuit diagrams, symbols of the same type are often arranged in
series or close to each other. In such cases it is common practice
to reduce the identification on the subsequent symbol to the cri-
teria, which are different from the previous symbol on the left.
BW 219 D-5 / BW 219 PD-5 131

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

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

n Thermometer
n Oil pressure gauge
R n Resistance n Heating resistance
n Potentiometer
n NTC resistor
132 BW 219 D-5 / BW 219 PD-5

Designation Meaning Example

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

Switches of modular design
Fig. 105
F Direction
BW 219 D-5 / BW 219 PD-5 133

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

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

Dismantling
Fig. 106
1. Lift up the interlock (5).
134 BW 219 D-5 / BW 219 PD-5

2. Fold down the switch block (4).

3. Loosen the screw (1).
Fig. 107: Folding down the switch

block
4. Lift up the interlock (2) and pull out the front element (3).
Fig. 108: Pulling out the front element
Assembly
Fig. 109: Assembly

1. Insert the front element (3) into the bore in the control panel.
BW 219 D-5 / BW 219 PD-5 135

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

tening flange.
3. Tighten the screw (1) with a tightening torque of 0.6 Nm.
Fig. 110: Observe the marks.
4. Clip on the switch block (4).
Hook in the switch block at the bottom first.
Fig. 111: Install the switch block
4.1.4 Deutsch connectors, DT and DTM series

General
NOTICE!
Do not crimp more than one lead per pin or per
socket.
Sockets and pins must not be soldered to leads,
they may only be crimped (see special tools for
electrics).
Fig. 112: Crimp connections When connecting sockets and plugs these must
engage with a noticeable click when both halves
interlock.
The plug connection should not be separable
(without loosening the interlock).
136 BW 219 D-5 / BW 219 PD-5

DT contacts
Fig. 113: DT series

DT and DTM plug connectors have a wedge which holds the pins
and sockets in place. The wedge can be removed and replaced
without having to cut through the wires.
Removing the DT contacts
1 2 3
S-ELE-0040
Fig. 114: Removing the DT contacts

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

socket.
In this case the interlock disassembly tool
serves as an aid to remove the wedges.
BW 219 D-5 / BW 219 PD-5 137

Installing the DT contacts
1 1.1 1.2
2
S-ELE-0041
Fig. 115: Installing the DT contacts

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

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

connection must easily withstand a withdrawal force of 45 N.
138 BW 219 D-5 / BW 219 PD-5

DTM contacts
Fig. 116: DTM series

DT and DTM plug connectors have a wedge which holds the pins
and sockets in place. The wedge can be removed and replaced
without having to cut through the wires.
Removing the DTM contacts
1 2 3
S-ELE-0042
Fig. 117: Removing the DTM contacts

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

socket.
In this case the interlock disassembly tool
serves as an aid to remove the wedges.
BW 219 D-5 / BW 219 PD-5 139

Installing the DTM contacts
1 1.1 1.2
S-ELE-0043
Fig. 118: Installing the DTM contacts

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

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

connection must easily withstand a withdrawal force of 45 N.
140 BW 219 D-5 / BW 219 PD-5

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

4.2.2 Operator’s stand.................................................... 145
4.2.3 Wiring..................................................................... 146
4.2.4 CAN BUS overview................................................ 166
4.2.5 List of equipment................................................... 169
4 5 6 7 8 9 10 11
3 12
13
14
2 15
16
1 17
18
19
20
31 30 29 28 27 26 25 24 23 22 21
S-586-0454
Fig. 119
1 Operating console and monitoring module, A15
2 Monitor for reversing monitoring, P42
3 Working head lights, front left, E23
4 Tachograph (P09) and tachograph electronics (A16)
5 Front windscreen wiper motor, M04
6 Radio (A12) and printer (P11)
7 Working head lights, rear left, E27
8 Working head lights, front right, E25
9 Rear windscreen wiper motor, M05
10 Camera for reversing monitoring, P32
11 Working head lights, rear right, E28
BW 219 D-5 / BW 219 PD-5 141

12 Travel lever, S55

13 Control elements of driver’s seat
14 Air filter maintenance switch (B03) and ambient temperature sensor (B218)
15 Float switch for coolant compensation tank, B55
16 Fuse box for exhaust gas aftertreatment system; only for machines with exhaust classification Tier4f and
STAGE V
17 Warning buzzer for reverse travel, H14
20 Pressure sensor for travel pump, B234, B235, B236 and B237
21 Battery disconnecting switch, S30
22 Power board for SCR heating, only machines with exhaust classification Tier4f and STAGE V
23 Fluid level sensor, R03
24 Battery, G01
25 Solenoid valve for brake, Y04
27 Front windscreen washer motor, M06 and rear windscreen washer motor, M07
28 Central electrics, travel control (A34), engine control unit (A48), measuring technology control (A83), Tel-
ematic module (A124), cross-slope sensor (B57), diagnostics interfaces (X32) and (X34), Powerboard
and connector strip (X100 to X109)
29 Keyboard for anti-theft protection, A76
142 BW 219 D-5 / BW 219 PD-5

4.2.1 Central electrics

Central electrics, old version
4 6
5 7
3 X32
X34
2
1
X41
B57 A124
X100 - X109
8
A48 X45
A34
9
A83
10
S-586-0448
Fig. 120: Central electrics old version

1 Travel control, A34
2 Cross-slope sensor, B57
3 Diagnostics interface BOMAG, X34
4 Diagnostics interface Deutz, X32
5 Connector strip X100 to X109
6 Power board
7 Telematic module, A124
8 Interface to diesel engine, X41
9 Engine control unit, A48
10 Measuring technology control, A83
BW 219 D-5 / BW 219 PD-5 143

Central electrics, new version
6 7
5
4
3 X41
8
2
1 X32
X100 - X109 A124
A161
X34
A162
B57
9
A34
A48
10
X45
A83
11
12
S-586-0447
Fig. 121: Central electrics new version

8 Module for CAN gateway, A161
10 Powerboard with folding function for better troubleshooting
144 BW 219 D-5 / BW 219 PD-5

4.2.2 Operator’s stand
6 1
2 3 4 5 7 12
MIN EC
O MAX
13
14
11 10 9 8 15
S-586-0484
Fig. 122
1 [A15] Instrument cluster
2 [S01] Emergency stop switch
3 [S09] Rotary switch for amplitude pre-selection, not on BVC machines
4 [S26] Rotary switch for working lights (optional equipment)
5 [S299] Button for regeneration, only on machines with exhaust classification STAGE V
6 [S299] Rotary button for regeneration, only on machines with exhaust classification Tier 4f
7 [S127] Rotary switch for engine speed
8 [S37] Rotary switch for direction indicators (optional equipment)
9 [S154] Rotary switch for hazard light system (optional equipment)
10 [S15] Rotary switch for lighting system (optional equipment)
11 [S42] Rotary switch for travel speed ranges
12 [S00] Starter switch
13 [S55] Travel lever
14 [S107] Rotary switch for BVC, only on BVC machines
15 [S09] Rotary switch for vibration, only on BVC machines
BW 219 D-5 / BW 219 PD-5 145

4.2.3 Wiring
A15
X33
S127
X26
X24
2
S299 X87
X99
S35 S107
S42
S01 S09
S36
S64
S55
S00
H07 X23
X14
X82 M06
M07
XS
X10
B11
B11
X79
GND
1 X4.B
X102
X4.A
X4.D
X6.B
X6.C
X102
X7.A
S-586-0228
Fig. 123
1 Wiring loom, instruments
2 Wiring loom, seat console
146 BW 219 D-5 / BW 219 PD-5

X78
B55
G02
X72
2 B124
X72
X73
X67
1 OPTION
OPTION
M35-Winterpaket
Kompressor Klimaanlage M35-Winter package
Compressor air-conditioning
Y15
X12
B218
B03
X68
OPTION
Druckschalter Klimaanlage
Pressure switch air conditioning
GND
-X0.B X1A
X101
X108
3
S-586-0450
Fig. 124
1 Wiring loom, engine
2 Wiring loom, adapter
3 Wiring loom, ground
BW 219 D-5 / BW 219 PD-5 147

X25 Y07
nicht benötigt X30
not required
1 Y08
H14
Y16
Y17
X81
X11
2 Y04
Y30
X69
X80
B21
nicht benötigt
not required
´B11.1
´B11.2
Y31
180° X2A
B60
X2B
X103
_
GND
S-586-0249
Fig. 125
1 Wiring loom, pump installation
2 Wiring loom, adapter warning horn
148 BW 219 D-5 / BW 219 PD-5

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. 126
1 Wiring loom, charge line
2 Wiring loom, starter
3 Wiring loom, main battery switch <> main battery fuse
4 Wiring loom, charge system
BW 219 D-5 / BW 219 PD-5 149

2 -G03
-G01
+G03
+G01
3
1
- 4
S30:3
S-586-0232
Fig. 127
1 Wiring loom, battery box <> fuses
2 Wiring loom, battery (-)
3 Wiring loom, battery (-)
4 Wiring loom, battery (+)
5 Wiring loom, ground engine <> ground frame
150 BW 219 D-5 / BW 219 PD-5

180°
X1.B
GND
X32
X48
X108
X41
X45
A48
S-586-0233
Fig. 128: Old design

1 Wiring loom, EMR
BW 219 D-5 / BW 219 PD-5 151

A
X1.B
GND
X108 X41
X32 X48
A
1
X45
S-586-0451
Fig. 129: New design

1 Wiring loom, EMR new version
152 BW 219 D-5 / BW 219 PD-5

180°
B216
X78
B224
B305 grau
schwarz schwarz
black grey black
B225 B215 B214
B223
Y293
X302
X301
X36 X300/30
A48
X300/31
1
+ G01
- G01
Y292
E104
E106
B222 E105
X31
S-586-0234
Fig. 130
1 Wiring loom, exhaust gas aftertreatment
BW 219 D-5 / BW 219 PD-5 153

B223
B224
B305 B214
B225
B215
B216
CSF
SCR
S-586-0250
Fig. 131: Sensors
154 BW 219 D-5 / BW 219 PD-5

X104
B59
Y30
S-586-0235
Fig. 132
1 Wiring loom, front frame
BW 219 D-5 / BW 219 PD-5 155

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. 133
2 Wiring loom, cabin internal
156 BW 219 D-5 / BW 219 PD-5

AZ 12 tachograph with connection

A12 Option
1
X205
P09
A16
S-586-0236
Fig. 134
1 Wiring loom, radio / tachograph
E21 radio
A12
A12:A
A12:B
X205 1
S-586-0237
Fig. 135
1 Wiring loom, radio adapter <> control console
BW 219 D-5 / BW 219 PD-5 157

E66 BOMAG Telematic Power

X6D
1 A124
A138
S-586-0238
Fig. 136
1 Wiring loom, Telematic
158 BW 219 D-5 / BW 219 PD-5

FS27 Electric anti-theft protection
X7B
180°
A67
X16
S-586-0239
Fig. 137
1 Wiring loom, immobilizer
BW 219 D-5 / BW 219 PD-5 159

K2 heating
F320
F321
XS28
X207
X76
X76
X7.C
Y14
S-586-0240
Fig. 138
1 Wiring loom, heater unit
2 Wiring loom, fuel pump
160 BW 219 D-5 / BW 219 PD-5

VM31 Bracket and cable BCM/GPS
X95A
1 A87
X91
2 3
X210
X96A
X211
X204
X93
X85
X90
S-586-0243
Fig. 139
1 Interface CAN-USB
2 Wiring loom BCM, Supply + CAN
3 Wiring loom GPS Power
BW 219 D-5 / BW 219 PD-5 161

VM33 BOMAG terrameter

X5.E
GND
180°
X107 A83
X88
2
X21
B171
X20
B62
S-586-0241
Fig. 140
1 Wiring loom, measuring computer
2 Wiring loom, acceleration transducer
162 BW 219 D-5 / BW 219 PD-5

VM20 Economizer
X109f
X109m
GND
2 180°
1 X5E3
XA161
X5E3
XA103
A103
180°
X39
X39
B84
S-586-0463
Fig. 141
1 Wiring loom, transducer for Economizer
2 Wiring loom, Economizer
BW 219 D-5 / BW 219 PD-5 163

VM38 measuring technology inter-

face
X400
X110
X7.C.2
A162
X5.E.2
X7.C.2
X5.E.2
2
S-586-0452
Fig. 142
1 Wiring loom, measuring technology interface
2 Wiring, measuring technology interface
164 BW 219 D-5 / BW 219 PD-5

M35 winter package
XR79
X67
R79
S-586-0453
Fig. 143
1 Wiring loom, adapter for fuel pre-heater
2 Fuel heater
BW 219 D-5 / BW 219 PD-5 165

4.2.4 CAN BUS overview
A87
P15
CAN 4
X400
A67
A161 A162
A162
A178
A161
CAN 3
A103
CAN 1
A15
A83
X34
A124
S55
A175
CAN 2
A124
A48
A34
A48
X32
S-586-0449
Fig. 144: CAN bus

A15 Monitoring module
A34 Travel control
166 BW 219 D-5 / BW 219 PD-5

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

was created by Bosch for applications in the automotive industry.
The objectives of this development was to ensure real-time, reli-
able and cheap communication between control units, such as
gearbox and engine control unit, but also less time-critical functions
in the area of convenience electronics, such as air-conditioning.
Why CAN? n Connection of control units to realise complex functions.
n Reduction of effort when installing cables and plug-in connec-
tions.
n Better possibilities for diagnostics (central diagnostics socket).
Features of CAN
It is a serial communication interface. The individual bits are trans-
ferred one at a time; only 2 lines are required.
CAN lines are twisted together 30 to 40 times per metre. Electro-
magnetic interferences always occur simultaneously in both lines,
which makes it easier for the software to filter out any interference
signals.
A unified colour assignment does not exist. Both wires may have
different colours, depending on the manufacturer.
At Bomag, a standard has been defined for the wires. Ä Fig. 145
Fig. 145 n Wire (+)
= cable colour blue
n Wire (-)
= cable colour yellow
Measuring at the CAN Signals transmitted through the bus line can generally not be
measured with simple measuring instruments. Testing is therefore
quite complicated for the user. Only the correct line connections
can be tested by means of a continuity test. For the fitter or user to
recognize faults or retrieve information from the BUS, BOMAG
connects display modules to the BUS.
BW 219 D-5 / BW 219 PD-5 167

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

120 Ohm. For an individual CAN bus device on a stub line, this
functions just like a single 60 Ohm resistor, which is installed at the
branch location.
168 BW 219 D-5 / BW 219 PD-5

4.2.5 List of equipment

This table contains all electrical components used in the machine,
except terminal strips and plugs.
Operating Function text Technical character-

equipment istics
A02 Direction indicator module
A12 Radio module
A34 Travel control
A48 ECU engine control unit
A67 Keyboard
A93 GPS Receiver
A108 Heating/air conditioning unit
B03 Air filter service switch
B11.1 Warning horn max. 3.5 A
B11.2 Warning horn max. 3.5 A
B21 Differential pressure switch for hydraulic oil filter
B51.L Radio loudspeaker
B51.R Radio loudspeaker
B55 Float switch in coolant compensation tank
B57 Cross-slope sensor speed range selection 0.5-4.5 V
B59 Rotary speed sensor for drum speed
B60 Rotary speed sensor for axle speed
B62 Acceleration transducer
B84 Acceleration sensor, left
B88 EMR engine oil pressure
BW 219 D-5 / BW 219 PD-5 169


equipment istics
B93 EMR fuel pressure rail
B97 Sensor slewing motor
B104 Pressure switch for air conditioning
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 fuel pressure
B171 Acceleration transducer
B208 EMR sensor Delta p Venturi
B209 EMR sensor temperature EGR after Venturi
B214 EMR temperature sensor exhaust gas before oxy catalytic
converter
B215 EMR temperature sensor exhaust gas after oxy catalytic con-
verter
B216 EMR sensor differential pressure DPF
B218 Temperature sensor for ambient temperature
B221 Sensor for urea pressure after pump
B222 Sensor, urea temperature and filling level
B223 Exhaust gas temperature sensor upstream of SCR catalytic
converter
B224 NOx sensor upstream of SCR cat
B225 NOx sensor downstream of SCR cat
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 counterpressure DPF before tur-
bocharger
B305 EMR pressure sensor, pressure after DPF
B312 Sensor for height adjustment of plates 4-20 mA
B313 Sensor for lateral adjustment of plates 4-20 mA
D2.1 Control light for relay K32
170 BW 219 D-5 / BW 219 PD-5


equipment istics
D05 Control light for relay K13
Dx Control lamp for fuse test
E08 Direction indicator, front left 21 W
E09 Direction indicator, rear left 21 W
E10 Direction indicator, front right 21 W
E11 Direction indicator, rear right 21 W
E12 Parking light, left 5W
E13 Tail light, left LED
E14 Parking light, right 5W
E15 Tail light, right LED
E16 Head lights, left 55 W
E17 Head lights, right 55 W
E23 Working head lights, front left 12 V, 55 W
E25 Working head lights, front right 12 V, 55 W
E27 Working head lights, rear left 12 V, 55 W
E28 Working head lights, rear right 12 V, 55 W
E29 Cabin light
E30 Heating unit
BW 219 D-5 / BW 219 PD-5 171


equipment istics
E32 Flashing beacon 12 V, 70 W
E72 Illumination of control switch
E104 Heating pressure line
E105 Heating suction line
E106 Heating of return line
E107 Heating supply module
F00 Main fuse for battery 125 A
F05 Fuse for socket 20 A
F07 Fuse for hazard light 10 A
F08 Fuse for direction indicator 10 A
F09 Fuse for parking and tail light, left 10 A
F10 Fuse for parking and tail light, right 10 A
F11 Fuse for front working head lights, left 15 A
F13 Fuse for starter switch 15 A
F17 Fuse for radio 5A
F19 Fuse for working head lights, front left 15 A
F22 Fuse for working head lights, rear 15 A
F23 Fuse for warning horns 15 A
F24 Fuse for monitoring module 10 A
F27 Fuse for wiper and washer, front 15 A
F28 Fuse for wiper and washer, rear 15 A
F29 Fuse for suspended seat compressor 15 A
F39 Main fuse for cabin 80 A
F40 Fuse for cabin heater 30 A
F48 Fuse for heating flange 150 A
F67 Fuse control (potential 30) 15 A
F68 Fuse for potential 30 15 A
F84 Fuse for control (contact 54) 10 A
F91 Fuse for sensors 5A
F95 Fuse for engine control unit 30 A
F103 Fuse for potential 15 15 A
F122 Fuse for engine control unit 10 A
F124 Fuse for fuel pre-heater 25 A
172 BW 219 D-5 / BW 219 PD-5


equipment istics
F129 Fuse MD+ 3A
F143 Fuse for rear windscreen heating 20 A
F150 Fuse for GPS receiver 5A
F157 Fuse for magnetic switch starter motor 30 A
F164 Fuse for B+ charge line 150A
F169 Fuse for starting current 5A
F238 Fuse for exhaust gas recirculation 15 A
F243 Fuse for BOMAG Telematic (potential 30) 7.5 A
F244 Fuse for BOMAG Telematic (potential 15) 5A
F250 Fuse for SCR control 30 A
F251 Fuse for NOx sensors 10 A
F264 Fuse for BCM05 10 A
F266 Fuse for radio/tachograph 10 A
F268 Fuse for fuel pump 20 A
F271 Fuse for BCM-Net 10 A
F272 Fuse for controller of cabin operating console 5A
F279 Fuse for spare 15 A
F310 Fuse for urea quality sensor 5A
F312 Fuse for spare max. 20 A
F313 Fuse for spare max. 20 A
F320 Fuse, timer for optional heater (potential 30) 5A
F321 Fuse, timer for optional heater (potential 15) 5A
Fx Fuse holder for fuse test
FM1 Fuse for sensors 1A
FM2 Fuse for sensors 1A
G01 Battery 12 V / 88/110 Ah
G02 Generator 14 V / 150 A
G03 Battery 12 V / 88 Ah
H06 Control light for hazard light
H07 Warning buzzer for malfunctions 70 mA
H14 Warning buzzer for reverse travel 300 mA
BW 219 D-5 / BW 219 PD-5 173


equipment istics
K05 Relay for start current 12 V / 25 A
K06 Relay for rear working head lights 12 V / 25 A
K09 Relay for air conditioning 12 V / 25 A
K11 Relay for potential 30 to 15 12 V / 70 A
K13 Relay for warning horn 12 V / 25 A
K14.1 Pre-heating relay
K16 Relay for working head lights, front 12 V / 25 A
K20 Relay for front windscreen wipers 12 V / 25 A
K21 Relay for rear windscreen wipers 12 V / 25 A
K22 Relay for engine shut-down solenoid actuator 12 V / 25 A
K32 Relay for cabin 12 V / 25 A
K38 Relay for starter control 12 V / 40 A
K39 Relay for starter motor
K41 Disconnecting relay 12 V / 25 A
K43 Relay for vibration 12 V / 25 A
K48 Relay for travel lever “0” position 12 V / 25 A
K61 Relay for charge control 12 V / 25 A
K141 Relay for rear windscreen heating 12 V / 25 A
K145 Relay for starter solenoid actuator 12 V / 40 A
K192 Relay for SCR control 12 V
K189 Brake relay 12 V
K193 Relay for heating urea feed module 12 V
K194 Relay for heating urea suction line 12 V
K195 Relay for heating urea throttle line 12 V
K196 Relay for heating urea pressure line 12 V
K209 Relay for fuel pump 12 V / 25 A
K227 Relay for potential 30 to 15 12 V
M01 Starter
M04 Windscreen wiper motor, front 4.7 A
M05 Windscreen wiper motor, rear 4.7 A
M06 Windscreen washer motor, front 3.5 A
M07 Windscreen washer motor, rear 3.5 A
M10 Compressor of air cushioned seat 12 V / < 9 A
174 BW 219 D-5 / BW 219 PD-5


equipment istics
M41 Urea pump
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 for driver's seat 12 V / 6.85 A
R10 Parallel resistor 82 Ω
R19 Heating flange 167 A
R20 Terminating resistor CAN 120 Ω
R33 Terminating resistor CAN 121 Ω/0.6 W
R34 Terminating resistor CAN 121 Ω/0.6 W
R40 Resistance 18.2 Ω/0.6 W
R79 Fuel pre-heating 200 W
R80 Rear windscreen heating approx. 11 A
S00 Starter switch
S01 Emergency stop switch
S06 Seat contact switches
BW 219 D-5 / BW 219 PD-5 175


equipment istics
S09 Switch front vibration
S14 Switch for hazard light
S15 Switch for StVZO lighting
S25 Switch for operator’s seat heating
S26 Switch for working lights
S28 Timer
S29 Switch for air suspended seat
S30 Battery isolator switch 250 A
S35 Switch, vibration low / high
S36 Switch, vibration of attachment plates
S37 Switch for direction indicator
S42 Travel stage switch
S55 Travel lever
S107 Switch for amplitude setting 4-20 mA
S127 Switch for engine speed
S139 Potentiometer, frequency setting for attachment plates
S299 Switch for regeneration mode
T14 Aerial for BOMAG TELEMATIC
T21 Radio aerial
V01 Diode S5G-E3
V02 Diode SF 64
V03 Diode SF 64
V04 Diode SF 64
V05 Diode SF 64
V06 Diode SF 64
V07 Diode S1M
V08 Diode S1M
V09 Diode S1M
V010 Diode S1M
Y04 Brake solenoid valve 2.41 A
Y07 Solenoid valve, front vibration high 640...1580 mA
Y08 Solenoid valve for front vibration, small 640...1580 mA
Y15 Magnetic clutch for air conditioning compressor 3.5 A
176 BW 219 D-5 / BW 219 PD-5


equipment istics
Y16 Solenoid valve for travel direction forward 640...1580 mA
Y17 Solenoid valve for travel direction backward 640...1580 mA
Y30 Solenoid valve for drum travel speed range 2.41 A
Y31 Solenoid valve for axle travel speed range 1.05 A
Y60 Solenoid valve for floating position
Y72 Solenoid valve for travel direction forward 640...1580 mA
Y73 Solenoid valve for travel direction backward 640...1580 mA
Y98 Solenoid valve, vibration pump for plates 400-1200 mA
Y102 Solenoid valve for floating position
Y122 Solenoid valve, plates up
Y123 Solenoid valve, plates down
Y137 EMR actuator
Y140 Solenoid valve exciter up 400-1200 mA
Y141 Solenoid valve exciter down 400-1200 mA
Y142 Solenoid valve, shift plates to the left
Y143 Solenoid valve, shift plates to the right
Y144 Solenoid valve, plates floating position
Y145 Solenoid valve, plates (priority)
Y147 Injector A1
Y148 Injector A2
Y149 Injector A3
Y166 Injector A4
Y169 Injector A6
Y170 Injector A5
Y174 EMR exhaust gas recirculation
Y261 EMR throttle valve for intake air
Y291 Solenoid valve for urea extraction system
Y292 Solenoid valve for urea tank heating
Y293 Solenoid valve for urea dosing
Y378 Solenoid valve for dozer blade priority
Y379 Solenoid valve for dozer blade up
Y380 Solenoid valve for dozer blade down
BW 219 D-5 / BW 219 PD-5 177

4.2.5.1 Table of operating means, comparison BOMAG Deutz

Comparison of operating means The BOMAG designations for the operating means of the diesel
designation BOMAG - Deutz engine are different from the Deutz designations. The following
table compares both designations.
BOMAG Deutz Designation

A48 D2 Engine control unit EMR4 (EDC 17-CV52)
B88 B6 EMR engine oil pressure

B93 B49 EMR fuel pressure rail
B113 B43 EMR coolant temperature sensor
B114 B40.1 EMR engine speed sensor 1
B130 B40.2 EMR engine speed sensor 2
B133 B48 EMR sensor charge air pressure / temperature
B145 B51 EMR low fuel pressure
B208 B61 EMR sensor Delta p Venturi
B209 B64 EMR sensor temperature EGR after Venturi
B214 B65 EMR temperature sensor exhaust gas before oxy catalytic converter
B215 B66 EMR temperature sensor exhaust gas after oxy catalytic converter
B216 B58 EMR differential pressure sensor DPF
B220 F80 Temperature sensor, ambient temperature
B221 B63 Sensor, urea pressure after pump
B222 B90 Sensor, urea temperature and filling level
B223 B78 Temperature sensor exhaust gas before SCR catalytic converter
B224 B54 Sensor NOx before SCR catalytic converter
B225 B56 Sensor NOx after SCR catalytic converter
B305 B88 EMR pressure sensor, pressure after DPF
E104 R Heating pressure line

E105 R Heating suction line
E106 R Heating of return line
E107 R Heating supply module
K14 K2 Pre-heating relay

K192 K31 Relay, SCR control
K193 K27 Relay, heating urea feed module
178 BW 219 D-5 / BW 219 PD-5

BOMAG Deutz Designation

K194 K28 Relay, heating urea suction line
K195 K29 Relay, heating urea throttle line
K196 K30 Relay, heating urea pressure line
M41 M10 Urea pump
X36 X39 Plug with wiring loom, EMR <> engine interface
X44 D2.1 (A) Plug with wiring loom, EMR <> engine interface
X45 D2.2 (K) Plug with wiring loom, EMR <> machine side
Y137 Y19 EMR actuator

Y147 Y15.1 Injector A1
Y174 Y20 EMR exhaust gas recirculation
Y261 Y35 Throttle valve for intake air
Y291 Y30 Solenoid valve for urea extraction system
Y292 Y31 Solenoid valve for urea tank heating
Y293 Y24 Solenoid valve for urea dosing
Deutz designations of operating means which are

not stated in this table, do not have a corre-
sponding BOMAG designation.
BW 219 D-5 / BW 219 PD-5 179

Electric systems – Starting the engine with jump leads
4.3 Starting the engine with jump leads
NOTICE!
A wrong connection will cause severe damage
in the electric system.
– Bridge the machine only with a 12 Volt auxiliary
battery.
1. Connect the plus pole of the external battery first with the
plus pole of the vehicle battery using the first jump lead.
2. Then connect the second battery cable first to the minus pole
of the current supplying auxiliary battery and then to engine
or chassis ground, as far away from the battery as possible.
3. Start the engine.
NOTICE!
Danger of damage to the electronic system!
If no powerful consuming device is switched on,
Fig. 146
voltage peaks may occur when separating the con-
necting cables between the batteries, which could
damage electrical components.
4. Once the engine is running switch on a powerful consumer

(working light, etc.).
5. After starting disconnect the negative poles first and the posi-
tive poles after.
6. Switch off the consumer.
180 BW 219 D-5 / BW 219 PD-5

Electric systems – Fuse assignment
4.4 Fuse assignment

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

Fuse Amperage Designation
F05 20 A 12-V socket
F07 10 A Hazard light
F08 10 A Direction indicators
F09 10 A Parking and tail light, left
F10 10 A Parking and tail light, right
F11 15 A Head lights, front
F13 15 A Starter switch
F19 15 A Working head lights, front
F22 15 A Working head lights, rear
F23 15 A Warning horn
F24 10 A Instrument cluster
F29 15 A Compressor - air suspended seat, seat heating
F39 80 A Main fuse for cabin
F40 30 A Heating, air conditioning, fan
F67 15 A Control (potential 30)
F68 15 A Reserve (potential 30)
F84 10 A Control (contact 54)
F91 5A Sensors
F122 10 A Engine control unit
F124 25 A Fuel pre-heating
F157 30 A Starter
F169 5A Start current
BW 219 D-5 / BW 219 PD-5 181


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
4.4.3 Main fuses

The main fuse box is located in the engine compartment.
Fig. 147

F164 150 A (B+) charge line
F00 125 A Main fuse (potential 30)
Fig. 148

F48 150 A Preheating system
182 BW 219 D-5 / BW 219 PD-5

4.4.4 Exhaust gas aftertreatment system

The fuse box for the exhaust gas aftertreatment system is located
in the engine compartment under the battery cover.

F238 15 A Exhaust gas recirculation
F250 30 A SCR control
F251 10 A NOx sensors
(NOx: Nitric oxides)
F310 5A Sensor for AdBlue®/DEF quality
F312 20 A Spare
F313 20 A Spare
4.4.5 Control console cabin
Fig. 149
Position Fuse Amperage Designation

1 F17 5A Radio
2 F264 10 A BCM
3 F271 10 A BCM net
4 F150 5A GPS
5 F266 10 A Radio/Tachograph
6 F143 20 A Rear windscreen heating
7 F28 15 A Rear windscreen wiper
8 F27 15 A Front windscreen wiper
BW 219 D-5 / BW 219 PD-5 183


9 F279 15 A Spare
10 F272 5A Control console cabin
4.4.6 Auxiliary heating
B-586-0424
Fig. 150

F320 5A Timer for auxiliary heating (potential 30)
184 BW 219 D-5 / BW 219 PD-5

Electric systems – Central electrics
4.5 Central electrics

4 6
5 7
3 X32
X34
2
1
X41
B57 A124
X100 - X109
8
A48 X45
A34
9
A83
10
S-586-0448

6 Power board
BW 219 D-5 / BW 219 PD-5 185

6 7
5
4
3 X41
8
2
1 X32
X100 - X109 A124
A161
X34
A162
B57
9
A34
A48
10
X45
A83
11
12
S-586-0447

186 BW 219 D-5 / BW 219 PD-5

Connector strip, old version
X32
X105 X34
X107 X109
X104
X108
X106
X101
X103
X102
X100
S-586-0226
Fig. 153
Connector strip, new version
X105
X107
X109 X110
X104
X106
X108
X103
X101
X102
X100
S-586-0468
Fig. 154
BW 219 D-5 / BW 219 PD-5 187

4.5.1 Power board

Solid press-fit technology for high-
current applications NOTICE!
Processing
– During assembly, installation and use, twisting
and warping of the assembly must not occur
under any circumstances.
– A printed circuit board must never be
machined, adjusted or manipulated in any
other way with sharp-edged or metallic tools;
neither may objects such as tools, screws, etc.,
be placed on a printed circuit board, as this
might damage the insulating solder resist and
conductor tracks.
– Fuses may only be replaced and not repaired
or bridged.
– Conductive contamination of the assembly or
contact with aggressive media (greases, oils,
cleaning agents, conductive dust, fertilizers,
etc.) must be avoided at all costs.
– The power board may only be put into opera-
tion after it has been installed.
S-ELE-0039
Fig. 155: Example figure of solid press-fit technology

In press-fit technology, a connection is made between the plated-
through sleeve of a printed circuit board and the contact pin, e.g. of
a plug connector. The result is a powerful, gas-tight electrical con-
nection between pin and sleeve, which also has an extremely low
electrical resistance. This makes the solid press-fit technology par-
ticularly suitable for use in the high-current range and in harsh
environmental conditions.
188 BW 219 D-5 / BW 219 PD-5

This has the following advantages:

n Particularly quick connection with the wiring loom of the vehicle
n Possibility of combining high-current and signal lines
n Highest possible avoidance of connecting and wiring faults
n Gain in space due to the possibility of compact design (e.g. by
placement from both sides) as well as weight reduction
n Increased reliability and prolonged lifetime of the overall
system
n Clear display of switching states by means of LEDs (simple
diagnostics)
S-586-0312
Fig. 156: Plug side

X0A Supply potential 30
X0B Supply GND
X0C Supply potential 30 before battery
BW 219 D-5 / BW 219 PD-5 189

K43/K78
30A
S-586-0313 F148/F25 F103/F41
Fig. 157: 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
On each relay is a green control LED which is activated parallel to
the coil. This indicates if the coil is energised.
190 BW 219 D-5 / BW 219 PD-5

K38
K41
K13
K145
K05
K61
K22
K209
K16
K43
K78 K09
K06
A02
K11
K48
S-538-0055
Fig. 158: Installed relays

A01 Flasher encoder
K05 Relay for start current
K06 Relay for working head lights
K09 Relay for air conditioning
K11 Relay for potential 30 to 15
K13 Relay for warning horn
K16 Relay for working head lights, front
K22 Relay for engine solenoid
K38 Relay for starter control
K41 Disconnecting relay
K43 Vibration relay for single drum roller
K48 Relay for travel lever “0” position
BW 219 D-5 / BW 219 PD-5 191

K61 Relay for charge control

K78 Relay for emulsion pump for BW 11 RH-5
K145 Relay for starter solenoid actuator
FM2 F19
FM1 F22
F243
F39
F157
F23 F268
F68
F11
F13 F84
F09 F67
F10 F07 F146
F124
F40
F91
F103 / F41
F08
F05
F244
F29
F24
F169 F122
F148 / F25 S-538-0056
Fig. 159: Installed fuses

1 Fuse test cap
192 BW 219 D-5 / BW 219 PD-5

Test base for fuses

The printed circuit board is equipped with a fuse test socket (fuse
test). When plugging in an intact fuse, the LED "DX" lights up.
Fig. 160: Pictogram
BW 219 D-5 / BW 219 PD-5 193

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

4.6.1 CPU control units and electrical modules.............. 194
4.6.2 Power board for SCR-heating................................ 199
4.6.4 Sensors and actuators........................................... 202
4.6.1 CPU control units and electrical modules

Control units (ECU = electronic control unit or ECM = electronic
control module) are electronic modules which are mainly installed
in places where something needs to be controlled or regulated.
Control units are used in many electronic sectors in the automotive
industry, as well as for controlling machines, plants and other tech-
nical processes.
Control units generally work according to the IPO model. IPO
stands for input-process-output. Sensors are available for the
input. They determine a physical parameter like e.g. speed, pres-
sure, temperature etc. This value is then compared with a calcu-
lated or fixed nominal value that has been entered into the control
unit. If the measured value does not match the stored value, the
control unit regulates the physical process by means of actuators,
so that the measured actual values match the nominal values
again. This means that the actuators correct the running process.
In modern vehicles, control units are connected to each other via
system buses (CAN bus). The units exchange information
throughout the vehicle’s system, such as the operating states and
other relevant data. Furthermore, the on-board diagnostics or the
diagnostic system of the vehicle are connected by means of these
buses (and possible K-lines). Furthermore, external diagnostic
devices (alternatively normal personal computers or laptops with a
matching interface) can communicate with the control units. In this
case, the system will be prompted to find out whether the constant
self tests of the control unit have revealed and registered any faults
in the system or on the connected sensors.
194 BW 219 D-5 / BW 219 PD-5

Travel control (A34) and measuring

technology control (A83)
Fig. 161
The freely programmable control unit is an independently-working
measuring- and control device for managing the sensors and
actuators. It can process multiple independent or connected tasks
in real time.
All inputs and outputs are protected against overvoltage and short
circuits and are diagnosable.
A sturdy aluminium die cast housing (protection class IP 65, opt. IP
67, with a GORE-TEX ® membrane for pressure compensation)
not only ensures high protection against electromagnetic interfer-
ences, but also provides reliable protection against mechanical
stress.
BW 219 D-5 / BW 219 PD-5 195

Component description of engine

control unit, A48
EDC17
Fig. 162
Designation Technical data

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

n Injection quantity
n Injection timing
n Injection rate (number of injections)
n Injection pressure (rail pressure)
n Exhaust gas aftertreatment system
The ECU is also equipped with:
n Fault log
n Diagnostic function
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).
196 BW 219 D-5 / BW 219 PD-5

The Deutz part-number specified on the EMR-con-

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

A162
S-870-0191
Fig. 163
A gateway is an electronic device that enables the connection of
different network technologies.
The CAN gateway is a compact device for automotive applications.
It can be used for a whole range of applications thanks to its small
size and easy installation.
BW 219 D-5 / BW 219 PD-5 197

4.6.1.1 Electronic module for air conditioning, A108
Fig. 164
1 Switch for fresh air (S44)
2 Rotary switch for air conditioning
3 Cabin fan (M09)
B104 Pressure switch for air conditioning
Y15 Solenoid valve for air conditioning compressor
198 BW 219 D-5 / BW 219 PD-5

4.6.2 Power board for SCR-heating
X302
X301
K192
F313/2
K196
K195 X300/30
F312/2
K194 K227
K193
X300/31
F251 F310 F238 F250 F313 F312

S-586-0245
Fig. 165
K192 Relay, SCR control
K193 Relay, heating Urea feed module
K194 Relay, heating Urea suction line
K195 Relay, heating Urea throttle line
K196 Relay, heating Urea pressure line
BW 219 D-5 / BW 219 PD-5 199

4.6.3 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. 166
K20 Relay for front windscreen wipers
K21 Relay for rear windscreen wipers
K32 Relay for cabin
K141 Relay for rear windscreen heating
X200 Potential 30, power supply
X201 Potential 31, ground
X202 Connection of power board
X203 Connection for cabin equipment
X204 Connection BCM and printer
X205 Connection radio and tachograph
X206 Connection of optional headlights
200 BW 219 D-5 / BW 219 PD-5

Fig. 167
Push button assignment

Pos. Designation Note
1 Side lights/additional illumination left Optional equipment
2-7 not used
8 Side lights/additional illumination right Optional equipment
9 Rear windscreen wiper Interval/on/off
10 Washer nozzles for rear windscreen
11 Rear windscreen heating The rear windscreen heating is switched
off after three minutes.
12 Rear working lights
13 Cabin light
14 Front working lights
15 Flashing beacon
16 Washer nozzles for front windscreen
17 Front windscreen wiper Interval/on/off
BW 219 D-5 / BW 219 PD-5 201

4.6.4 Sensors and actuators

4.6.4.1 Acceleration transducer, B62 & B171................. 202
4.6.4.2 Differential pressure switch for hydraulic oil filter,
B21..................................................................... 203
4.6.4.3 Air filter vacuum switch, B03............................... 203
4.6.4.4 Sensor, water in fuel, B124................................. 204
4.6.4.5 Float switch coolant tank, B55............................ 204
4.6.4.6 Level sensor in diesel tank (R03)....................... 205
4.6.4.7 Charge control light............................................. 205
4.6.4.1 Acceleration transducer, B62 & B171
Fig. 168
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.
202 BW 219 D-5 / BW 219 PD-5

The piezoelectric acceleration sensor comprises two basic compo-

nents:
n Piezoelectric material
n Seismic mass
Once side of the piezo disc is connected with the seismic mass,
the other one with a rigid carrier. When this combination is set to
oscillate, the seismic (sluggish) mass transfers a force to the piezo
disc. According to Newton's Law the resultant force is the product
of acceleration and mass. The piezoelectric effect generates a
charge (u) on the electrodes, which is proportional to the force and
Fig. 169 thus also to the acceleration (a).
1 Seismic mass (m)
2 Piezoelectric material
3 Acceleration (a)
4.6.4.2 Differential pressure switch for hydraulic oil filter, B21

The differential pressure switch switches to ground at a pressure
differential of Δp 3.6 bar.
Hydraulic oil filter warning light: The switching condition is
detected by the ESX-control (A34) and forwarded to the instrument
cluster (A15) via the CAN bus connection.
Designation Note
Hydraulic oil Lights up if the hydraulic oil filter is
filter warning blocked. Warning buzzer sounds. The
light engine is shut down after approx. 2
minutes.
Check the hydraulic system and
Fig. 170
replace the hydraulic oil filter.
4.6.4.3 Air filter vacuum switch, B03

At a vacuum of > 50 mbar the vacuum switch (1) will switch to
ground.
Air filter warning light: The switching condition is detected by the
ESX-control (A34) and forwarded to the instrument cluster (A15)
via the CAN bus connection.
Designation Note
Air filter Lights up if the air filter is blocked.
warning light
Clean or replace the air filter.
Fig. 171
BW 219 D-5 / BW 219 PD-5 203

4.6.4.4 Sensor, water in fuel, B124

The sensor data are detected by the EMR control (A48) and
passed on to the instrument cluster (A15) via the CAN-bus connec-
tion.
Designation Note
Water in fuel Lights up when the water content in
warning light the fuel pre-filter reaches the sensor
contacts. The warning buzzer
sounds.
Clean the water separator.
Fig. 172
4.6.4.5 Float switch coolant tank, B55

In case of a too low coolant level the float switch will switch to
ground.
Coolant level warning light: The switching condition is detected
by the ESX-control (A34) and forwarded to the instrument cluster
(A15) via the-CAN bus connection.
Designation Note
B55
Coolant level Lights up if the coolant level is too
warning light low. The engine is shut down after a
short while.
Check coolant level, check cooling
system for leaks, repair if necessary.
S-921-0202
Fig. 173
204 BW 219 D-5 / BW 219 PD-5

4.6.4.6 Level sensor in diesel tank (R03)

The sensor inside the tank is equipped with a float, which drops or
rises with the fuel level. Contact springs mounted on the float
thereby slide along two resistor wires arranged parallel to the
movement of the float and generate a resistance value, which is
proportionate to the fluid filling level. The corresponding resistance
value is measured by an electric meter and displayed as fluid level
value.
Fig. 174: 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. 175: A15
4.6.4.7 Charge control light

Charge control light: The switching condition on the generator
terminal (D+) is detected by the ESX control (A34) and forwarded
to the instrument cluster via the CAN bus connection.
Designation Note
Charge control Lights up if the battery is not being
light charged.
Check V-belt, if necessary repair the
generator.
Fig. 176
BW 219 D-5 / BW 219 PD-5 205

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.
206 BW 219 D-5 / BW 219 PD-5

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

4.7.1 Electrics training machine control
BW 219 D-5 / BW 219 PD-5 207

Service Training
Electrics
Single Drum Rollers – 5
Version 01:05
Version/Status: V01:05 / 02/04/2019

Author: Brand / EE
1/125
208 BW 219 D-5 / BW 219 PD-5

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

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

3.3.1 Meaning of the firmware number......................................................................................19
4 Fault log – displaying and deleting ............................................................................20

4.1 Showing logged faults .......................................................................................................20
4.1.1 Code 700 with two-colour display .....................................................................................20
4.1.2 Code 700 with multi-coloured display ...............................................................................20
4.1.3 Switching off function “Show stored faults”.......................................................................21
4.1.4 Deleting all stored faults ...................................................................................................21
4.2 Deleting engine control unit fault log ...............................................................................22
4.2.1 Deleting logged engine faults ...........................................................................................22
4.2.2 Deleting active engine faults ............................................................................................22
5 Settings and queries ...................................................................................................23

5.1 Setting the machine type ...................................................................................................23
5.1.1 BW145 D/DH/PDH ...........................................................................................................23
5.1.2 BW177 D/DH/PDH/BVC ...................................................................................................24
5.1.3 BW197 DH .......................................................................................................................24
5.1.4 BW211 D/PD/DH/PDH .....................................................................................................25
5.1.5 BW212 D/PD/DH..............................................................................................................25
5.1.6 BW213 D/DH/PDH/BVC ...................................................................................................26
5.1.7 BW214 D ..........................................................................................................................26
5.1.8 BW216 D/PD/DH/PDH .....................................................................................................27
5.1.9 BW219 D/PD/DH/PDH/BVC .............................................................................................27
5.1.10 BW226 DH/PDH/BVC/DI/RC............................................................................................28
5.1.11 Procedure for initial commissioning of a control ...............................................................29
5.1.11.1 4-button travel lever ..................................................................................................... 29
5.1.11.2 7-, 8- or 9-button travel lever ........................................................................................ 29
5.1.12 Procedure for changing a machine type ...........................................................................29
5.2 Driving against the closed brake ......................................................................................30
5.3 Automatic detection of surge currents in travel system (information code 1090) ......31
5.3.1 Procedure.........................................................................................................................32
5.4 Display of coil current on the travel pump ......................................................................33
5.4.1 Procedure.........................................................................................................................33

Author: Brand / EE 2/125
BW 219 D-5 / BW 219 PD-5 209

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

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

210 BW 219 D-5 / BW 219 PD-5

5.26 Carrying out calibration of ECONOMIZER (information code 4081) .............................48

5.26.1 Procedure.........................................................................................................................48
5.27 Reading out counter for “Regeneration suppressed” ....................................................49
5.27.1 Procedure.........................................................................................................................49
5.28 Deleting counter for “Regeneration suppressed” ..........................................................49
5.28.1 Procedure.........................................................................................................................49
5.29 Activating/deactivating the dozer blade...........................................................................50
5.29.1 Procedure.........................................................................................................................50
5.30 Activating/deactivating the attachment plates ................................................................51
5.30.1 Procedure.........................................................................................................................51
5.31 Activating/deactivating the reversing lock with lowered attachment plates ...............51
5.31.1 Procedure.........................................................................................................................51
5.32 Adjusting the plates despite missing sensors ................................................................52
5.32.1 Procedure.........................................................................................................................52
5.33 Setting the cross-slope sensor (information code 1265) ...............................................53
5.33.1 Procedure.........................................................................................................................53
5.34 Displaying the cross slope ................................................................................................53
5.34.1 Procedure.........................................................................................................................53
5.35 Flushing the double pumps hydrostatically ....................................................................54
5.35.1 Procedure.........................................................................................................................54
5.36 Testing double pumps individually ..................................................................................55
5.36.1 Procedure.........................................................................................................................55
5.37 Setting the coolant filling level sensor.............................................................................56
5.37.1 Procedure.........................................................................................................................56
5.38 The “Water in fuel” sensor shuts down the engine ........................................................56
5.38.1 Procedure.........................................................................................................................56
5.39 Performing the EOL test (information code 5180) ..........................................................57
5.39.1 Procedure.........................................................................................................................57
6 Other explanations ......................................................................................................58

6.1 Extended machine functions.............................................................................................58
6.1.1 Hydraulicoil filter monitoring .............................................................................................58
7 Replacement of components .....................................................................................59

7.1 How to proceed when replacing components .................................................................59
7.2 Replacement of an ESX control ........................................................................................59
7.3 Replacement of a travel pump / axle drive motor / drum drive motor ..........................59
7.4 Replacement of a vibration pump / vibration motor .......................................................59
7.5 Component replacement without adjustment procedure ..............................................60
8 Description of the signals on the ESX control ..........................................................61
9 Description of signals on the travel lever ..................................................................67
10 Descriptions of signals on the display ......................................................................69
11 Fault codes of the ESX control ..................................................................................71

BW 219 D-5 / BW 219 PD-5 211

12 Input codes of the ESX control ..................................................................................72

13 History .........................................................................................................................72
14 Terminology in connection with ESX.........................................................................73

212 BW 219 D-5 / BW 219 PD-5

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

1.00 23/06/2015 Version 1.00 for single drum rollers -5 created. Brand
1.01 22/11/2016 Functional supplements. Brand

BW 219 D-5 / BW 219 PD-5 213

1.2 Software
Vers. Date Description of changes resp.

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

214 BW 219 D-5 / BW 219 PD-5


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

BW 219 D-5 / BW 219 PD-5 215


V 3.14 09/08/2016 Fault “Communication machine on test stand” rectified. Brand
Engine speed low idle for TCD6.1 adjusted.
Emergency stop function adjusted.
Saving parameters on the display added.
V 3.15 15/11/2016 Fault “Vibration at standstill” rectified. Brand
BW211 PD Tier 3 released.
V 3.16 16/11/2016 Parameter fault ECOstop on Tier 3 machines rectified. Brand
V 3.17 08/06/2017 Plates held in top position. Brand
V 3.18 04/08/2017 Fault “Backward travel with lowered plates” rectified. Brand
V 3.19 08/08/2017 Input code “Display of backward travel with lowered Brand
plates activated” added.
V 3.20 20/10/2017 Fault in regeneration switch/button rectified. Brand
The software V3.xx has been replaced by the software V5.yy and will not be further maintained.
If a machine still has software V3.xx, the version V 3.20 has to be installed first and then version
V 5.yy.

216 BW 219 D-5 / BW 219 PD-5


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

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

BW 219 D-5 / BW 219 PD-5 217


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

218 BW 219 D-5 / BW 219 PD-5


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

BW 219 D-5 / BW 219 PD-5 219

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

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

aftertreatment
5161 5153 5154

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

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

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

220 BW 219 D-5 / BW 219 PD-5

2 Known faults
Despite the fault monitoring of inputs and outputs on the ESX control, the ESX control is not able to
detect all faults. The following list contains a selection of known fault reactions of the control, which
mostly have a different cause to the one described in this documentation.
Effect: Cause:
Fault code 5100, 5140 and engine does not Switch the ignition off and on and restart the
respond to full speed switch or travel lever machine immediately.

BW 219 D-5 / BW 219 PD-5 221

3 The diagnostics system

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

warning
triangle
Fault message
* *
Warning
* *
Note
* *
Display and measuring Values ranging from 0000-9999
values to be called up via input codes
Parameter setting Values ranging from 0000-9999
to be called up via input codes
Negative display values are identified by a “minus sign”.
If several faults are detected, the displayed fault codes will change in a 3 second cycle.
Version/Status: V01:05 / 02/04/2019 Functions of ESX Control

222 BW 219 D-5 / BW 219 PD-5

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

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

3.2.1.1 Calling up service mode

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

Input mode starts with flashing of the left hand digit. There is the option here of switching to service
mode using access code “9999”. The “INFO 1” button is used to increase (briefly press the button) or
reduce (press the button for approx. 3 seconds) the values at the relevant position. By pressing the
“INFO 2” button briefly, the next (right) digit can be selected. Once the last right hand digit has been
entered, the code will be transferred to the control by briefly pressing the “INFO 2” button once again.
To go back one position to the left, the “INFO 2” button must be pressed longer (approx. 3 seconds).
If the access code has been entered correctly, the “Spanner” symbol is displayed and the first input
digit flashes again. Individual operating states of the machine can now be requested by transferring
the input code to the control (as described above).
By pressing both INFO buttons again for approx. 3 seconds, another input code can be entered. The
service mode is quit by entering code “0000” or by switching the ignition off.
If the travel lever is shifted out of the brake lock while in service mode, all machine functions will
become active, with the exception of the display, which remains in service mode and continues to
display the operating values requested last.

BW 219 D-5 / BW 219 PD-5 223

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

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

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

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

2: – button (green button)

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

3: – button (green button)


224 BW 219 D-5 / BW 219 PD-5

3.2.2.1 Calling up service mode

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

Input mode starts with flashing of the left hand digit. There is the option here of switching to service
mode using access code “9999”. The green buttons can be used to increase or reduce the values of
the corresponding digit. By pressing the right hand blue button, the next (right) digit can be selected.
Once the last right hand digit has been entered, the code will be transferred to the control by pressing
the right hand blue button once again. To go back one position to the left, the left hand blue button
must be pressed.
If the access code has been entered correctly, the “Spanner” symbol is displayed and the first input
digit flashes again. Individual operating states of the machine can now be requested by transferring
the input code to the control (as described above).
By pressing both INFO buttons again for approx. 3 seconds, another input code can be entered. The
service mode is quit by entering code “0000” or by switching the ignition off.
If the travel lever is shifted out of the brake lock while in service mode, all machine functions will
become active, with the exception of the display, which remains in service mode and continues to
display the operating values requested last.

BW 219 D-5 / BW 219 PD-5 225

3.3 Querying firmware version
The firmware or software version of the travel control can be displayed using input code “0555”
(see appendix with input codes).
3.3.1 Meaning of the firmware number
The firmware version is displayed in the following layout:
V[Version].[Revision]
Example: A firmware version with the number V4.59 contains the following information:
- Version = 4
- Revision = 59
Version number:
Any change to the version number requires a change in the part number of the control.
Exchanging controls with different part numbers is not intended.
When flashing a fimware, make sure that it "matches" the control to be flashed (part number blank).
Revision number:
Any change in revision number indicates a change of the firmware while the part number remains
unchanged. The firmware is downwards compatible to firmware versions with the same version
number.

226 BW 219 D-5 / BW 219 PD-5

4 Fault log – displaying and deleting

4.1 Showing logged faults
There are two possibilities of displaying the logged faults:
4.1.1 Code 700 with two-colour display
• Enter code number “0700” (WITHOUT service code “9999”). This code number enables the
function “Show stored faults”.
The faults stored in the ESX are displayed in flashing mode. If several faults are stored, these are
successively displayed in cycles of 3 seconds. After the last fault has been displayed, the first fault will
appear again. If no fault is stored, “-----” is shown on the display.
4.1.2 Code 700 with multi-coloured display
• Enter code number “0700” (WITHOUT service code “9999”). This code number enables the
The faults stored in the ESX are displayed in the centre of the
display. If several faults are stored, these are successively
displayed in cycles of 3 seconds. Below the red triangle, the index
of the displayed fault and the total number of faults is shown. After
the last fault has been displayed, the first fault will appear again.
In the image on the top right this would mean:

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

the display (see image below right).

BW 219 D-5 / BW 219 PD-5 227

4.1.3 Switching off function “Show stored faults”
To switch off the function “Show stored faults”, proceed as follows:
• Enter code number “0701” (WITHOUT service code “9999”). This code number disables the
4.1.4 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 “0710” (!WITHOUT service code 9999).
• Switch the ignition off and on again.
All stored faults are now deleted.
The stored faults can only be deleted when the engine is not running.
i Note

228 BW 219 D-5 / BW 219 PD-5

4.2 Deleting engine control unit fault log

4.2.1 Deleting logged engine faults
Execute the function “Delete all logged faults in engine control unit”:
• Service code “9999”.
• Enter code number “0760”.
All stored engine faults are now deleted.
4.2.2 Deleting active engine faults

Execute the function “Delete all logged faults in engine control unit”:
• Service code “9999”.
• Enter code number “0761”.
All active engine faults are now deleted.

BW 219 D-5 / BW 219 PD-5 229

5 Settings and queries

5.1 Setting the machine type
Since the same control software is used for all single drum rollers of generation 5 (with electronically
controlled engines), the control must be matched to the machine in which it is actually installed (setting
the machine type).
This is necessary during commissioning as well as in case of a spare parts replacement.
This type setting is necessary, because different machine types/variants can have different parameter
sets, e.g. different wheel or axle drive motors (different numbers of pulses) or electrically different
hydraulic components (valve spools), or may be equipped with attachment plates or other optional
equipment.
For simple checking of the currently set machine type simply enter the code “0720”.
EXAMPLE: Machine code for BW 213 D: 7223
• Parameter adjustments can only be made when the engine is not

i Note running!
• This function can only be activated/deactivated when the travel lever

is locked in the brake gate. ( Input mode).
The following machine types can be adjusted:
5.1.1 BW145 D/DH/PDH
Exhaust First Last Machine

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

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

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

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

230 BW 219 D-5 / BW 219 PD-5

5.1.2 BW177 D/DH/PDH/BVC

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

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

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

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

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

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

BW 219 D-5 / BW 219 PD-5 231

5.1.4 BW211 D/PD/DH/PDH

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

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

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

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

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

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

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

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

7222
Stage V 101 587 18 1001 101 587 18 XXXX

232 BW 219 D-5 / BW 219 PD-5

5.1.6 BW213 D/DH/PDH/BVC

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

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

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

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

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

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

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

BW 219 D-5 / BW 219 PD-5 233

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

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

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

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

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

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

101 586 32 1001 101 586 32 XXXX

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

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

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

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

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

234 BW 219 D-5 / BW 219 PD-5

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

101 586 41 1001 101 586 41 XXXX

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

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

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

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

BW 219 D-5 / BW 219 PD-5 235

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

• Switch the ignition on. After switching on, the inscription “CODE” is displayed for approx. 3 seconds.
After this the display changes and shows code “7200”.
5.1.11.1 4-button travel lever

• Use the INFO 1 button to select the correct machine type code from the listed codes.
• Confirm the selection with the INFO 2 button.
• After a short while (< 10 seconds), the new parameters are loaded, in accordance with the set
machine type. Do not switch the ignition off during this time!
• After this switch the ignition off and on again to accept the configuration.
• After this the normal display will appear again.
5.1.11.2 7-, 8- or 9-button travel lever

• Use the green buttons to select the correct machine type code from the listed codes.
• Confirm the selection with the right hand blue button.
5.1.12 Procedure for changing a machine type
• Enter code number “9999” (activation of service mode).

• Enter code number “7010”. This code number activates the function “Adjusting machine type”.
• The display module now permanently shows the code “7200”.
• According to the tables above, select and confirm the machine code (like described in chapter
5.1.11.1 or 5.1.11.2). After confirming, the control switches automatically off and on again.
A machine must not be operated with a wrong type setting, because in

i Note such a case the correct function of the control cannot be assured!
New controls are delivered with a default machine type setting “7200”.
This does not enable to drive or steer the machine. It only serves the
purpose of commissioning.

236 BW 219 D-5 / BW 219 PD-5

5.2 Driving against the closed brake

After entering code number “0500”, the brake will not be released. If the travel lever is disengaged
from the brake gate and moved in any travel direction, the travel pumps will be triggered according to
the chosen travel direction. At the same time, the pressure in the hydraulic travel circuit is shown on
the display. The brake control light in the LCD display remains activated.
In order to terminate this function and to release the brake either enter code number “0501” or switch
the ignition off. After entering code number “0501”, the function is aborted and “OK” is displayed as
confirmation for 5 seconds. After this the code needs to be entered again.
This function can only be activated/deactivated when the travel lever is

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

BW 219 D-5 / BW 219 PD-5 237

5.3 Automatic detection of surge currents in travel system

(information code 1090)
For a sensitive and exact function of the travel system the surge currents in the travel system must be
determined for both travel directions. The surge currents are automatically determined after entering a
code number, so that no electric meter is required.
The surge currents must only be determined during initial commissioning in the factory, after a service
during which the control of the travel pump or the complete travel pump has been replaced or after the
replacement of the ESX control.
The measurement is identical for both travel directions: after entering the respective code number the
current is increased by the control solenoid of the travel pump in small steps, starting from 580mA.
After each current increase the system waits for 3 seconds. If a considerable axle or drum movement
is measured during the waiting time, the surge current is reached. In order to enhance the measuring
result this measurement is performed several times. The mean value of the measured values
represents the final surge current. This surge current is automatically stored and is valid from the next
start of the machine.
Before the measurement, always make sure that the machine is parked on level ground and has a
sufficient distance for movement to front and back, because the machine will move to the respective
direction when performing the measurement.
Attention! First set the machine to input mode (code “9999”). Make absolutely sure that the speed
sensors work correctly. For function testing, enter the code number “1116” (sensor on axle, available
on all machines) or the code number “1106” (sensor on drum, DH/BVC machines only) into the
display module. This code can be used to display the number of path pulses from the speed sensor.
The displayed value must change when the machine is driven.
If this value does not change even though the machine is moving, the measurement must not
be performed!
The speed sensor must first be restored to its proper condition, as otherwise the movement of the
machine will not be detected. (See also: “Resetting the surge currents in the travel system”)
During the measurement the machine will move when the surge current is
! Danger reached!
Do not leave the machine while the measurement is progressing!
Please take notice of the emergency stop button to be able to quickly shut
down the machine if this is required.
During the measurement, watch your environment and interrupt the

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

238 BW 219 D-5 / BW 219 PD-5

5.3.1 Procedure
• The speed selection switch must be in position ECO

• If necessary, enter code number “9999” to access the service mode.
• Then enter code number “1090”. This code number activates the function “Automatic detection of
surge currents in the travel system”; the display now shows the reading “0000” 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
function again after the teach function has been completed or the machine has been
restarted.
• The measurements (forward/reverse) must be started by entering a code number. The code
number required to teach the travel direction is as follows:
Determination of control surge currents 1091
• After the input of the above code number, the display shows “FORW”. Shifting the travel lever
forward starts the first surge current measurement for forward travel.
• During the measurement the actual current is displayed (display value = current in mA).
• Once the surge current measurement in forward is finished, the display will show the reading “OK”
for a period of 5 seconds.
• After this wait time, the display reading changes to “BACK”. Now shift the travel lever backward to
start the surge current measurement in reverse.
• During the measurement the actual current is displayed (display value = current in mA).
• After completion of the measurement in reverse, the display will show “OK” again.
• The travel lever must now be returned to braking position.
• Once both surge currents have been taught correctly and the travel lever is in “braking position”,
the display shows the reading ”DONE”, 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 be aborted at any time by means of the emergency stop or the ignition
switch.

BW 219 D-5 / BW 219 PD-5 239

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

240 BW 219 D-5 / BW 219 PD-5

5.5 Display of pressure on the travel pump
5.5.1 Procedure for DH/PDH/BVC/DI/RC machines
Input Description
• 1270 Display of pressure on travel pump axle forward in bar.
Pressure sensor, B234.
or
• 1275 Display of pressure on travel pump axle reverse in bar.
or
• 1280 Display of pressure on travel pump drum forward in bar.
or
• 1285 Display of pressure on travel pump drum reverse in bar.
• The display now shows the chosen travel pressure in bar.
5.5.2 Procedure BW145/177 D-machines
Input Description
• 1270 Display of pressure on travel pump forward in bar.
Pressure sensor, B234
or
• 1275 Display of pressure on travel pump reverse in bar.
• The display now shows the chosen travel pressure in bar.
5.6 Display of pressure on the vibration pump
5.6.1 Procedure BW145/177 D-machines
Input Description
• 3270 Display of pressure on vibration pump low amplitude in bar.
or
• 3275 Display of pressure on vibration pump high amplitude in bar.
• The display now shows the chosen vibration pressure in bar.

BW 219 D-5 / BW 219 PD-5 241

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

242 BW 219 D-5 / BW 219 PD-5

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

BW 219 D-5 / BW 219 PD-5 243

5.9 Ports BW211-226 DH/PDH/BVC/DI/RC
pump axle
Y17
Y16
Travel
X56
Travel pump
Y73
Y72
drum
X55
X58
Y07
Y08
X57
Vibration pump
BW211-226 DH/PDH/BVC/DI/RC
X55 B234 1210, 1211 or 1212 1270, 1271, 1272 or 1273
X56 B235 1220, 1221 or 1222 1274, 1275, 1276 or 1277
X57 B236 1240, 1241 or 1242 1284, 1285, 1286 or 1287
X58 B237 1230, 1231 or 1232 1280, 1281, 1282 or 1283

244 BW 219 D-5 / BW 219 PD-5

5.10 Activating / deactivating the pressure override

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

BW 219 D-5 / BW 219 PD-5 245

5.11 Calibrating the speed detection (calibration of wheel diameter)
5.11.1 Procedure
Input Description
• 1160 Allow function “Calibrate the speed detection”.
• 1161 Start function “Calibrate the speed detection” for a 5 m distance.
or 1162 for 10m distance
• The display shows: “FORW”: Move the travel lever forward (or back).
• 1168 Load original value.
• 1169 Save the values.
5.11.2 Explanation
The function “Calibrate speed detection” offers the possibility to calibrate the internal calibration
value of the speed detection.
For this purpose the input code “1160” (enable function) and “1161 - 1165” (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 “1169” and is now a valid
criterion for the speed detection.
With the input code “1168” it is also possible to adjust the basic values (“1160"-> “1168”).
Attention! If the speed detection is extremely falsified because of

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

246 BW 219 D-5 / BW 219 PD-5

5.12 Show pulses per 10 metres
5.12.1 Procedure

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

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

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

BW 219 D-5 / BW 219 PD-5 247

5.15 Showing the pulses of the rotary speed sensor
5.15.1 Procedure

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

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

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

248 BW 219 D-5 / BW 219 PD-5

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

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

BW 219 D-5 / BW 219 PD-5 249

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

i Note the software. Only switch the ignition on, do NOT start the machine!
On machines of generation -5 the software always assumes that there is a cabin. If a machine has no
cabin, the fault 9109 appears on the display and the cabin needs to be deactivated.
5.19.1 Procedure
Input Description
• 8821 Enable function “Activate or deactivate cabin”.
• 8822 Activate the cabin.
or
• 8823 Deactivate the cabin.
• Use code 8820 to check, whether the cabin is active (0 – ROPS; 1 – cabin).

250 BW 219 D-5 / BW 219 PD-5

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

i Note
5.20.1 Procedure with 4-button travel lever
Input Description
• 4010 Enable the function “Adjust serial number”.
• 4011 Adjust the serial number.
• The display now shows the value “1001” which can be edited with the two yellow buttons.
• If the correct serial number was adjusted, the number can be confirmed with the orange button.
The display shows for 5 seconds “OK”.
• With the help of the input code “4019”, the complete serial number can be shown on the display.
• With codes “4012”, “4013” or “4014”, the other three blocks of the serial number can also be
adjusted. However, this should only be made, if they do not contain the correct value.
5.20.2 Procedure with 7-, 8- or 9-button travel lever
Input Description
• 4010 Enable the function “Adjust serial number”.
• 4011 Adjust the serial number.
• The display now shows the value “1001” which can be edited with the two green buttons.
• If the correct serial number was adjusted, the number can be taken on with the right blue button.
The display shows for 5 seconds “OK”.
• With the help of the input code “4019”, the complete serial number can be shown on the display.
• With codes “4012”, “4013” or “4014”, the other three blocks of the serial number can also be
adjusted. However, this should only be made, if they do not contain the correct value.

BW 219 D-5 / BW 219 PD-5 251

5.21 Activating/deactivating the measuring technology
During the input, the diesel engine of the machine should not be running!
i Note Any change to the setting of the measuring technology will only become
effective after switching the ignition off and back on again!
If the machine is equipped with measuring technology, it most certainly needs to be activated. This
also applies for a possibly installed printer.
5.21.1 Procedure
Input Description
• 3011 Enable function “Activate or deactivate measuring technology”.
• 3012 Activate the measuring technology.
or
• 3013 Deactivate the measuring technology.
• Use code 3010 to check, whether the measuring technology is active.
5.22 Activating/deactivating the printer
i Note Any change to the setting of the printer will only become effective after
switching the ignition off and back on again!
5.22.1 Procedure
Input Description
• 3016 Enable function “Activate or deactivate printer”.
• 3017 Activate the printer.
or
• 3018 Deactivate the printer.
• Use code 3015 to check, whether the printer is active.

252 BW 219 D-5 / BW 219 PD-5

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

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

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

BW 219 D-5 / BW 219 PD-5 253

5.24 Carrying out the acceleration transducer position test

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

254 BW 219 D-5 / BW 219 PD-5

5.25 Activating ECONOMIZER

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

BW 219 D-5 / BW 219 PD-5 255

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

256 BW 219 D-5 / BW 219 PD-5

5.29 Activating/deactivating the dozer blade
i Note Any change to the setting of the dozer blade will only become effective
after switching the ignition off and back on again!
5.29.1 Procedure
Input Description
• 3021 Enable function “Activate or deactivate dozer blade”.
• 3022 Activate the dozer blade.
or
• 3023 Deactivate the dozer blade
• 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).

BW 219 D-5 / BW 219 PD-5 257

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

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

258 BW 219 D-5 / BW 219 PD-5

5.32 Adjusting the plates despite missing sensors

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

BW 219 D-5 / BW 219 PD-5 259

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

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

260 BW 219 D-5 / BW 219 PD-5

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

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

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

BW 219 D-5 / BW 219 PD-5 261

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

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

262 BW 219 D-5 / BW 219 PD-5

5.37 Setting the coolant filling level sensor
The machines are fitted with two different coolant filling level sensors. One is a normally closed type,
the other one is a normally open type. The machine can work with both variants, but may need to be
adjusted to the matching sensor.
i Note During the input, the diesel engine of the machine should not be running!
5.37.1 Procedure
Input Description
• 5041 Enable function “Set coolant filling level sensor”.
• 5042 Set the coolant filling level sensor as a normally open contact (old version).
or
• 5043 Set the coolant filling level sensor as normally closed contact (new version).
• Code 5040 can be used to check which sensor is currently set
(0 or 1 – normally open; 2 – normally closed).
5.38 The “Water in fuel” sensor shuts down the engine
The machines are equipped with a sensor that checks if there is water in the fuel. Under normal
conditions, an audible warning signals this problem. There are users who want to have the engine
shut down after a certain time (2 minutes), if water is detected in the fuel. This can be set with the
following input codes:
i Note During the input, the diesel engine of the machine should not be running!
5.38.1 Procedure
Input Description
• 5055 Enable function “Water in fuel”.
• 5056 The “Water in fuel” sensor can shut down the engine.
or
• 5057 The “Water in fuel” sensor cannot shut down the engine.

BW 219 D-5 / BW 219 PD-5 263

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

264 BW 219 D-5 / BW 219 PD-5

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

BW 219 D-5 / BW 219 PD-5 265

7 Replacement of components
7.1 How to proceed when replacing components
Each machine is adjusted individually during initial commissioning. This adjustment or teaching
process is necessary to make sure that the travel and vibration functions are almost identical on all
machines. Background of these adjustment procedures are the tolerances of the components used,
e.g. hydraulic pump for travel system and ESX control. These tolerances apply for both mechanical as
well as electrical functions and are unavoidable for manufacturing reasons.
To enable simple and quick adjustment procedures expensive tools have deliberately been excluded.
All that is needed is this manual and a bit of time. By following the described procedure, it is possible
to put a machine back into operation after the replacement of one of the components specified above
and to re-establish the usual functional quality, with almost no previous knowledge. Even an
incorrectly or incompletely conducted teaching procedure can be repeated without problems as often
as necessary. At first glance, performing this adjustment work on every machine may seem a bit
complicated, but this procedure enables the operation of all machines with the same operating
software. Ultimately, this will considerably increase the spare parts availability.
7.2 Replacement of an ESX control

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

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

266 BW 219 D-5 / BW 219 PD-5

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

i Note

BW 219 D-5 / BW 219 PD-5 267

268
Service Training WZ –5 Description of Signals on the ESX Control
8 Description of the signals on the ESX control

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

terminal
X35:1 AGND = Analogue ground: Ground potential for sensors (steering angle approx. 0 V measured against ground (terminal 31)
sensor, steering unit, etc.)
X35:2 Output travel motor axle Y31 active, i.e. min. displacement approx. 12 V
Digital output (max. 2.5 A) inactive, i.e. max. displacement 0V
X35:3 Output travel motor drum Y30 active, i.e. min. displacement approx. 12 V
Digital output (max. 2.5 A) inactive, i.e. max. displacement 0V
X35:4 Interface RS 232 RxD is not used for normal operation. Measurement not possible!
X35:5 Interface RS 232 RxD is 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 mA..20 mA) from pressure sensor on travel 600 bar approx. 20 mA
pump.
(only on DH machines)
X35:7 Input hydraulic pressure travel pump circuit axle reverse B235 0 bar approx. 4 mA
pump.
BW 219 D-5 / BW 219 PD-5

X35:8 Input sensor for height adjustment of plates B312
Analogue input (current input 4 mA..20 mA) from height-way measuring
system for attachment plates.
(only on machines with attachment plates)
X35:9 Input D+-signal Active approx. 12 V
Analogue input (voltage input 0..12 V) inactive 0V
X35:10 Input Release vibration pump for plates
Digital input active low.
Version/Status: V01:05 / 02/04/2019 Description of Signals on the ESX Control


terminal
X35:11 Output floating position of dozer blade Y102 active, i.e. floating position switched on approx. 12 V
or inactive, i.e. floating position switched off 0V
Output floating position of attachment plates Y60
Digital output (max. 2.5 A)
(only on machines with dozer blade or attachment plates)
X35:12 Input axle speed B60 Signal changes between approx. 0 V and approx. 12 V, when machine is
Frequency input (0-7.5 kHz) moving.
Frequency with travel speed m/min
Machine type:
XX m/min approx. XX Hz
Machine type:
Machine type:
X35:13 Input direction of rotation axle B60 Rotary direction forward approx. 12 V
Digital input active high Rotary direction reverse 0V
X35:14 Input BTS brake (from travel lever) Brake released approx. 12 V
Digital input active high Brake applied 0V
X35:15 Input seat contact switch S06 Seat actuated 0V
Digital input active high Seat not actuated ?V
BW 219 D-5 / BW 219 PD-5

X35:16 Input arm rest switch B146 Arm rest actuated 0V
Digital input active high Arm rest not actuated ?V
(only BW145/177/197)
X35:17 Input rotary direction of drum B60 Rotary direction forward approx. 12 V
Digital input active high Rotary direction reverse 0V
X35:18 Input engine oil pressure switch B06
Digital input active low
(only BW177 D/DH/PDH with Tier 3 engines)
X35:19 Input coolant temperature switch B53

269
270

terminal
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 vibration pump for plates 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 state (limp home function) This voltage must be measured against AGND.
X35:24 Output relay engine shut-down solenoid active, i.e. engine shut down approx. 12 V
Digital output (max. 2.5 A) inactive, i.e. engine not shut down 0V
X35:25 Output relay warning horn active, i.e. warning horn switched on approx. 12 V
Digital output (max. 2.5 A) inactive, i.e. warning horn not switched on 0V
X35:26 Interface CAN-Bus 1 Wire - is used for communication with MESX, ESX,
Measurement not possible!
the cabin module and with the immobilizer.
X35:27 Interface CAN-Bus 1 Wire + is used for communication with MESX, ESX,
X35:28 Input potential terminal 15 Control switched on approx. 12 V
Digital input active high Control switched off approx. 2 V

This signal must be present so that the control can work.
BW 219 D-5 / BW 219 PD-5

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


terminal
X35:31 Input sensor for height adjustment of plates B313
Analogue input (current input 4-20 mA) from side way measuring system
for attachment plates.
X35:32 Input cross-slope sensor B57
(only on DH/BVC machines)
X35:33 Interface CAN-Bus 2 Wire - is used for communication with the travel lever
and the engine EMR.
X35:34 not used
X35:35 Input drum speed B59 Signal changes between approx. 0 V and approx. 12 V, when machine is
Frequency input (0-7.5 kHz) moving.
(only on DH machines) Frequency with travel speed m/min
Machine type:
Machine type:
Machine type:
X35:36 Input fuel water separator sensor, B124
BW 219 D-5 / BW 219 PD-5

X35:37 Input differential pressure switch hydraulic oil filter, B21
X35:38 Input air filter pressure switch B03
Digital input
X35:39 Input coolant float switch B55
Digital input
X35:40 Input engine speed sensor B92
Frequency input active low (0-7.5 kHz)

271
272

terminal
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. levelling blade/plates up approx. 12 V
or inactive, i.e. levelling blade/plates not up 0V
Output plates up Y122
X35:43 Output levelling blade down Y380 active, i.e. levelling blade/plates down approx. 12 V
or inactive, i.e. levelling blade/plates not down 0V
Output plates down Y123
X35:44 Output Relay engine speed K114 active, i.e. max. idle speed approx. 12 V
Digital output (max. 4 A) inactive, i.e. min. idle speed 0V
X35:45 Output floating position of attachment plates 2 Y144 active, i.e. floating position switched on approx. 12 V
Digital output (max. 2.5 A) inactive, i.e. floating position switched off 0V
X35:46 Output travel pump axle forward Y16 Forward travel active 600-1800 mA
PWM power output (max. 4 A) Forward travel inactive 0 mA
X35:47 Output travel pump axle reverse Y17 Reverse travel active 600-1800 mA
PWM power output (max. 4 A) Reverse travel inactive 0 mA
BW 219 D-5 / BW 219 PD-5

X35:48 Output Amplitude switch-over active, i.e. high amplitude approx. 12 V
Digital output (max. 2.5 A) inactive, i.e. low amplitude 0V
(not on BVC machines)
X35:49 Output Vibration pump Ports BW145/177/197 DH/PDH/BVC
PWM power output (max. 4 A) Vibration active 400-1200 mA
Vibration inactive 0 mA
On all machines
Vibration active 600-1200 mA
Vibration inactive 0 mA
X35:50 Output plates left Y142 active, i.e. move plates to the left approx. 12 V
Digital output (max. 5 A) active, i.e. do not move plates to the left approx. 0 V


terminal
X35:51 Output plates right Y143 active, i.e. move plates to the right approx. 12 V
Digital output (max. 5 A) active, i.e. do not move 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 for communication with the travel
lever and the engine EMR.
X35:54 Voltage supply for electronics (permanent voltage) Control running approx. 12 V
Control not running 0V
X35:55 Ground connection electronics 0 V (measured against ground)
X35:56 Voltage supply for outputs (permanent voltage) approx. 12 V (measured against ground)
X35:61 Output warning buzzer, H14 Warning buzzer active approx. 12 V
Digital output (max. 4 A) Warning buzzer inactive 0V
X35:62 Output levelling blade priority Y378 Active approx. 12 V
or inactive 0V
Output plates priority Y145
BW 219 D-5 / BW 219 PD-5

X35:63 Output operating hour meter plates, P43 Active approx. 12 V
Digital output (max. 2.5 A) inactive 0V
X35:64 Output brake Y04 Open brake approx. 12 V
PWM power output (max. 4 A) Close brake 0V
X35:65 Ground connection approx. 0 V

273
274
Service Training WZ -5 Description of Signals on the Travel Lever
9 Description of signals on the travel lever

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

Travel lever
X23:1 Voltage supply (permanent voltage) Electronics working approx. 12 V
Electronics not working 0V
X23:2 Ground connection 0V (measured against ground)
X23:3 Output BTS brake Brake opens approx. 12 V
Digital output (max. 4 A) Brake closes 0V
X23:4 not used
X23:5 Output Voltage supply for additional analogue evaluations Nominal voltage = approx. 5,0 V
This output supplies the 12-stage travel speed range switch. This voltage Permissible range: approx. 4.8-5.2 V
is required to connect and evaluate further analogue switches to the This voltage must be measured against AGND.
travel lever.
X23:6 Interface CAN-Bus 2 Wire + is used to communicate with ESX and Measurement not possible!
engine EMR.
X23:7 Interface CAN-Bus 2 Wire - is used to communicate with ESX and Measurement not possible!
engine EMR.
X23:8 AGND = Analogue ground: Ground potential for additional analogue approx. 0 V measured against ground (terminal 31)
BW 219 D-5 / BW 219 PD-5

evaluations
Reference to PIN X23:5
X23:9 Node address addressing 1 Connection to machine ground (0 V)
X23:10 Node address addressing 2 Connection to machine ground (0 V)
X23:11 Input travel speed range switch The voltage signal changes with the adjusted travel speed range
Analogue input Travel speed range min. ?? V
Travel speed range max. ?? V
X23:12 not used ---
X24:1 Input Low amplitude Low amplitude active approx. 12 V
Digital input active high Low amplitude inactive 0V
X24:2 Input High amplitude High amplitude active approx. 12 V
Digital input active high High amplitude inactive 0V
Version/Status: V01:05 / 02/04/2019 Description of Signals on the Travel Lever

Service Training WZ -5 Description of Signals on the Travel Lever

Travel lever
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 required Voltage supply inactive 0V
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.)
BW 219 D-5 / BW 219 PD-5

Version/Status: V01:05 / 02/04/2019 Description of Signals on the Travel Lever
275
276
Service Training WZ -5 Description of Signals on the Display
10 Descriptions of signals on the display

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

Display
X33:1 not used
X33:2 Input tank sensor R03 The signal changes with the filling level in the fuel tank.
Resistance input 0-140 Ohm
X33:3 Output warning buzzer, H07 Warning buzzer active approx. 12 V
Digital output (max. 1.5 A) Warning buzzer inactive 0V
X33:4 Output Vibration Telematic A124 Vibration active approx. 12 V
Digital output (max. 1.5 A) Vibration inactive 0V
X33:5 Input lighting S15 Lighting switched on approx. 12 V
Digital input active high Lighting switched off 0V
X33:6 Interface RS232 RxD is not used for normal operation. Measurement not possible!
X33:7 Interface RS232 TxD is not used for normal operation. Measurement not possible!
X33:8 Input indicator relay Indicator active approx. 12 V
Digital input active high Indicator inactive 0V
X33:9 Input engine speed low idle S120 Low idle active approx. 12 V
Digital input active high Low idle inactive 0V
X33:10 Input engine speed high idle S120 High idle active approx. 12 V
BW 219 D-5 / BW 219 PD-5

Digital input active high High idle inactive 0V
X33:11 Input suppress regeneration S299 Suppress regeneration active approx. 12 V
Digital input active high Suppress regeneration inactive 0V
(only machines with Tier 4f engines)
X33:12 Input request regeneration S299 High idle active approx. 12 V
Digital input active high High idle inactive 0V
(only machines with Tier 4f engines)
X33:13 not used
X33:14 not used
X33:15 not used
X33:16 not used
X33:17 not used
Version/Status: V01:05 / 02/04/2019 Description of Signals on the Display
Author: Brand / EE
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Service Training WZ -5 Description of Signals on the Display

Display
X33:18 not used
X33:19 not used
X33:20 not used
X33:21 Interface CAN-Bus 1 Wire + is used for communication with MESX, ESX, Measurement not possible!
X33:22 Interface CAN-Bus 1 Wire - is used for communication with MESX, ESX, Measurement not possible!
X33:23 not used
X33:24 not used
X33:25 Ground connection 0 V (measured against ground)
X33:26 Voltage supply (permanent voltage “ignition on”) Electronics working approx. 12 V
Electronics not working 0V
BW 219 D-5 / BW 219 PD-5

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Author: Brand / EE
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277
278
Service Training WZ -5
11 Fault codes of the ESX control
Fault reaction Description of fault reaction
1 Warning.
Fault code is displayed.
2 Warning.
The fault code is displayed and an audible signal occurs.
3 Impairment of function.
The faulty function is overridden by a limp home function.
4 Fault in a partial function.

The faulty function cannot be overridden by a limp home function. After the fault occurs, the machine is stopped.
The machine can still be driven to a limited extent, but must be repaired by the service department as soon as possible.
5 Serious fault in a partial function -> the diesel engine is shut down.
The faulty function cannot be overridden by a limp home function.
The machine is no longer able to drive, e.g. because parts of the travel system are defective.
BW 219 D-5 / BW 219 PD-5

6 Fatal fault -> the control and the diesel engine are shut down.
Fault code is displayed and the signal lamp in the monitoring module is constantly lit up. NO audible signal occurs.
Note: Faults with fault reaction 1 and 2 are only warning messages and are NOT saved in the fault log!
See list of fault codes.
Version/Status: V01:05 / 02/04/2019 Terminology

12 Input codes of the ESX control

See list of input codes.
13 History

BW 219 D-5 / BW 219 PD-5 279

14 Terminology in connection with ESX

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

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

280 BW 219 D-5 / BW 219 PD-5

Short circuit to ground

Line, terminal has direct connection to vehicle ground, often in connection with wire
breakage
Digital
There are only two permissible states, e.g. switched on or off; lamp on/off; current flows/does
not flow; valve open/closed (black/white valve)
Analogue
In contrast to Digital many states are permitted within a certain range. E.g. room temperature
0° to 40°, current 4mA to 20mA; voltage 0V to 8.5V; resistance 100 Ω to 300Ω; valve 0% to
100% opened (proportional valve)

BW 219 D-5 / BW 219 PD-5 281

Control system
Controlling describes the process during which an input value influences a distance (the
value to be controlled), following a fixed command. For this purpose, all possible interfering
factors (e.g. temperature, humidity, etc.) must be known.
Disturbance
variable (z)
Input (w) Control Output (y)

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

Governor Distance
Identification Control Control system

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

282 BW 219 D-5 / BW 219 PD-5

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

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

BW 219 D-5 / BW 219 PD-5 283

284
FaultLocation Output brake valve Y04 1001
FCode FaultDescription Terminal Possible Cause Diag Reac
1001 No or too low current flow out of this X35:64 1744
1548
2Line breakage in current path 5
output
1002 The output to the valve has ground X35:64 1745
1549
4Short 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 1746
1550
3Current path has connection to +Ub (15 or 30) 5
FaultLocation Input BTS brake 1005

1005 Plausibility conflict in evaluation of X35:14 5
travel lever X- axis to the brake
contact signal
FaultLocation Output warning horn, K13 1015
1015 Although the output is switched off, X35:25 1751
1551
voltage is present
1547
than permitted.

1553
BW 219 D-5 / BW 219 PD-5

FaultLocation Output backup warning (rear), H14 1020
1554
output
1555
than permitted.
1556
77/125
FaultLocation Travel lever, S55 1025
1025 Summarizing error X-axisError in CAN 2 3
redundant evaluation of axis
1026 Cable breakage X-axisSignal CAN 2 3
outside the valid range (see signal
description)
1027 Parameterization X-axis CAN 2 3
1028 Direction evaluation X-axisThe CAN 2 3
direction of travel lever movement
could not be determined
1029 Differential error X-axisError in CAN 2 3
redundant evaluation of travel lever
signal
1030 Software error X-axisSoftware does CAN 2 3
not work correctly
1031 Summarizing error Y-axisError in CAN 2 3
redundant evaluation of axis
1032 Cable breakage Y-axisSignal CAN 2 3
description)
1033 Parameterization Y-axis CAN 2 3
BW 219 D-5 / BW 219 PD-5

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
78/125
285
286
FaultLocation Input travel stage selector switch, S42 1040
1040 Ground Connection faultySignal 1769
1557
X23:7, X23:15 2Line breakage in current path 3
outside the valid range
1041 Supply connectionSignal outside 1770
1558
X23:7, X23:15 3Current 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 1050
1050 The required control power cannot be X35:46 1772
1565
transmitted to the proportional
solenoid.
1051 Output to proportional valve shorted X35:46 1773
1567
to ground.
1052 Supply voltage Ub is applied to the X35:46 1774
1569
proportional valve output, even
though the output is not switched.
1566
solenoid.

1568
BW 219 D-5 / BW 219 PD-5

to ground.
1570
1056 Fault current regulator X35:46 5
1058 Hardware initializing error X35:46 2
1190 5
79/125
FaultLocation Output valve travel pump (rear) reverse, Y17 1060
1572
solenoid.
1573
to ground.
1574
1575
solenoid.
1576
to ground.
1577
BW 219 D-5 / BW 219 PD-5

FaultLocation Output valve travel pump (front) forward, Y72 1070
1559
solenoid.
1560
to ground.
1561
80/125
287
288
1562
solenoid.
1563
to ground.
1564
1180 5
FaultLocation Output valve travel pump (front) reverse, Y73 1080
1578
solenoid.
1579
to ground.

1580
BW 219 D-5 / BW 219 PD-5

1581
solenoid.
1582
to ground.
1583
81/125
FaultLocation Teach function travel pump flow controller 1090
1090 Informative code - The teach function System 1812
1585
1Informative 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
BW 219 D-5 / BW 219 PD-5

1099 Fault in surge currentValue outside System 2696
2394
the limiting values 2696
2395
8Software parameter fault, software update may be required.
2696
2396
5Excessive current in current path
FaultLocation Output valve travel speed range selection front, Y30 1100
1586
output
1587
than permitted.
82/125
289
290
1588
valve output, even though the valve is
not switched.
FaultLocation Input speed sensor travel motor B59 1105
1105 No pulses from the speed sensor are X35:35 1820
1589
detected, ven though the travel pump 1820
1590
3Current path has connection to +Ub (15 or 30)
is actuated.
1820
1591
4Short circuit to ground (31) in the current path
1820
1592
11Hardware defect sensors, replacement required
1106 Plausibility of the sense of rotation X35:17 1821
1593
does not match 1821
1594
1821
1595
1821
1596
FaultLocation Output valve travel speed range selection rear, Y31 1110
1597
output
1598
than permitted.
BW 219 D-5 / BW 219 PD-5

1599
valve output, even though the valve is
not switched.
FaultLocation Input speed sensor travel motor, B60 1115
1115 No pulses from the speed sensor are X35:12 1825
1600
detected, ven though the travel pump 1825
1601
is actuated.
1825
1602
1825
1603
83/125
1116 Plausibility of the sense of rotation X35:13 1826
1604
does not match 1826
1605
1826
1606
1826
1607
FaultLocation Input inclination sensor, B57 1201

1201 Ground Connection of sensor/switch X35:32 3
faultyThe voltage applied to the
input is outside the specified range
(see signal description).
1202 Supply connection Connection of X35:32 3
sensor/switch faultyThe voltage
applied to the input is outside the
specified range (see signal
description).
1203 Signal faultSignal outside the valid X35:32 3
range
1265 Information message, no fault! The X35:30 3723
3101
cross-slope sensor has not been
adjusted.
FaultLocation Input pressure sensor travel pump (rear) forward 1210
BW 219 D-5 / BW 219 PD-5

1608
output
1211 Signal rangeThe current signal is X35:6 3
specification)
1212 Pressure sensor does not measure any X35:6 3
pressure
1213 X35:6 2
84/125
291
292
1255 The sensor is not correctly connected, X35:6 2042
2165
14Sensors not correctly installed or not adjusted 2
it may be mixed up with another 2042
2166
1131Sensor mixed up by mistake
sensor.
FaultLocation Input pressure sensor travel pump (rear) reverse 1220
1609
output
specification)
pressure
1223 X35:7 2
2167
2168
sensor.
FaultLocation Input pressure sensor travel pump (front) forward 1230
1610
output

BW 219 D-5 / BW 219 PD-5

specification)
pressure
1233 X35:29 2
2169
2170
sensor.
FaultLocation Input pressure sensor travel pump (front) reverse 1240
85/125
1611
output
specification)
pressure
1243 X35:30 2
2171
2172
sensor.
FaultLocation Input seat contact switch, S06 1300
1300 Informative message, no fault! X35:15 1842
1612
Driver's seat not occupied (driver not

seated!) or cable breakage in signal
line
FaultLocation Input armrest right, B146 1330
1330 Information message, no fault! X35:16 0
BW 219 D-5 / BW 219 PD-5

Right armrest raised Machine does
not pick up throttle and is braked to
stop.
1613
range 1854
1614
1332 Short circuit X35:16 2
1333 System fault, replace control X35:16 2
FaultLocation Output vibration pump, low amplitude, Y08 3000
86/125
293
294
1615
output
1616
to ground.
1617
3003 No or too low current flow out of this 2
output
1618
to ground.
1619
3006 Fault current regulator System 2
3008 Hardware initializing error System 2
FaultLocation Vibration frequency controller, low amplitude 3011
3011 Frequency adaptation, saved control 1868

1620
8Software parameter fault, software update may be required. 0
BW 219 D-5 / BW 219 PD-5

values are outside limiting values
3012 Frequency adaptation, controller has System 1869
1621
reached upper limiting value
3013 Frequency adaptation, controller has System 1870
1622
reached lower limiting value
3014 Frequency/speed to high System 2
1623
9ESX hardware defect, hardware replacement may be 3
necessary
1624
necessary
87/125
FaultLocation Output vibration pump, high amplitude, Y07 3020
1626
output
1629
to ground.
1628
1625
output
1630
to ground.
1627
3028 Hardware initializing error ystem 2
FaultLocation Vibration frequency controller, high amplitude 3031
BW 219 D-5 / BW 219 PD-5

3031 Frequency adaptation, saved control 1886
1632
values are outside limiting values
3032 Frequency adaptation, controller has 1887
1631
reached upper limiting value
3033 Frequency adaptation, controller has 1888
1633
reached lower limiting value
3034 Frequency/speed to high 2
3035 Hardware initializing error 1890
1635
necessary
88/125
295
296
1634
necessary
FaultLocation Vibration system 3040
3040 Fault in vibration frequencyValue 2697
2398
outside the limiting values 2697
2399
8Software parameter fault, software update may be required.
FaultLocation Output vibration pump plates, Y98 3051

3051 Signal faultSignal outside the valid 1
range
range (see signal description)
3054 The required control power cannot be 3309
3077
transmitted to the valve
3078
3056 Fault current regulator 1
BW 219 D-5 / BW 219 PD-5

FaultLocation Input plates position measuring system height adjustment, B3123060
3060 Cable breakage or sensor defective 3314
3079
FaultLocation Input plates position measuring system side adjustment, B313 3063
89/125
FaultLocation Attachment plates potentiometer, S139 3066
3067 Cable breakage UB 1
FaultLocation Backup alarm 3077
3077 Information message, no fault! The 1
machine travels backwards with
lowered attachment plates.
FaultLocation Output amplitude changeover relay, K43 3090
1636
output
3091 Output to relay shorted to ground. X35:48 1894
1637
BW 219 D-5 / BW 219 PD-5

1638
relay output, even though it is not
switched.
FaultLocation Input pressure sensor vibration pump, high amplitude 3230
3130
output
specification)
90/125
297
298
pressure
3132
3133
sensor.
FaultLocation Input pressure sensor vibration pump, low amplitude 3240
3131
output
specification)
pressure
3134
3135
sensor.
FaultLocation Input exciter position, B97 4001
4001 Cable breakage UB X88:9 2159
2381
4002 Cable breakage GND X88:9 2160

2380
BW 219 D-5 / BW 219 PD-5

range
4201 ADC initialization 4
4208 Sensor 1 software error 2
4209 Input initialization error 4
FaultLocation Input switch amplitude adjustment, S107 4010
4010 Cable breakage UB X88:32 2163
2382
91/125
4011 Cable breakage GND X88:32 2164
2383
4012 Signal lineSignal outside the valid X88:32 2
range
FaultLocation Metrology controller 4019
4019 Information message, no fault! The 3725
3100
serial number has not been adjusted.
4071 3858
3167
4071 3855
3156
4150 Software incompatibility metrology 2
software to machine software
4210 Incorrect parameter setting 2
BW 219 D-5 / BW 219 PD-5

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.
92/125
299
300
4271 Fault: Overvoltage 8.5 V supply 4
4272 Fault: Undervoltage 8.5 V supply 4
4990 Measuring technology not compatible System 1
1886
3219 0
FaultLocation Output valve exciter up, Y140 4021

4023 Cable breakage or sensor defective X88:47 2
FaultLocation Output valve exciter down, Y141 4026
FaultLocation 4081
BW 219 D-5 / BW 219 PD-5

4081 3856
3157
1886
3218 0
4777 Unknown fault in control of System
measuring technology
FaultLocation Input acceleration transducer, B62 4101
4101 Signal faultSignal outside the valid X88:29, 2
93/125
FaultLocation Input acceleration transducer, B171 4106
FaultLocation Input engine speed B92 5014
5014 Fault: Engine speed sensor 1897
3202
1897
3203
14Sensors not correctly installed or not adjusted
1897
3204
17No voltage supply (+Ub Pot 15 or 30)
1897
3205
5015 Fault: Engine speed sensor 1898
3206
1898
3207
1898
3208
14Sensors not correctly installed or not adjusted
1898
3209
17No voltage supply (+Ub Pot 15 or 30)
5016 Frequency/speed to high 1899
3210
1899
3211
26Parameter error, possibly machine type incorrectly chosen,
BW 219 D-5 / BW 219 PD-5

control see adjustment instructions
FaultLocation Input D+ detection 5017
5017 Engine running but no D+ signal X35:9 1900
1639
present 1900
1640
27Generator or charge regulator defective
FaultLocation Input engine oil pressure monitoring, B06 5020

5020 Warning: No oil pressure X35:37 0
94/125
301
302
5021 Fault: No oil pressure X35:37 5
FaultLocation Input coolant level monitoring, B55 5024
5024 Warning: Coolant filling level too low X35:39 0
5025 Fault: Coolant filling level too low X35:39 1904
1641
1904
1642
725Check the coolant level, top up if necessary
FaultLocation Input air filter sensor, B03 5026

5026 Warning: Air filter dirty X35:38 1
5027 Fault: Air filter dirty X35:38 1906
1643
1906
1644
25Check filter, if necessary clean or replace as per service
instructions
FaultLocation Input water separator, B124 5028
5028 Warning: Water in fuel filter X35:36 0
5029 Fault: Water in fuel filter X35:36 5
FaultLocation Output relay solenoid gas control, K 114 5040
BW 219 D-5 / BW 219 PD-5

5040 Wire breakage at the output to the X35:44 1913
3191
relay
5041 Output to relay shorted to ground. X35:44 1914
3193
3194
switched.
FaultLocation Input feedback from solenoid for throttle control 5043
95/125
5043 The voltage applied to the input is X35:52 1916
3195
1916
3196
1540Solenoid mechanically blocked
below the valid range
FaultLocation Output engine shut-down, K22 5045
5045 Wire breakage at the output to the 5
relay
5046 Supply voltage Ub is applied to the 2
switched.
5047 Insufficient current flow at output to 5
relay
FaultLocation Input level switch for fuel filling level, R03 5050
1645
range (see signal description) 1917
1646
FaultLocation Engine speed detection 5061

2400
2698
2401
BW 219 D-5 / BW 219 PD-5

2402
2699
2403
FaultLocation Engine control unit 5100

5100 Info message - Engine control unit System 1918
1647
reports a warning
5101 Error message - Engine control unit System 1919
1648
reports an error
96/125
303
304
5102 Error message - Engine control unit System 1920
1649
reports a severe fault and has
switched off
5110 Throttle pedal position Motor 1
5111 Engine oil level not correct Motor 1922
1650
1922
1651
1922
1652
1922
1653
5112 Fault: No oil pressure Motor 1923
1654
1923
1655
1923
1656
1923
1657
5113 Turbo charger pressure not correct Motor 1924
1658
1924
1659
1924
1660
1924
1661
5114 Fault: Intake manifold temperature Motor 1925
1662
1925
1663
1925
1664
BW 219 D-5 / BW 219 PD-5

1925
1665
5115 Fault: Ambient pressure sensor Motor 1926
1666
1926
1667
1926
1668
1926
1669
5116 Fault: Engine temperature sensor Motor 1927
1670
1927
1671
1927
1672
1927
1673
97/125
5117 Fault: Diesel temperature sensor Motor 1928
1674
1928
1675
1928
1676
1928
1677
5118 Fault: Engine speed sensor Motor 1929
1678
1929
1679
1929
1680
1929
1681
5119 Warning: Water in fuel filter Motor 1930
1682
1930
1683
1930
1684
1930
1685
5120 Communication fault with engine System 1931
1688
715CAN communication fault 1
control unit 1931
1689
2Line breakage in current path
5121 Communication fault with engine System 5
control unit
5123 Communication fault with engine Motor 1
control unit
BW 219 D-5 / BW 219 PD-5

control unit
control unit
1694
control unit 1937
1695
2Line breakage in current path
1937
1696
1937
1697
98/125
305
306
5127 Fault: Coolant filling level too low Motor 1938
1698
1938
1699
1938
1700
1938
1701
5128 Fault: Injection pressure in rail system Motor 1
5130 Fault: Oil pressure sensor Motor 1940
1702
1940
1703
1940
1704
1940
1705
5131 Fault: Turbocharger pressure sensor Motor 1941
1706
1941
1707
1941
1708
1941
1709
1710
1942
1711
1942
1712
1942
1713
5133 Fault: Engine temperature sensor Motor 1943

1714
1943
1715
BW 219 D-5 / BW 219 PD-5

1943
1716
1943
1717
5134 Fault: Engine speed sensor Motor 1944
1718
1944
1719
1944
1720
1944
1721
99/125
5135 Fault: Water in fuel filter Motor 1945
1722
1945
1723
1945
1724
1945
1725
1726
1946
1727
1946
1728
1946
1729
5137 Fault: Coolant level sensor Motor 1947
1730
1947
1731
1947
1732
1947
1733
5138 Fault: Sensor for injection pressure in Motor 1948
1734
rail system 1948
1735
1948
1736
1948
1737
5139 Fuel pump Motor 1949
1739
1949
1740
1949
1741
BW 219 D-5 / BW 219 PD-5

1949
1742
5Excessive current in current path
1949
1743
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
5144 1
5145 1
100/125
307
308
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 5180
5180 Information message, no fault!The Motor 1
EndOfLine test (EOL test) has not
BW 219 D-5 / BW 219 PD-5

been performed.
6064 Fault: No DEF system pressure Motor 3390
1887
3220 0
building up! 3390
1888
3221
3390
1889
3222
6068 Fault: DEF system pressure outside of Motor 0
limit values!
6069 Fault: Regeneration requirement Motor 0
ignored too long!
6070 Engine oil change required Motor 3
6071 DPF filter change required Motor 3
101/125
6072 DPF filter change required, system Motor 3
response is active
6073 Power reduction Step 1 Motor 0
6074 Power reduction Step 2 Motor 0
6200 Motor 0
6201 Motor 0
6202 Motor 0
6203 Motor 0
6204 Motor 0
6205 Motor 0
FaultLocation Engine fault 5190
5190 Diesel engine recording does not 4003
3246
work. Communication error.
5191 Diesel engine recording does not 3
work. Communication error.
FaultLocation Input hydraulic oil filter 5500
5500 Warning: Hydraulic oil filter dirty X35:37 1978
1744
25Check filter, if necessary clean or replace as per service 1
instructions
BW 219 D-5 / BW 219 PD-5

5501 Fault: Hydraulic oil filter dirty X35:37 1979
1745
25Check filter, if necessary clean or replace as per service 5
instructions
FaultLocation Exhaust Gas Recirculation (EGR) 6000
6000 Fault: Differential pressure below Motor 0
limit value!
FaultLocation DEF quality sensor, B222 6001
6001 Plausibility error, DEF tank fill level Motor 0
102/125
309
310
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).
BW 219 D-5 / BW 219 PD-5

6016 Fault: DEF quality invalid! Motor 0
description).
103/125
6065 Fault: CAN message failed! Motor 0
FaultLocation Diesel particulate filter (DPF) 6004
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 6006
6006 Short circuit towards Ub Motor 0
6007 Cable breakage or sensor defective Motor 0
6008 The output to the valve has ground Motor 0
than permitted.
BW 219 D-5 / BW 219 PD-5

6062 Fault: Valve blocked! Motor 0
FaultLocation DEF supply module 6017
6017 Fault: Pressure too high! Motor 0
6041 Signal outside the valid range Motor 0
104/125
311
312
6050 Fault: Temperature has dropped Motor 0
below lower limit value!
6051 Fault: Temperature implausible! Motor 0
FaultLocation Temperature sensor upstream of SCR catalyst, B223 6018
6018 Fault: Temperature has exceeded Motor 0
upper limit value!
6022 Fault: Temperature too low! Motor 0
FaultLocation DEF pump, M41 6025
6025 Supply voltage Ub is applied to the Motor 0
output to the pump, even though the
output is not switched.
6026 Output to pump shorted to ground Motor 0
FaultLocation DEF suction valve, Y291 6028
BW 219 D-5 / BW 219 PD-5

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
105/125
FaultLocation Temperature sensor upstream of OXY catalyst, B214 6031
upper limit value!
FaultLocation Temperature sensor downstream of OXY catalyst, B215 6032
upper limit value!
FaultLocation Temperature sensor upstream of SCR catalyst, B224 6042
BW 219 D-5 / BW 219 PD-5

6055 Short circuit Motor 0
6057 Fault: Lambda has exceeded upper Motor 0
limit value!
6059 Fault: Lambda has dropped below Motor 0
lower limit value!
FaultLocation Temperature sensor downstream of SCR catalyst, B225 6045
106/125
313
314
6053 Short circuit Motor 0
6056 Fault: Lambda has exceeded upper Motor 0
limit value!
6058 Fault: Lambda has dropped below Motor 0
lower limit value!
FaultLocation Pressure sensor upstream of SCR catalyst, B305 6048
6048 Fault: Pressure has exceeded upper Motor 0
limit value!
6049 Fault: Pressure has dropped below Motor 0
lower limit value!
FaultLocation EndOfLine test (EOL test) 6186
6186 Warning: Error before EOL test has Motor 0
started (read out error log)!
6187 Warning: Diesel engine not running! Motor 0
BW 219 D-5 / BW 219 PD-5

6188 Fault: Excessive soot load! Motor 0
6189 Warning: Check OXY cat sensors! Motor 0
6190 Warning: Error during EOL test (read Motor 0
out error log)!
6191 Warning: Check parking brake (travel Motor 0
lever in brake gate?)!
6192 Warning: Diesel engine no longer at Motor 0
operating point!
6193 Warning: Temperature downstream of Motor 0
Oxy catalyst too high!
107/125
6194 Warning: Differential pressure too Motor 0
high!
6195 Warning: EAT system not warmed up! Motor 0
6196 Warning: Diesel engine not warmed Motor 0
up!
6197 Warning: Stationary conditions not Motor 0
met!
6198 Warning: SCR system not ready! Motor 3408
1887
3223 0
3408
1888
3224
3408
1889
3225
6199 Warning: Check NOx sensors! Motor 0
FaultLocation Machine type management 7012
7012 Machine type conflict After replacing System 2
match the old one.
FaultLocation Setup operating hour meter 7013
7013 Operating hour meter not yet System 1987
1746
reconstructed
BW 219 D-5 / BW 219 PD-5

FaultLocation Software Approval System 7020
7020 Software Approval Missing System 4
7021 Software release incomplete System 3
FaultLocation CAN communication 9005
108/125
315
316
9005 Fault: CAN communication Bus 1, 3958
3212
check bus hardware 3958
3213
760Faults on CAN line
9055 Fault: CAN communication Bus 2, 3960
3216
check bus hardware 3960
3217
760Faults on CAN line
FaultLocation Immobilizer A67 9107

FaultLocation Cabin module 9109
BW 219 D-5 / BW 219 PD-5

109/125
Functional System500Output brake valve, Y04
Input Description Category ValueRange
500 Start function "Drive against closed brake" 1 [bar]
501 Quit function "Drive against closed brake" 1
Functional System554BMESX Module

554 Display of serial number 1
Functional System555System
555 Display of the firmware version of the travel 1
control (ESX)
556 Display of firmware version in display 1
720 Display of machine type 1
4010 Enable parameter change serial number 2
4011 Start parameter change serial number - xxx 2
xxx xx XXX
4012 Start parameter change serial number - type - 2
BW 219 D-5 / BW 219 PD-5

xxx xxx xx XXX
4013 Start parameter change serial number - high 2
number - xxx xxx xx XXX
4014 Start parameter change serial number - works 2
number - xxx xxx xx XXX
4019 Display of serial number 2
1001Output brake valve Y04

Functional System
110/125
317
318
1001 Display voltage output brake 1 Display in V
1020Travel lever, S55

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

Functional System
1030 Display inclination sensor status 1 0 = no movement1 = up2 = down3 = error
1260 Display inclination sensor position 1 -1000..1000
1261 Display inclination sensor value in percent 1 -1000..1000 > -100 % ..100%
gradient
1262 Display inclination sensor voltage measuring 1 [mV/ Digit]

value
BW 219 D-5 / BW 219 PD-5

1263 Display inclination sensor voltage measuring 1
value standardized to 1000
1264 Display inclination sensor status 1 0= Not Initialized, 1 = Initialized (Normal operation), 2 = Error
1265 Enable parameter change inclination sensor 1
1266 Set inclination sensor to zero 1
1040Input travel stage selector switch, S42

Functional System
111/125
1040 Display "Selected travel range" 1
1041 Display input voltage for travel range switch 1 10 mv/ Digit
track 1
1050Output valve travel pump (front) forward, Y72
Functional System
1050 Display "Actual current value travel pump 1 1 mA/ Digit
forward"
1058 Display start current valve travel pump 1 Display in mA
forward
1059 Display final current valve travel pump 1 Display in mA
forward
1060Output valve travel pump (front) reverse, Y73
Functional System
reverse"
1068 Display start current valve travel pump reverse 1 Display in mA
1069 Display final current valve travel pump reverse 1 Display in mA
1070Output valve travel pump (rear) forward, Y16

Functional System
BW 219 D-5 / BW 219 PD-5

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
112/125
319
320
1080Output valve travel pump (rear) reverse, Y17
Functional System
reverse"
1088 Display start current valve travel pump reverse 1 Display in mA
1089 Display final current valve travel pump reverse 1 Display in mA
1090Teach function travel pump flow controller

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

Functional System
BW 219 D-5 / BW 219 PD-5

1100 Display of pulses per 10m 1
1104 Travel speed 1 Display in km/h
1105 Travel speed 1 Display in m/min
1106 Pulses of speed sensor 1
1107 Display "Movement direction of machine" 1 0 = Backwards
1 = Forwards
1109 Status display travel motor 1 0: Qmax1: Qmin
113/125
1114 Travel speed 1 Display in km/h
1110Input speed sensor travel motor, B60

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

Functional System
1160 Release of teach function pulses from rotary 1
speed sensor
1161 Teach function pulses from rotary speed 1
sensor for 5m
sensor for 10m
BW 219 D-5 / BW 219 PD-5

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
114/125
321
322
1270Input pressure sensor travel pump (rear) forward
Functional System
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
1274Input pressure sensor travel pump (rear) reverse

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

Functional System
BW 219 D-5 / BW 219 PD-5

value in mA
115/125
1284Input pressure sensor travel pump (front) reverse
Functional System
value in mA
1286 Display pressure sensor measuring value 0.. 1000
1300Input seat contact switch, S06

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

Functional System
1330 Status of right armrest 1 1= arm rest up; 2= arm rest down
1331 Status of right armrest 1 Display in V
3010Metrology controller
Functional System
BW 219 D-5 / BW 219 PD-5

3010 Display enable metrology 2 0= Off1 = On
3011 Enable parameter change metrology 2
3012 Activate metrology 2
3013 Deactivate metrology 2
3014 2
3015 Display enable printer 2 0= Off1 = On
3016 Enable parameter change metrology 2
116/125
323
324
3017 Activate printer 2
3018 Deactivate printer 2
4020 Release of change to printer language 2
4021 Printer language - German 2
4022 Printer language - English 2
4023 Printer language - French 2
4024 Printer language - Dutch 2
4025 Printer language - Danish 2
4026 Printer language - Spanish 2
4027 Printer language - Finnish 2
4028 Printer language - Swedish 2
4029 Printer language - Portuguese 2
4030 Printer language - Hungarian 2
4031 Printer language - Italian 2
4032 Printer language - Norwegian 2
4033 Printer language - Polish 2
4034 Printer language - Slovakian 2
BW 219 D-5 / BW 219 PD-5

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
117/125
4060 Display vibration operation hour meter 2
4555 Display of the firmware version of the 2
measuring control (ESX)
3020Dozewr blade parameters
Functional System
3020 Display "Enabled dozer blade" 1 0= Off1 = On
3021 Enable dozer blade parameter change 1
3022 Activate the dozer blade 1
3023 Deactivate the dozer blade 1
3047Vibration system
Functional System
3047 Release of change to parameter vibration no 2
travel speed limit
3048 Change to parameter vibration activate travel 2
speed limit
3049 Change to parameter vibration no travel speed 2
limit
3050 Enable parameter change vibration 2
BW 219 D-5 / BW 219 PD-5

3052 Enable parameter change low amplitude 2
3053 Enable parameter change high amplitude 2
3058 Display of vibration parameter low amplitude 1
3059 Display of vibration parameter high amplitude 1
3060Attachment plate parameters

Functional System
3060 Display enable attachment plates 1
118/125
325
326
3061 Enable parameter change attachment plates 1
3062 Activate parameter change attachment plates 1
3063 Deactivate parameter change attachment plates 1
3068 Display actual current vibratory pump 1 Display in mA
attachment plates
3069 Display nominal current vibratory pump 1 Display in mA
attachment plates
3075 Enable adjust attachment plates if position 1
measuring system defective
3076 Enable vibrate attachment plates if position 1
measuring system defective
3077 Enable parameter change reverse travel with 1
lowered attachment plates
3078 Activate reverse travel with lowered 1
attachment plates.
3079 Deactivate reverse travel with lowered 1
attachment plates.
3080 Display attachment plates connected 1 0= Off1 = On
3081 Display attachment plates value position 1 0..1000
measuring system vertical

3082 Display attachment plates position measuring 1 0..1000
BW 219 D-5 / BW 219 PD-5

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
119/125
3089 Display valve attachment plates priority, Y145 1 0= Off1 = On
3090 Display valve attachment plates floating 1 0= Off1 = On
position, Y60/Y144
3280Input pressure sensor vibration pump, high amplitude
Functional System
3280 Display of vibration pressure 1 [bar]
value in mA
3284Input pressure sensor vibration pump, low amplitude

Functional System
3284 Display of vibration pressure 1 [bar]
value in mA
3286 Display pressure sensor measuring value 0.. 1000
BW 219 D-5 / BW 219 PD-5

4070Acceleration transducer
Functional System
4070 1 0 = not Ok1 = ok
4071 1
4072 1
120/125
327
328
4080
Functional System
4080 1 0 = not Ok1 = ok
4081 1
4082 1
4100
Functional System
4100 1 0 = not active,1 = active
4101 1
4102 1
4103 1
5000Engine speed detection

Functional System
5000 Display of diesel engine speed 1 Display in rpm
5001 Display of diesel engine speed command 1 Display in rpm
5002 Display engine speed mode diesel engine, 1
BW 219 D-5 / BW 219 PD-5

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)
121/125
5004Engine speed default
Functional System
5004 Display input switch min (idle speed position) 1 0= Off1 = On
5005 Display input switch max (full speed position) 1 0= Off1 = On
5030 Enable parameter change engine speed 2
5032 Enable parameter change min. engine speed 2 Display in rpm
(idle speed)
5033 Enable parameter change max. engine speed 2 Display in rpm
(full speed)
5020Input engine oil pressure monitoring, B06
Functional System
5020 Display status oil pressure switch in diesel Oil pressure present: = 1 = ok No oil pressure = 0 = not ok
engine when engine is running
5021Input coolant level monitoring, B55

Functional System
5021 Display "Engine status - coolant level" 1 0= Coolant level OK1= Coolant level too low
5024Input D+ detection
Functional System
BW 219 D-5 / BW 219 PD-5

5024 Display D+ status of engine 1 0 = not Ok1 = ok
5025Input air filter sensor, B03

Functional System
5025 Display "Engine status - air filter" 1 0= Air filter OK1= Air filter soiled
122/125
329
330
5026Input water separator, B124
Functional System
5026 Display "Status water separator in filter" 0 = ok 1 = Water in filter
5055 Release of parameter change for water 1
separator
5056 Parameter change water separator - engine 1
shut-down in case of water in fuel
5057 Parameter change water separator - no engine 1
shut-down in case of water in fuel
5040Input coolant level monitoring B55
Functional System
5040 Display of coolant filling level sensor mode 1 0: Normally open contact
1: Normally open contact
2: Normally closed contact
5050Input level switch for fuel filling level, R03

Functional System
5050 Display input level sensor in fuel tank 1 0..255 (raw values)
BW 219 D-5 / BW 219 PD-5

5060Exhaust gas after-treatment
Functional System
5060 Display DPF: Ash load 1 0..100%
5150 1
5151 1
5152 1
5153 1
123/125
5160 Status display regeneration switch 1 100 = Suppress regeneration010 = automatic
regeneration001 = Request regeneration at standstill
5161 Display of DPF-load 1 0..100%
5170 Display type regeneration switch 1 0 = grid (default) 1=
grid 2=
button
5171 Input code enable change to regeneration 1
switch
5172 Input code regeneration switch type switch 1
5173 Input code regeneration switch type button 1
5110Setup operating hour meter

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

Functional System
5180 Enable start EOL test 2
5181 Start EOL test 2
BW 219 D-5 / BW 219 PD-5

5600Auto-Stop system
Functional System
5600 Display of release of Auto-Stop-System 2 0= Off1 = On
5601 Release of parameter change to Auto-Stop- 2
System
5602 Activate Auto-Stop system 2
5604 Deactivate Auto-Stop system 2
5608 Release of changes to time Auto-Stop.System 2
124/125
331
332
5609 Change to time Auto-Stop.System 2
7090Immobilizer A67
Functional System
7090 Release to enter the immobilizer code via 1
travel lever
7091 Start to enter the immobilizer code via travel 1
lever
8830 Release activation of immobilizer 2
8831 Activate immobilizer 2
8800Setup display
Functional System
8800 Enable parameter change display units 1
8801 Enable code - Display units in metric 1 Units in metric
8802 Input code - Display units in imperial Units in imperial
8820Cabin module
Functional System
8820 Display of cabin module release 1 0= Off1 = On
BW 219 D-5 / BW 219 PD-5

8821 Release of parameter change for cabin module 1
8822 Activate cabin module 1
8823 Deactivate cabin module 1
125/125
Electric systems – Inspection and maintenance work
4.8 Inspection and maintenance work

4.8.1 Maintenance Table
No. Maintenance works Page

Every 500 operating hours
4.8.2.1 Servicing the battery, checking the main battery isolation 333
As required
4.8.3.1 Battery service during prolonged machine downtimes 334
4.8.2 Every 500 operating hours

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

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

n Protective gloves
n Safety goggles
1. Park the machine in secured condition Ä Chapter 1.3.4
‘Parking the machine in secured condition’ on page 64.
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. 177
BW 219 D-5 / BW 219 PD-5 333

4.8.2.1.2 Checking the main battery shutoff

out.
2. Check by turning the ignition key, whether the battery is dis-
connected from the electric system of the machine.
Fig. 178
4.8.3 As required
4.8.3.1 Battery service during prolonged machine downtimes
WARNING!
ture!
the battery.
the battery.

n Protective gloves
n Safety goggles
1. Switch off all consuming devices (e.g. ignition, light).
2. Measure the open-circuit voltage of the battery at regular
intervals (at least 1 x per month).
ð Reference values: 12.6 V = fully charged; 12.3 V = dis-
charged to 50%.
3. Recharge the battery immediately after an open-circuit
voltage of 12.25 V or less is reached. Do not perform boost
charging.
ð The open-circuit voltage of the battery occurs approx. 10
hours after the last charging process or one hour after
the last discharge.
4. Switch off the charging current before removing the charging
clamps.
5. After each charging process allow the battery to rest for one
hour before taking it into service.
334 BW 219 D-5 / BW 219 PD-5

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

always disconnect the battery. Do not forget to perform reg-
ular open-circuit voltage measurements.
BW 219 D-5 / BW 219 PD-5 335

336 BW 219 D-5 / BW 219 PD-5

Hydraulic system
5 Hydraulic system
BW 219 D-5 / BW 219 PD-5 337

Hydraulic system – Basic principles
5.1 Basic principles...................................................... 338

5.1.1 Open and closed hydraulic circuit.......................... 339
5.1.2 Swash plate principle, pump.................................. 341
5.1.3 Swash plate principle, motor.................................. 342
5.1.4 External gear pumps.............................................. 344
5.2 Overview of hydraulics.......................................... 347
5.3 Description of hydraulic components.................. 350
5.3.1 Travel / vibration pump, H1.................................... 350
5.3.2 Travel motor, H1.................................................... 354
5.3.3 Vibration motor A2FM............................................ 356
5.3.4 Steering valve........................................................ 358
5.4 Description of hydraulic circuits........................... 360
5.4.1 Charge circuit......................................................... 361
5.4.2 Travel circuit........................................................... 363
5.4.3 Vibration circuit...................................................... 368
5.4.4 Steering circuit....................................................... 375
5.5 Flushing and bleeding............................................ 378
5.5.1 Flushing in general................................................ 378
5.5.2 Flushing the travel circuit....................................... 381
5.5.3 Flushing the vibration circuit.................................. 390
5.5.4 Bleeding................................................................. 395
5.6 Inspection and maintenance work........................ 399
5.6.2 Checks prior to start up.......................................... 399
5.6.4 Every 1000 operating hours................................... 400
5.1 Basic principles

5.1.1 Open and closed hydraulic circuit.......................... 339
5.1.2 Swash plate principle, pump.................................. 341
5.1.3 Swash plate principle, motor.................................. 342
5.1.4 External gear pumps.............................................. 344
338 BW 219 D-5 / BW 219 PD-5

5.1.1 Open and closed hydraulic circuit

Open circuit
Fig. 179: Open circuit

Open in this case means that the suction line of a pump (1) nor-
mally is situated below the fluid level, the surface of which is in
open contact with atmospheric pressure. Reliable equalization of
pressure between the air in the hydraulic oil tank and the ambient
air ensures problem free suction of the pump.
In an open circuit the hydraulic oil is fed to the consumer (2 or 3)
and also returned to the tank through way valves.
BW 219 D-5 / BW 219 PD-5 339

Closed circuit
Fig. 180: 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.
340 BW 219 D-5 / BW 219 PD-5

5.1.2 Swash plate principle, pump
Fig. 181
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. 182
1 Drive shaft
2 Piston
3 Piston area
4 Piston stroke
5 Slipping disc
6 Adjusting angle
7 Cylinder
BW 219 D-5 / BW 219 PD-5 341

8 Through drive
9 Valve plate
10 Top dead centre TDC
11 Bottom dead centre BTC
12 Control slots in suction side of swash plate (for sense of rota-
tion shown)
13 Control slot on pressure side
Driven by the engine, the drive shaft rotates and drives the cylinder
via a splined connection. The cylinder rotates with the drive shaft
and drives the 9 pistons. The pistons rest with their slipper pads on
the sliding face of the swashing cradle and perform an axial move-
ment. The slipper pads are held on the sliding face and are posi-
tively guided by a retaining device. During a complete rotation of
the cylinder block each piston moves through the bottom and top
dead centre back to its initial position. From dead centre to dead
centre is performs a full piston stroke. During this process the flow
volume determined by the stroke is drawn in through the control
slots in the valve plate or pumped out. During the suction stroke
the hydraulic fluid is drawn into the increasing piston chamber, i.e.
it is actually pressed in. On the opposite side the oil is pressed out
of the piston bores into the hydraulic system during the compres-
sion stroke.
5.1.3 Swash plate principle, motor
Fig. 183
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.
342 BW 219 D-5 / BW 219 PD-5

Fig. 184
1 Drive shaft
2 Piston
3 Piston area
4 Piston stroke
5 Slipping disc
6 Adjusting angle
7 Cylinder
8 Through drive
9 Valve plate
10 Top dead centre TDC
11 Bottom dead centre BTC
12 Control slots in suction side of swash plate (for sense of rota-
tion shown)
13 Control slot on pressure side
The motor function is a reversal of the pump function. In this case
the hydraulic fluid the hydraulic system directs the oil flow to the
hydraulic motor. The medium flows through control slots in the
valve plate to the cylinder bores. 4 or 5 cylinder bores are opposed
to the kidney shaped control slots in the pressure side. The other
control slot is in this case connected with the rest of the cylinder
bores, which in turn are connected with the return flow side or are
partly covered by the connecting web between the kidney shaped
control slots. By loading the piston it slides down the slanted swash
plate and drives the cylinder that guides it. The cylinder with the 9
pistons rotates with the drive shaft, whereby the piston perform a
stroke-like movement. The hydraulic pressure generates the torque
on the cylinder and thus the rotation of the drive shaft. The sup-
plied fluid quantity determines the output speed.
BW 219 D-5 / BW 219 PD-5 343

5.1.4 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. 185: 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.
344 BW 219 D-5 / BW 219 PD-5

Function
Fig. 186
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. 187
1 Cover 6 Gear (driven)

2 Seals 7 Shaft
3 Housing 8 Flange
4 Gear (driving) 9 Bearing plate
5 Displacement chamber 10 Bearing plate
BW 219 D-5 / BW 219 PD-5 345

Multiple gear pumps Gear pumps are suited for multiple pump arrangements, in which
the drive shaft of pump 1 is extended to drive a second or third
pump. The shafts are connected by drivers in between. The indi-
vidual pump stages are sealed to each other, i.e. the suction ports
are separated from each other.
Fig. 188
346 BW 219 D-5 / BW 219 PD-5

Hydraulic system – Overview of hydraulics
5.2 Overview of hydraulics
Fig. 189
2 Steering valve
4 Travel pump
5 Vibration pump
6 Charge oil filter
7 Brake valve (Y04)
10 Manifold block with thermostat
11 Steering cylinder
12 Vibration motor
BW 219 D-5 / BW 219 PD-5 347

Fig. 190
1 Vibration pump
2 Travel pump
MS Pressure test port for charge pressure
ML Pressure test port for steering
Vibration pump
High amplitude Low amplitude
Current on coil C1 C2
Plugs Y07 Y08
Pressure on port A B
348 BW 219 D-5 / BW 219 PD-5

Travel pump
Forward travel Backward travel
Plugs Y16 Y17
BW 219 D-5 / BW 219 PD-5 349

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

5.3.1 Travel / vibration pump, H1.................................... 350
5.3.2 Travel motor, H1.................................................... 354
5.3.3 Vibration motor A2FM............................................ 356
5.3.4 Steering valve........................................................ 358
5.3.1 Travel / vibration pump, H1

5.3.1.1 Variable displacement pumps, H1 P045/P053/P060/P078/P089/P100 RA
General The variable displacement axial piston pump generates, controls
and regulates a volumetric pressure fluid flow. It has been
designed for mobile applications, e.g. in construction equipment.
The pump is a variable displacement axial piston pump in swash
plate design for hydrostatic drives in closed circuits. The volumetric
flow is proportional to drive speed and displacement.
350 BW 219 D-5 / BW 219 PD-5

Fig. 191: Axial piston pump H1

1 Control unit
2 Servo piston
3 Valve plate
4 Cover plate
5 Auxiliary pump (only with vibration pump)
6 Cylinder block
7 Swash disc
8 Drive shaft
9 Radial seal, drive shaft
10 Slipper pad
11 Piston
12 Feedback lever
NOTICE!
Components may get damaged!
– The aggregate must always be filled with
hydraulic oil and purged before start-up and
during operation.
– This must also be considered for longer
periods of rest, because the aggregate may
run empty through the hydraulic lines.
BW 219 D-5 / BW 219 PD-5 351

Schematic
Fig. 192: Block diagram

1 Control unit
2 Radiator
3 Tank
4 Charge pump
5 Charge oil filter
6 High pressure limiting valves
7 Hydraulic motor
8 Charge valve
9 Control pressure relief valves
10 Servo control
11 Servo adjustment plate
352 BW 219 D-5 / BW 219 PD-5

H High pressure
S Servo pressure
N Low pressure
R Return flow
High pressure relief valves with Pressure peaks occurring during very fast swashing processes, as
integrated boost check valves and well as the maximum pressures are safeguarded by superordinate
bypass for towing high pressure relief valves, which open when the adjusted value is
exceeded and relieve oil into the low pressure side.
The boost check valves are integrated in the high pressure relief
valves. These valves open to the low pressure side and let cool
and filtered oil flow from the charge oil circuit into the closed
hydraulic circuit, in order to compensate leaks and flushing quanti-
ties.
Bypass for towing operations:
NOTICE!
Do not back out more than 3 turns!
Observe the tightening torque of 70 Nm.
Charge pressure relief valve The charge pressure valve belongs to the group of safety elements
in a closed hydraulic circuit. This valve limits the pressure in the
charge circuit to a fixed value.
Control pressure relief valve, pres- If the adjusted pressure is reached, the pressure override will move
sure override the swash plate quickly back towards neutral position, thereby lim-
iting the system pressure. With its possibility to swash the swash
plate inside the pump back within a period of 90 ms, the pressure
override makes sure that the high pressure relief valves will only
respond in exceptional cases. This protects the hydraulic circuit
against overheating and reduces the load on the diesel engine.
BW 219 D-5 / BW 219 PD-5 353

RA - control
Fig. 193: RA - control

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

5.3.2.1 Swash plate motor (H1) with variable displacement
A plug-in fixed displacement motor converts the hydrostatic volu-
metric flow into mechanical rotary motion. It has mainly been
designed for installation into mechanical gear drives.
354 BW 219 D-5 / BW 219 PD-5

Fig. 194
1 Valve plate
2 Bearing plate
3 Synchronizing joint
4 Ring gear for sensor
5 Tapered roller bearing
6 Fastening flange
7 Piston
8 Minimum swashing angle setting
9 Sensor
10 Control piston
11 Flushing pressure relief valve
12 4-way valve
13 Shuttle valve
NOTICE!
during operation.
BW 219 D-5 / BW 219 PD-5 355

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

generated between the two sides (A & B) of the closed circuit. The
higher pressure moves the valve spool of the flushing valve against
the neutral setting spring, so that oil can flow out of the low pres-
sure side.
The flushing valve is fitted with a downstream 16 bar pressure
relief valve. This valve makes sure that only a certain quantity of
hydraulic oil is flushed out. This oil flows back to the hydraulic oil
tank and is immediately replaced by oil from the charge circuit.
Control The motor can be adjusted to two fixed displacements. This is

accomplished by changing the angle between cylinder block and
output shaft.
With a large angle position the motor works with maximum dis-
placement, slow speed and high torque.
When changing the swash plate position to minimal angle the
motor works with minimum displacement, high speed and low
torque.
The displacement is changed by a control piston, which is tightly
connected with the valve segment. The piston rod side (M5) is
thereby permanently pressurized with the actual travel pressure. In
1st gear the piston side (M4) is connected with the tank (solenoid
de-energized). In speed range 2 the solenoids are energized, the
valve switches and the piston side is also pressurized with the cur-
rent travel pressure. Due to the area differential between piston rod
side and piston side and the force resulting from this, the pilot con-
trol moves to Qmin position.
5.3.3 Vibration motor A2FM

5.3.3.1 Axial piston motor A2FE/FM
The plug-in fixed displacement motors A2FE and
A2FM just differ by a different housing.
NOTICE!
during operation.
356 BW 219 D-5 / BW 219 PD-5

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

piston drive of inclined axis design for hydrostatic drives in open
and closed circuits. Due to this inclined axle design the torque is
generated directly on the drive shaft. The pistons only apply very
little transverse forces to the cylinder, which has a favourable effect
on wear, efficiency and starting torque.
Fig. 195
1 Drive shaft
2 Piston
3 Cylinder
4 Valve plate
5 Connecting plate
6 Flushing valve, optional
In fixed displacement motors in inclined axis design, the pistons (2)
Ä Fig. 195 are arranged in an inclined position to the drive shaft
(1). The pistons perform an axial movement, which is then con-
verted to a rotary movement by the piston joint on the drive shaft
flange. The cylinder (3) is driven by the pistons.
Motor function A fixed displacement plug-in motor converts the hydrostatic energy
into mechanical energy. Pressure fluid is fed through the con-
necting plate (5) and the valve plate (4) into the cylinder bores. The
pistons (2) inside the cylinder bores perform an axial movement,
which is then converted to a rotary movement by the piston joint on
the drive shaft flange (1). The pistons thereby drive the cylinder (3)
and thereby generate the output torque on the drive shaft. The
output torque is generated by the force resulting from pressure and
piston area. The output speed is proportional to the supplied fluid
volume and the displacement. The available motor output torque
increases with the pressure drop between high and low pressure
side.
Flushing valve
The flushing valve is used to discharge heat from

the hydraulic circuit.
BW 219 D-5 / BW 219 PD-5 357

S-HYD-0088
Fig. 196
1 Flushing spool
2 Flushing pressure limiting valve
The hydraulic motor is equipped with an integrated flushing valve.
When the hydraulic circuit is switched on, a pressure difference will
be generated between the two sides of the closed circuit. The
sure side.
The flushing valve is fitted with a downstream 16 bar pressure lim-
iting valve. This valve makes sure that only a certain quantity of
hydraulic oil is flushed out. The oil flows back to the hydraulic oil
5.3.4 Steering valve

The steering unit works hydrostatically, i.e. there is no mechanical
connection between the steering wheel and the wheels to be
steered (articulated joint, drum, etc.). The mechanical connection is
replaced by hydraulic piping and hoses between the steering unit
and the steering cylinder(s).
When the steering wheel is operated, the steering unit measures
the exact oil quantity proportional to the rotation of the steering
wheel. This oil quantity is directed to the steering cylinders.
358 BW 219 D-5 / BW 219 PD-5

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

metering pump (gear set). The steering column connects the
steering unit to the steering wheel of the vehicle. When turning the
steering wheel, the rotary spool valve makes sure that oil from the
steering pump is guided through the gear set to the cylinder ports L
or R, depending on the turning direction of the steering wheel. The
gear set measures the oil flow to the steering cylinder proportion-
ally to the turning angle of the steering wheel.
Fig. 197
1 Check valve
2 Shock valve
3 Pressure limiting valve
4 Housing with replenishing valves
5 Inner spool
6 Neutral position spring
7 Pin
8 Outer spool
9 Cardan shaft
10 Distributor plate
11 Gear
12 Ring gear
13 Cover
The steering valve is additionally equipped with a pressure limiting
valve which limits the steering pressure.
Suddenly occurring pressure peaks, which may be caused by e.g.
external influences such as driving against a curb stone, are com-
pensated by two shock valves, which are integrated in the steering
valve. Each of these shock valves is fitted with an additional
replenishing valve. These replenishing valves protect the system
against cavitation which could be caused by the reaction of the
shock valves.
A check valve inside the steering unit makes sure that the
hydraulic oil cannot flow to the steering pump if outside forces are
introduced. In such a case, the steering cylinders would act as
pumps and press the oil back to the pump.
BW 219 D-5 / BW 219 PD-5 359

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

5.4.1 Charge circuit......................................................... 361
5.4.2 Travel circuit........................................................... 363
5.4.3 Vibration circuit...................................................... 368
5.4.4 Steering circuit....................................................... 375
360 BW 219 D-5 / BW 219 PD-5

5.4.1 Charge circuit
Fig. 198
2 Charge circuit filter
4 Vibration pump with integrated charge pump
5 Travel pump
6 Brake valve
7 Steering valve
BW 219 D-5 / BW 219 PD-5 361

B21 Differential pressure switch on charge circuit filter

MS Pressure test port for charge circuit
ML Pressure test port for steering
The charge circuit provides the oil for the charge system and the
control functions in the closed circuits for travel and vibration drive,
as well as to release the parking brakes.
The steering/charge pump is a gear pump with constant displace-
ment. The gear pump unit is driven by the auxiliary drive of the
diesel engine and draws the hydraulic oil directly out of the oil tank.
Another charge pump is integrated in the vibration pump.
The flows from steering/charge pump and integrated charge pump
(in vibration pump) are joined together before the charge circuit
filter.
The charge circuit is equipped with a 12 µ fine filter with bypass
valve. This valve opens at a differential pressure (pressure differ-
ence between filter inlet and filter outlet) of Δp = 3.5 bar. This differ-
ential pressure depends on the filter contamination and the vis-
cosity of the hydraulic oil.
The differential pressure switch (B21) switches when a differen-
tial pressure of Δp 2.5 bar is reached. The fault information will
therefore already be available before the bypass valve opens.
362 BW 219 D-5 / BW 219 PD-5

5.4.2 Travel circuit
2 MS
4
3 MA
L2
M3
MB
L4
B
1 A
Y04
P
T
A2
A1
5
55 - 70°C
B
10 D F
I
A
B
L2
6
T B
A
B
A
9
Y31
8
7
S-586-0188
Fig. 199
2 Radiator
3 Travel pump
4 Vibration pump
5 Brake valve
6 Axle with brake discs
7 Travel motor of axle drive
8 Travel gear with brake discs
BW 219 D-5 / BW 219 PD-5 363

9 Travel motor of drum drive

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

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

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

generated between the two sides (A & B) of the closed circuit. The
sure side.
The flushing valve is fitted with a downstream flushing pressure
relief valve. This valve makes sure that only a certain quantity of
hydraulic oil is flushed out. The oil flows back to the hydraulic oil
Return flows All return flows pass through the return flow manifold block with
thermostat. This thermostat guides the oil flow directly back to the
hydraulic oil tank, until the operating temperature is reached. At an
oil temperature of 55 °C the valve starts to switch over and at 70
°C the total amount of oil will flow through the hydraulic oil cooler.
Service brake During operation the closed hydrostatic travel circuit has the func-
tion of a service brake. When the travel lever is returned towards
neutral position, the displacement of the travel motor is adjusted
towards zero accordingly and the machine is hydraulically braked.
Parking brake To avoid creeping movements of the machine, the machine is addi-
tionally equipped with spring accumulator multi-disc parking brakes
in drum drive gear and in the axle. These close in neutral position
of the travel lever and when the engine is stopped.
364 BW 219 D-5 / BW 219 PD-5


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

primarily in slow-moving construction machinery. It enables both
wheels of an axle to be driven at the same constant speed and
with maximum power transmission.
The wheel with the lower speed is assigned the higher torque.
Structure
BW 219 D-5 / BW 219 PD-5 365

S-586-0482
Fig. 201: No-spin differential

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

When driving straight ahead, both the axle shafts are rigidly con-
nected to each other and to the drive shaft. This position corre-
sponds to a 100 percent locked axle with "normal” differential.
However, a "normal" axle with maximum locking causes problems
when cornering: Since the wheels are constantly driven with the
same speed and force, the lock must be released again when cor-
nering on solid ground, such as asphalt. Otherwise, mechanical
damage will occur to the axle gear due to the different rotational
speeds of the wheels. This is where the advantages of the no-spin
differential come into play. When cornering, the claw coupling of
the outer wheel is released.
Advantages
On the one hand, the wheels can rotate at different speeds
because there is no longer any rigid connection.
On the other hand, the entire power of the drive is directed into the
inner wheel of the curve and there is no loss of force.
366 BW 219 D-5 / BW 219 PD-5

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

less resistance. If a wheel loses grip or is on or in loose ground,
the claw coupling closes and both wheels are equally driven again.
The gearbox locks and releases itself “independently”, which
makes operation easier, eliminates the risk of mechanical damage
due to improper use and, at the same time, provides maximum
traction and off-road performance.
Locking value
The locking value defines the maximum difference of the torques
distributed on both wheels.
Example: 0% locking value: 0% is the locking value when there
is no slip between the wheels and the road.
Example: 50% locking value: 50% is the locking value when the
faster wheel is driven with 1/4 of the input torque and the slower
one with 3/4 (3/4 - 1/4 = 1/2 or 50%).
Example: 100% locking value: 100% lock means that the slow-
turning wheel receives the same power (100%) as the other wheel.
BW 219 D-5 / BW 219 PD-5 367

5.4.3 Vibration circuit
Fig. 202
2 Radiator
3 Travel pump
368 BW 219 D-5 / BW 219 PD-5

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

the neutral position to the opposite side, the flow direction of the oil
and the sense of rotation of the vibration motor will change.
Since the displacement of the vibration pump is different to the two
flow directions, the speeds of the vibration motor are also different.
S-586-0444
Fig. 203
1 Low amplitude
BW 219 D-5 / BW 219 PD-5 369

S-586-0446
Fig. 204
2 High amplitude
The vibration system is designed in such a way, that the high
exciter shaft speed (frequency) is coupled with the low amplitude
(1) Ä Fig. 203 and the low exciter shaft speed (frequency) with the
high amplitude (2) Ä Fig. 204.
The eccentric weights on the exciter shaft are fitted with additional
change-over weights. Depending on the sense of rotation of the
exciter shaft, these change-over weights are added to or sub-
tracted from the basic weights.
n Basic weight minus change-over weight = low amplitude (1)
Ä Fig. 203
n Basic weight plus change-over weight = high amplitude (2)
Ä Fig. 204
370 BW 219 D-5 / BW 219 PD-5

Fig. 205
1 Basic weight
2 Change-over weight
3 Exciter shafts
When vibration is switched on, the vibration motor must first move
the resting exciter shaft. This resistance causes a hydraulic starting
pressure, which is limited by the pressure override valve. Once the
exciter shaft has reached its final speed, the pressure will drop to
operating pressure. The value of the operating pressure mainly
depends on the condition of the ground (degree of compaction,
material etc.).
Hard ground = high operating pressure
Soft ground = low operating pressure
Fig. 206: low amplitude
BW 219 D-5 / BW 219 PD-5 371

Use of low amplitude

n thin layers
n gravels, sands, mixed soils
n gravel and road metal bearing courses
n surface compaction
Fig. 207: 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
372 BW 219 D-5 / BW 219 PD-5


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

the drum via a Bowex coupling. The rotation of the exciter shafts
with eccentric weights causes the vibration of the elastically sus-
pended drum.
Vibration motor with flushing valve The vibration motor is equipped with an integrated flushing valve.
In the closed hydraulic circuit the flushing and charge pressure
relief valve is used to avoid excessive temperatures and to secure
the minimum charge pressure. The valve is integrated in the con-
necting plate.
BW 219 D-5 / BW 219 PD-5 373

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.
374 BW 219 D-5 / BW 219 PD-5

5.4.4 Steering circuit
Fig. 209
2 Steering/ charge pump with installed vibratory plates, BVC or dozer blade as tandem gear pump
3 Charge circuit filter
4 (Optional equipment for cabin) Silencer, it is always subjected to hydraulic oil flow and has the function
of eliminating any vibrations and noises
5 Steering cylinder
6 Steering valve
ML Pressure test ports for steering
BW 219 D-5 / BW 219 PD-5 375

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. 210: Illustrated example: single drum rollers

1 Drum
2 Front frame
3 Oscillating articulated joint with two steering cylinders
4 Oscillating articulated joint with one steering cylinder
5 Steering cylinder
6 Rear frame
7 Drive axle
8 Single drum roller with one steering cylinder
9 Single drum roller with two steering cylinders
376 BW 219 D-5 / BW 219 PD-5

Oscillating articulated joints are used to flexibly connect the rear

and front frames of agricultural and construction machinery. The
machine can be steered around the vertical axis by means of an
articulated movement; the rear frame can oscillate on the hori-
zontal axis. The advantage of the oscillating articulated joint is the
fact that the front and rear frame move in the same track.
The oscillating joint compensates for uneven ground and creates
an even wheel pressure. The combination with a rigid axle pro-
vides good off-road performance. Good stability is achieved by the
low pivot point of the oscillating joint in connection with the low
centre of gravity of the machine.
BW 219 D-5 / BW 219 PD-5 377

Hydraulic system – Flushing and bleeding
5.5 Flushing and bleeding

5.5.1 Flushing in general................................................ 378
5.5.2 Flushing the travel circuit....................................... 381
5.5.3 Flushing the vibration circuit.................................. 390
5.5.4 Bleeding................................................................. 395
5.5.1 Flushing in general
NOTICE!
Changing a component
– Always flush the complete oil circuit after you
have replaced a component.
– Particulate contamination circulating in fluid
systems causes surface damage due to gener-
ally known wear mechanisms (abrasion, ero-
sion, surface fatigue).
Fig. 211
Effect of contamination
n Coarse particles (>15 µm)
– Sudden failure of components.
n Fine particle contamination (5–15 µm)
– Wear of components, internal leaks, inaccurate controlling
behaviour, blockage of valves.
n Extra fine particle contamination (<2–5 µm)
– Silting of oil, accelerated ageing of oil, corrosion.
378 BW 219 D-5 / BW 219 PD-5

n Water in oil
– Increased wear, accelerated ageing of oil.
n Chips (abrasion) in the oil
– Open and clean all components in the oil circuit; replace if
necessary.
– Clean all high pressure hoses in the oil circuit; replace if
necessary.
– If abrasion is found in the travel circuit you should also
flush the vibration circuit.
– If abrasion is found in the vibration circuit you should also
flush the travel circuit.
Before flushing
1. Change the filter element (1).
Fig. 212
2.
NOTICE!
Clean the hydraulic tank
Change the oil in case of excessive contami-
nation, oil discolouration or if the oil change
interval is almost due.
Filter the tank content with the filling and filtering unit and
pump it into an oil container.
3. Mark all hoses and disconnect them from the hydraulic oil
tank.
Fig. 213
4. Clean the oil tank thoroughly from inside; remove the tank
cover, if necessary.
5. Reconnect all hoses.
6. Fill the hydraulic oil tank again with the filling and filtering
unit.
BW 219 D-5 / BW 219 PD-5 379

Bleeding
1. Always bleed closed hydraulic circuits if lines had been
removed or connected.
Fig. 214
Servicing the flushing filter kit

1. Replace the filter element of the flushing filter when the red
control pin of the contamination indicator is pressed out
during the flushing process.
2. Clean hoses and connections and store the flushing kit in a
clean and protected environment.
Fig. 215
380 BW 219 D-5 / BW 219 PD-5

5.5.2 Flushing the travel circuit

Travel circuit flushing diagram, BW
211/212/213/214 D/PD-5
5
6
2 A B
7
A
8
4
9
OUT
IN
R 10
L
1
2 3 B
A
B
A
L
R 11
BW 211/212 D/PD
BW 213/214 D/PD
S-586-0129
Fig. 216
1 Elbow union (tool)
2 Connecting union (tool)
4 High pressure hose A <> B
5 Travel pump
6 High pressure hose B <> A
BW 219 D-5 / BW 219 PD-5 381

7 Flushing hose 25S - 20S (tool)

8 Screw socket R1 - 25S (tool)
9 Flushing filter with filter element 1μ (tool)
382 BW 219 D-5 / BW 219 PD-5

Travel circuit flushing diagram, BW

216/219 D/PD-5
5
6
2 A B
7
A
8
4
9
OUT
IN
A
10
B
1
A
2 3 B
A
A
B B
BW 216 D/PD
BW 219 D/PD
11 S-586-0491
Fig. 217
4 High pressure hose A <> B
5 Travel pump
6 High pressure hose B <> A
BW 219 D-5 / BW 219 PD-5 383

9 Flushing filter with filter element 1μ (tool)

5.5.2.1 Flushing the travel system
Observe the chapter "Flushing - General"
Installing the flushing filter

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

1. Take the drum drive motor (11) out of the hydraulic circuit by
joining the hoses together.
Fig. 218
384 BW 219 D-5 / BW 219 PD-5

Bleeding the travel circuit

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
BW 219 D-5 / BW 219 PD-5 385

3.
NOTICE!
Move the travel lever only to travel direction
forward, as otherwise the flushing filter will be
subjected to oil flow from the wrong direction.
Start the engine and shift the travel lever to travel direction
forward.
4. Perform the flushing process at various engine speeds for
approx. 10 minutes.
5. Shut down the engine.
6. Reconnect the high pressure hoses (L & R) to the drum drive
Fig. 222
motor (11).
Flushing the drum drive motor

WARNING!
Danger of accident!
The drum must rotate freely.
1. Jack up the front of the machine, so that the drum can rotate
freely.
2. Secure the rear wheels with chocks.
3. Pre-select the slow speed range.
Fig. 223
Fig. 224
386 BW 219 D-5 / BW 219 PD-5

5.
NOTICE!
Start the engine, run it with maximum speed and shift the
travel lever to travel direction forward.
6. Run the flushing procedure for approx. 10 minutes. During
this process keep changing the pump flow by shifting the
travel lever several times between full and halve forward
travel.
Fig. 225 7. Shut down the engine.
Flushing the axle motor

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

rotate freely.
2. Secure the drum with wheel chocks.
3. Pre-select the slow speed range.
Fig. 226
Fig. 227
BW 219 D-5 / BW 219 PD-5 387

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

1.
Bleeding the travel circuit, see chapter
"Bleeding the travel circuit".
Fig. 229
Circulating the tank content

1. After completing the bleeding process circulate the tank con-
tent with the filtering unit for another 15 minutes.
Fig. 230
388 BW 219 D-5 / BW 219 PD-5

Function test
1. Check the hydraulic oil level in the tank, fill up if necessary.
2. Check all connections for leaks with the engine running
(visual inspection).
3. Perform a test drive, load the travel system in forward and
reverse, e.g. by driving uphill or starting on a gradient.
4. Check all ports and connections once again for leak tightness
Fig. 231
BW 219 D-5 / BW 219 PD-5 389

5.5.3 Flushing the vibration circuit

Flushing diagram for vibration
drive
Fig. 232
1 Vibration pump
390 BW 219 D-5 / BW 219 PD-5

2 High pressure hose, A <> A

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

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

1. Take the vibration motor (6) out of the hydraulic circuit by
joining the hoses (3 & 9) together.
Fig. 233
BW 219 D-5 / BW 219 PD-5 391

Bleeding the vibration circuit

1.
Bleeding the vibration circuit, see chapter
"Bleeding the vibration circuit".
Fig. 234
Flushing the hoses

1. Block drum and wheels with suitable chocks.
Fig. 235
Fig. 236
3.
NOTICE!
D, DH and PDH machines: Use only high
frequency, as otherwise the flushing filter will
be subjected to oil flow from the wrong direc-
tion.
Switch on vibration with high frequency.

4. Start the engine and run it with maximum speed.
5. Flush the circuit for approx. 10 minutes, thereby switch the
Fig. 237 vibration on and off at intervals of approx. 30 seconds.
392 BW 219 D-5 / BW 219 PD-5

Flushing the vibration motor 1. Reconnect the hoses (3 and 9) to the vibration motor.
2. Unscrew the fastening screws for the vibration motor and pull
the motor out of the coupling.
Fig. 238
Fig. 239
4.
NOTICE!
D, DH and PDH machines: Use only high
tion.
Start the engine and run it with maximum speed.

5. Run the flushing procedure for approx. 10 minutes. Switch
the vibration on and off at intervals of approx. 30 seconds.
Removing the flushing filter and 1. Remove the flushing filter, install the vibration motor and
reinstalling the vibration motor reconnect the high pressure hoses (2 & 3).
BW 219 D-5 / BW 219 PD-5 393

Bleeding the vibration circuit

1.
Bleeding the vibration circuit, see chapter
"Bleeding the vibration circuit".
Fig. 241
Circulating the tank content

1. After completing the bleeding process, circulate the tank con-
tent with the filling and filtering unit for approx. 15 minutes.
Fig. 242
Function test
1. Check the hydraulic oil level in the tank, fill up if necessary.
2. Perform a test drive.
3. Check all ports and connections once again for leak tightness
Fig. 243
394 BW 219 D-5 / BW 219 PD-5

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

vents the engine from starting.
Fig. 244
4. Hold the open ends of the pressure test hoses into a con-
tainer.
5. Operate the starter motor for approx. 30 seconds. Wait one
minute and repeat this procedure until oil starts to run out of
the pressure test hoses.
6. Remove the pressure test hoses.
Fig. 245
7. Unlock the emergency stop switch.
Fig. 246
BW 219 D-5 / BW 219 PD-5 395

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

port and run the diesel engine max. 15 seconds at idle
speed.
9. Wait for approx. 30 seconds and keep repeating this proce-
dure until the gauge shows a constant charge pressure
reading.
Fig. 247
10.
NOTICE!
With the flushing filter installed shift the travel
lever only to travel direction forward, as oth-
erwise the flushing filter will be subjected to
oil flow from the wrong direction.
NOTICE!
Run the engine with idle speed.
Fig. 248 Start the diesel engine.

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

procedure until the indicated charge pressure drops directly
to zero when shutting down the diesel engine.
396 BW 219 D-5 / BW 219 PD-5

5.5.4.2 Bleeding the vibration circuit

1. Install a pressure test hose to the charge pressure test port.
2. Install a pressure test hose each to the high pressure test
ports.
WARNING!
The engine must not start.
3. Actuate the emergency stop switch.
Fig. 249
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. 250
7. Unlock the emergency stop switch.
Fig. 251
BW 219 D-5 / BW 219 PD-5 397

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. 252
10.
NOTICE!
With the flushing filter installed use only high
tion.
For bleeding switch on vibration with high frequency.

12. After running the engine 1 to 2 minutes pause for approx.
Fig. 253 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.
398 BW 219 D-5 / BW 219 PD-5

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


Checks prior to start up
5.6.2.1 Checking the hydraulic oil level 399
5.6.3.1 Checking the hydraulic lines 400
5.6.4.1 Replacing the hydraulic oil filter 400
5.6.5.1 Changing the hydraulic oil 401
5.6.2 Checks prior to start up

5.6.2.1 Checking the hydraulic oil level
NOTICE!
– Check the hydraulic oil level at room tempera-
ture (approx. 20 °C (68 °F)).
– If, during the daily inspection of the oil level the
hydraulic oil level is found to have dropped,
check all lines, hoses and components for
leaks.
– Use only oil of the permitted specification
Ä Chapter 2.5.5 ‘Hydraulic oil’ on page 88.

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

edge of the inspection glass
Minimum level Middle of inspection glass
2. For topping up, clean the area around the filler opening.
3. Unscrew the cap and fill in hydraulic oil.
4. Close the cap.
Fig. 254
BW 219 D-5 / BW 219 PD-5 399


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

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

one year.
400 BW 219 D-5 / BW 219 PD-5

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
2. Allow the engine to cool down.
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 pos-
sible failure of components.
– In this case determine the cause and replace
or repair the defective components, if neces-
Fig. 255 sary.
– 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.

5.6.5.1 Changing the hydraulic oil

two years.
The hydraulic oil must also be changed after major repairs in the
hydraulic system.
BW 219 D-5 / BW 219 PD-5 401

Always replace the hydraulic oil filter after each hydraulic oil
change. Change the hydraulic oil filter only after the hydraulic oil
change and after the test run.
Do not start the engine after draining off the hydraulic oil.
Do not use any detergents to clean the system.
Use only lint-free cleaning cloths for cleaning.
When changing from mineral oil based hydraulic oil to an ester
based biologically degradable hydraulic oil, you should consult the
lubrication oil service of the oil manufacturer, or our customer
service for details.
NOTICE!
Risk of damage!
– Perform the oil change when the hydraulic oil is
warm.
– Use only hydraulic oil of the permitted specifi-
cation Ä Chapter 2.5.5 ‘Hydraulic oil’
on page 88.
– Filling quantity: Ä Chapter 2.6 ‘List of fuels and
lubricants’ on page 90.

n Safety shoes
n Protective gloves
1. Park the machine safely Ä Chapter 1.3.4 ‘Parking the
machine in secured condition’ on page 64.
2. Clean the area around the filling port and remove the cap.
Fig. 256
402 BW 219 D-5 / BW 219 PD-5

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

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

with fine filter to fill the system. This ensures finest
filtration of the hydraulic oil, prolongs the lifetime of
the hydraulic oil filter and protects the hydraulic
B-586-0392
system.
Fig. 257 6. Fill in new hydraulic oil.
7. Check the oil level in the inspection glass.
Normal level Approx. 3 cm (1.2 in) below the top

edge of the inspection glass
Minimum level Middle of inspection glass
8.
The breather filter for the hydraulic oil tank is
integrated in the cap, you must therefore
replace the complete cap.
Fig. 258 Close the tank with a new cap.

9. Dispose of oil in line with environmental regulations.
BW 219 D-5 / BW 219 PD-5 403

404 BW 219 D-5 / BW 219 PD-5

Machine assemblies
6 Machine assemblies
BW 219 D-5 / BW 219 PD-5 405

Machine assemblies
6.1 Diesel engine........................................................... 407

6.1.1 Overviews.............................................................. 408
6.1.2 Lubrication oil circuit TCD 4.1 / 6.1........................ 416
6.1.3 Coolant circuit TCD 4.1 / 6.1.................................. 418
6.1.4 Common Rail System (CRS)................................. 419
6.1.5 Wastegate charge pressure controller................... 426
6.1.6 Exhaust gas recirculation....................................... 428
6.1.7 EAT – Exhaust Aftertreatment System.................. 429
6.1.8 Engine electrics..................................................... 442
6.1.9 Inspection and maintenance work......................... 463
6.2 Drum........................................................................ 499
6.2.1 Repair overview for drum....................................... 500
6.2.2 Dismantling the drum............................................. 503
6.2.3 Dismantling and assembling the change-over
weight.................................................................... 517
6.2.4 Assembling the drum............................................. 521
6.2.5 Changing the rubber buffers, adjusting the preten-
sion........................................................................ 543
6.2.6 Smooth drum scraper; installation and removal.... 548
6.2.7 Pad foot scraper; installation and removal............. 552
6.3 Padfoot shell........................................................... 562
6.3.1 Attaching the padfoot shells................................... 562
6.3.2 Removing the padfoot shells................................. 574
6.4 Oscillating articulated joint.................................... 582
6.4.1 Overview................................................................ 582
6.4.2 Dismantling the oscillating articulated joint............ 583
6.4.3 Assembly of oscillating articulated joint................. 584
6.5 Drive axle................................................................. 588
6.5.2 Checks prior to start up.......................................... 588
6.5.5 As required............................................................ 595
6.6 Air conditioning...................................................... 597
6.6.1 Overview of air conditioning system...................... 597
6.6.2 Physical principles................................................. 600
6.6.3 Refrigerant R134a................................................. 602
6.6.4 Compressor oil / refrigeration oil............................ 604
6.6.5 Working principle of the air conditioning system.... 606
6.6.6 Monitoring devices................................................. 607
6.6.7 Description of components.................................... 608
6.6.8 Compressor........................................................... 613
6.6.9 Emptying in case of repair..................................... 615
6.6.10 Drying and evacuation......................................... 616
6.6.11 Filling instructions................................................. 616
6.6.12 Steam table for R134a......................................... 619
406 BW 219 D-5 / BW 219 PD-5

Machine assemblies – Diesel engine
6.6.13 Inspection and maintenance work....................... 623

6.7 Auxiliary heating, AIRTRONIC............................... 631
6.7.1 Description of function........................................... 632
6.7.2 Fuse assignment................................................... 635
6.7.3 Control panel......................................................... 635
6.8 Cabin assembly...................................................... 640
6.8.1 Safety..................................................................... 640
6.8.2 Preparations.......................................................... 641
6.8.3 Cabin assembly..................................................... 642
6.8.4 Final function tests and checks.............................. 647
6.9 ROPS/FOPS assembly........................................... 649
6.9.1 Safety..................................................................... 649
6.9.2 Preparations.......................................................... 650
6.9.3 ROPS/FOPS assembly.......................................... 651
6.9.4 Final work.............................................................. 655
6.1 Diesel engine

6.1.1 Overviews.............................................................. 408
6.1.2 Lubrication oil circuit TCD 4.1 / 6.1........................ 416
6.1.3 Coolant circuit TCD 4.1 / 6.1.................................. 418
6.1.4 Common Rail System (CRS)................................. 419
6.1.5 Wastegate charge pressure controller................... 426
6.1.6 Exhaust gas recirculation....................................... 428
6.1.7 EAT – Exhaust Aftertreatment System.................. 429
6.1.8 Engine electrics..................................................... 442
BW 219 D-5 / BW 219 PD-5 407

6.1.1 Overviews
1
2
7 6 5 4 3
S-586-0461
Fig. 259
1 Diesel engine
3 Main fuses
408 BW 219 D-5 / BW 219 PD-5


4 6
5 7
3 X32
X34
2
1
X41
B57 A124
X100 - X109
8
A48 X45
A34
9
A83
10
S-586-0448

6 Power board
BW 219 D-5 / BW 219 PD-5 409

6 7
5
4
3 X41
8
2
1 X32
X100 - X109 A124
A161
X34
A162
B57
9
A34
A48
10
X45
A83
11
12
S-586-0447

410 BW 219 D-5 / BW 219 PD-5

Fig. 262
1 Fuel lift pump
2 Fuel pre-filter with water separator, drain valve and optional fuel pre-heating (R79)
3 Water level sensor (B124)
4 Main fuel filter
5 Fuel tank
6 Diesel engine
BW 219 D-5 / BW 219 PD-5 411

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.
ECOMODE
The standard BOMAG "ECOMODE” ensures a clean result. Active
engine management provides power to the roller operator when
needed and reduces power when the application allows. Intelligent
sensors combined with a sophisticated control immediately detect
the actual power requirement and the engine speed is automati-
cally adjusted.
With conventional rollers, the hydrostatic drive of the vibration unit
depends on the diesel engine speed. As a result, the diesel engine
must be driven at “full load” to maintain the corresponding speed of
the exciter shaft. This is independent of whether the engine power
is actually needed at maximum speed or not. “ECOMODE”
reduces the speed of the diesel engine towards the optimum
engine torque. The drive pump of the vibration unit hydrostatic
drive now regulates the volume flow so that the speed of the
exciter shaft is not affected by it. The pump and engine always pro-
vide the “correct” speed of the vibration shaft for the closed circuit
of the vibration drive. If the diesel engine is actuated by increasing
the driving pressure, the engine speed will increase with simulta-
neous adjustment of the exciter shaft speed.
To summarise: “ECOMODE” allows the engine speed to be
reduced while full power is still available in the hydraulic system.
Fuel consumption and noise levels are reduced, vibration frequen-
cies and centrifugal forces remain unaffected.
ECOSTOP
With the optional ECOSTOP the engine is shut down automatically
after a defined period of idle speed. This also reduces fuel con-
sumption and wear.
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.
412 BW 219 D-5 / BW 219 PD-5

1 adjustable transport beam

2 Transport device, remove before starting operation of engine
Fig. 263
EAT System – Exhaust Aftertreat- This system is characterized by the following technologies:
ment System
n CSF (Catalyzed Soot Filter) module: Diesel Oxidation Cata-
lyst (DOC) + Diesel Particulate Filter (DPF)
n SCR (Selective Catalytic Reduction) module with ammonia slip
catalyst
Fig. 264: Principle diagram

1 Mixing tube
2 Pressure sensor after SCR- catalyst (B305)
3 Nox Sensor before SCR- system (B224)
4 Dosing module
5 Temperature sensor (B215)
6 Nox sensor after SCR-system (B225)
7 SCR- catalyst
8 Module bracket
9 CSF (Catalyzed Soot Filter) module
BW 219 D-5 / BW 219 PD-5 413

10 Differential pressure sensor after CSF-module (B216)

11 Differential pressure sensor before CSF-module (B216)
Flywheel side
Fig. 265
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
414 BW 219 D-5 / BW 219 PD-5

Flywheel end
Fig. 266
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
BW 219 D-5 / BW 219 PD-5 415

6.1.2 Lubrication oil circuit TCD 4.1 / 6.1
Fig. 267: 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
416 BW 219 D-5 / BW 219 PD-5

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.
BW 219 D-5 / BW 219 PD-5 417

6.1.3 Coolant circuit TCD 4.1 / 6.1
Fig. 268: 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.
418 BW 219 D-5 / BW 219 PD-5

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.
6.1.4 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.
BW 219 D-5 / BW 219 PD-5 419

Fig. 269: 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.
420 BW 219 D-5 / BW 219 PD-5

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. 270: 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.
BW 219 D-5 / BW 219 PD-5 421

Fuel pre-cleaner
Fig. 271: 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
422 BW 219 D-5 / BW 219 PD-5

Fuel control unit (FCU)
Fig. 272: 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.
BW 219 D-5 / BW 219 PD-5 423

High pressure pump
Fig. 273: 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.
424 BW 219 D-5 / BW 219 PD-5

Rail
Fig. 274: 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.
BW 219 D-5 / BW 219 PD-5 425

Injector
Fig. 275: 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.
6.1.5 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.
426 BW 219 D-5 / BW 219 PD-5

Fig. 276: Exhaust gas turbocharger with Wastegate

1 Control line
2 Pressure control valve
3 Bypass valve closed
The bypass valve is normally closed.
BW 219 D-5 / BW 219 PD-5 427

6.1.6 Exhaust gas recirculation

Overview
Fig. 277
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
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
428 BW 219 D-5 / BW 219 PD-5

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).
6.1.7 EAT – Exhaust Aftertreatment System

6.1.7.1 Selective Catalytic Reduction, SCR.................... 432
6.1.7.2 Description of the SCR system components...... 434
6.1.7.3 SCR system warning strategy............................ 439
1
2
6
5 4
S-586-0457
Fig. 278
1 Diesel engine
2 Fuel filter
4 Main fuses and power board for SCR heating
BW 219 D-5 / BW 219 PD-5 429


7 Central electrics, engine control unit (A48) and diagnostics interface for engine (X32)
EAT System – Exhaust Aftertreat- This system is characterized by the following technologies:
ment System
n CSF (Catalyzed Soot Filter) module: Diesel Oxidation Cata-
lyst (DOC) + Diesel Particulate Filter (DPF)
n SCR (Selective Catalytic Reduction) module with ammonia slip
catalyst
Fig. 279: Principle diagram

1 Mixing tube
2 Pressure sensor after SCR- catalyst (B305)
3 Nox Sensor before SCR- system (B224)
4 Dosing module
6 Nox sensor after SCR-system (B225)
7 SCR- catalyst
8 Module bracket
9 CSF (Catalyzed Soot Filter) module
10 Differential pressure sensor after CSF-module (B216)
11 Differential pressure sensor before CSF-module (B216)
430 BW 219 D-5 / BW 219 PD-5

Duty of the diesel oxidation cata-

lyst (DOC)
Fig. 280
The DOC serves the purpose of increasing the temperature before
the diesel particlulate filter (DPF).
Background: With a too low temperature the particles in the
exhaust gas will not burn off. By passing through the DOC the
exhaust gas is heated up to such an extent, that the chemical reac-
tion can take place in the DPF.
The conversion of CO & HC to CO2 & H2O takes place inside the
DOC
BW 219 D-5 / BW 219 PD-5 431

Function of the diesel particulate

filter (DPF)
Fig. 281
The diesel particulate filter (DPF) collects and burns the particles
contained in the exhaust gas. These particles are caught by the
diesel particulate filter (DPF) and combusted at high exhaust gas
temperatures.
6.1.7.1 Selective Catalytic Reduction, SCR
Fig. 282
1 Exhaust gas from engine
2 Hydrolysis section
3 SCR catalyst
4 Exhaust gas after reduction
5 AdBlue®injection CO (NH2)2 + H2O
SCR stands forSelective Catalytic Reduction. This term describes
a technology for the reduction of nitrogen oxides NOx in exhaust
gases from combustion engines.
432 BW 219 D-5 / BW 219 PD-5

The chemical reactions in the SCR-catalyst is selective, i.e.

nitrogen oxides (NO, NO2) are preferably reduced, while undesired
side effects (such as the oxidation of sulphur dioxide to sulphur tri-
oxide) is almost completely suppressed.
This reaction requires ammonia (NH3), which is generated by
mixing AdBlue® into the exhaust gas. The products of the reaction
of exhaust gas with ammonia are water (H2O) and nitrogen (N2).
Honeycombs mainly consisting of titanium dioxide (TiO2), wolfram
oxide (WO3) and vanadium pentoxide (V2O2) are used as catalytic
converters.
BW 219 D-5 / BW 219 PD-5 433

6.1.7.2 Description of the SCR system components
Fig. 283: Schematic representation of the SCR system

1 Diesel engine
2 Heating line via engine cooling circuit
3 Solenoid valve for tank heating, Y292
4 AdBlue tank
5 AdBlue tank level sensor, B222
6 AdBlue temperature sensor, B222
7 AdBlue suction line
8 AdBlue return line
9 Electric heating, suction line (E105), return line (E106)
10 AdBlue feed module, pump (M41), solenoid valve (Y291), pressure sensor (B221)
11 Electric heating feed module, E107
12 SCR module
434 BW 219 D-5 / BW 219 PD-5

13 SCR catalytic converter

14 NOx sensor with control unit, B225
15 End pipe
16 Mixer
17 Dosing unit (AdBlue injector), Y293
18 Cooling line via engine cooling circuit
19 Exhaust pipe
20 Flexible element
21 Exhaust turbocharger
22 Exhaust gas temperature before SCR, B223
23 NOx sensor with control unit, B224
24 Electric heating pressure line, E104
25 AdBlue pressure line
26 Ambient temperature sensor on air filter, B218
Closed loop control The following sensors are used to control and monitor the SCR-
system:
n (14 & 23) NOx sensors (control of the AdBlue- injection quantity
and system monitoring)
n (22) temperature sensor before the metering unit (control of the
AdBlue- injection quantity)
n (5 & 6) AdBlue- tank level and temperature sensor (monitoring
and control of the heat-up strategy)
n (26) ambient temperature sensor (control of the heat-up
strategy)
(3) Solenoid valve for tank heating

In order to prevent freezing up or to ensure operation of the SCR-
system at temperatures below freezing, the tank needs to be
heated. This is accomplished by a heating line inside the tank (2),
which carries engine coolant. The coolant flow through the tank is
controlled via the solenoid valve. This enables a targeted heating
of the tank at low temperatures.
Fig. 284
BW 219 D-5 / BW 219 PD-5 435

(4) AdBlue tank

A Dispenser unit
B Heating coil, level sensor
C Plastic tank
D Emergency drain opening (with plastic thread)
E Filler neck
The AdBlue® tank stores the AdBlue provision. In order to ensure
delivery of AdBlue from the tank to the metering unit at any time
and state of operation, the tank needs to be heated at low ambient
temperatures.
Heating of the tank at low ambient temperatures is accomplished
via the engine cooling circuit (2). In order to protect the tank
against excessive heating up, the supply flow is controlled by a
tank heating (3) solenoid valve. For monitoring purposes the tank
is fitted with a temperature sensor (6) and a level sensor (5).
Fig. 285: Schematic representation of

tank with heating coil
Fig. 286: CAN-BUS connection
436 BW 219 D-5 / BW 219 PD-5

(10) Feed module

A AdBlue- pressure line
B AdBlue- return line
C AdBlue- suction line
The feed module pumps reduction agent from the tank (4) to the
metering unit (17), from where it is atomized under pressure into
the exhaust gas line. The pressure between feed module and
metering unit is thereby maintained at a constant level of 9 bar.
The change-over valve inside the feed pump makes sure that com-
ponent protection is ensured should the system freeze up. Once
the engine is shut down, both the suction and pressure lines (8 &
9) are pumped empty in order to minimize the AdBlue quantity in
the system. However, this does not generally prevent freezing of
the system, but protects against damage to components. Further-
Fig. 287 more, an electric heater (11) in the feed module prevents freezing
of the feed module. The feed module is controlled by the engine
control unit.
(13) SCR- catalyst The SCR catalyst has a catalytic surface, on which the nitric oxides
(NOx) contained in the exhaust gas are reduced by the ammonia
(NH3). A sufficiently high catalyst temperature of more than 280 °C
is a prerequisite for high NOx conversion rates.
Due to their design, SCR-catalysts have noise reducing properties.
The noise reduction rate is approx. 8-12 dB, depending on the
engine product range.
(16) Mixer The static mixer is installed downstream of the metering unit at an
exactly defined position in the exhaust gas line. The mixer supports
the distribution and treatment of the AdBlue injected into the
exhaust gas line. The AdBlue jet is directed in such a way, that it
hits the mixer, whereby AdBlue drops are atomized and deflected
in direction of the exhaust gas flow.
BW 219 D-5 / BW 219 PD-5 437

(17) Metering unit (AdBlue- injector)

A Cooling lines (feed and return flow are freely selectable)
B AdBlue- feed
C Metering valve (connection to control unit)
The sheet metal seal around the injection nozzle

must be replaced during disassembly (disposable
seal).
The AdBlue provided by the feed module is injected and atomized

in flow direction via the metering unit (17) installed in the exhaust
line before the SCR- catalyst (13).
The required AdBlue injection quantity is calculated by the engine
control, by means of NOx sensor (22) and temperature sensor (23),
both installed upstream from the metering unit. The metering unit is
protected against overheating by a cooling system (18). Besides
the water cooling, the injector is additionally cooled by the flowing
AdBlue.
NOTICE!
Fig. 288
If no AdBlue is flowing, e.g. if no AdBlue had been
refilled, the AdBlue injector may overheat and
suffer considerable damage (defect).
Another effect of this cooling is the prevention of gas bubble forma-

tion when the AdBlue squirts out of the injection valve. This pre-
vents non-uniform atomizing of the injected AdBlue.
438 BW 219 D-5 / BW 219 PD-5

6.1.7.3 SCR system warning strategy

Overview
Fig. 289
1 Control and warning lamps
2 INFO 3 display field
5 Engine rpm-meter
6 AdBlue®/DEF level gauge
7 Fuel level gauge
8 not used
Control and warning lamps
Designation Note
Warning lamp AdBlue®/DEF Lights up if the AdBlue®/DEF filling level is low, if the
AdBlue®/DEF quality is insufficient or if there is a fault in the
exhaust gas after-treatment system.
Flashes in case of an extremely low AdBlue®/DEF filling level.
Fill up AdBlue®/DEF or have the exhaust gas after-treatment
system checked immediately.
Central warning lamp Flashes in case of system faults, warnings and for information.
BW 219 D-5 / BW 219 PD-5 439

Monitoring the SCR-functionality During operation the SCR-system is monitored by the installed
sensors. This monitoring thereby covers the following areas:
n Tank level monitoring
n Malfunction, defect
n Manipulation (incorrect filling, manipulation of sensors, etc.)
If all warnings concerning filling level, malfunction

and manipulation are ignored, an entry will be
made in the error log and the SCR-system is sub-
sequently shut down. Apart from this, further coer-
cive measures in the form of engine power reduc-
tion are then applied. The power reduction takes
place to such an extent, that normal operation of
the machine is no longer possible.
Torque limitation / power reduction In case of severe faults or if faults are not properly rectified, the
system will respond with an engine power reduction. Depending on
the type of fault the power will be reduced in one or two stages.
n Power reduction stage 1 = 75% of the torque curve
Warning of a too low tank level

Power reduction stage 1 = 75% of
the torque curve
Once the tank filling level has dropped below 15%, the warning will
be issued.
the torque curve
n If the tank is still not filled up and the filling level drops below
10%, the system will change to the next warning stage.
n Once the tank contents drops below 5%, the next warning
stage is activated. Moreover, a reduction related to the max-
imum power of the engine is activated after a certain count-
down time (Step 1)
n If no filling of the SCR-tank has been recognized, another
power reduction (Step 2) will be activated after a certain count-
down time.
Tank level Warning System reaction Limitation

> 15% None None None
< 15% None None
Level < 15%
440 BW 219 D-5 / BW 219 PD-5


< 10% None None
Level < 10%

< 5% Power reduction after Power reduction Step 1
countdown
Power reduction
< 5% Power reduction Step 2 Power reduction Step 2
after countdown
Power reduction
empty Power reduction Step 2 Power reduction Step 2
Power reduction
Test with the Service & Diagnostics With the Service and Diagnostics program SERDIA 2010 it is pos-
Tool SERDIA 2010 sible to test the SCR system.
Fig. 290
The SERDIA 2010 operating instructions contain a

detailed description of the procedure for using this
function.
BW 219 D-5 / BW 219 PD-5 441

6.1.8 Engine electrics

6.1.8.1 Power board for SCR-heating............................. 445
6.1.8.2 CAN BUS overview............................................. 446
6.1.8.3 EMR4 system overview...................................... 448
6.1.8.4 EMR4 system components................................. 453
1
2
7 6 5 4 3
S-586-0461
Fig. 291
1 Diesel engine
3 Main fuses
442 BW 219 D-5 / BW 219 PD-5


4 6
5 7
3 X32
X34
2
1
X41
B57 A124
X100 - X109
8
A48 X45
A34
9
A83
10
S-586-0448

6 Power board
BW 219 D-5 / BW 219 PD-5 443

6 7
5
4
3 X41
8
2
1 X32
X100 - X109 A124
A161
X34
A162
B57
9
A34
A48
10
X45
A83
11
12
S-586-0447

444 BW 219 D-5 / BW 219 PD-5

6.1.8.1 Power board for SCR-heating
X302
X301
K192
F313/2
K196
K195 X300/30
F312/2
K194 K227
K193
X300/31
F251 F310 F238 F250 F313 F312

S-586-0245
Fig. 294
K192 Relay, SCR control
K193 Relay, heating Urea feed module
K194 Relay, heating Urea suction line
K195 Relay, heating Urea throttle line
K196 Relay, heating Urea pressure line
BW 219 D-5 / BW 219 PD-5 445

6.1.8.2 CAN BUS overview
A87
P15
CAN 4
X400
A67
A161 A162
A162
A178
A161
CAN 3
A103
CAN 1
A15
A83
X34
A124
S55
A175
CAN 2
A124
A48
A34
A48
X32
S-586-0449
Fig. 295: CAN bus

A34 Travel control
A48 ECU engine control unit, not available in BW177D-5 (Kubota engine, exhaust classification Tier3a)
446 BW 219 D-5 / BW 219 PD-5

A67 Keyboard anti-theft protection

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

was created by Bosch for applications in the automotive industry.
The objectives of this development was to ensure real-time, reli-
able and cheap communication between control units, such as
gearbox and engine control unit, but also less time-critical functions
in the area of convenience electronics, such as air-conditioning.
Why CAN? n Connection of control units to realise complex functions.
n Reduction of effort when installing cables and plug-in connec-
tions.
n Better possibilities for diagnostics (central diagnostics socket).
Features of CAN
It is a serial communication interface. The individual bits are trans-
ferred one at a time; only 2 lines are required.
CAN lines are twisted together 30 to 40 times per metre. Electro-
magnetic interferences always occur simultaneously in both lines,
which makes it easier for the software to filter out any interference
signals.
A unified colour assignment does not exist. Both wires may have
different colours, depending on the manufacturer.
At Bomag, a standard has been defined for the wires. Ä Fig. 296
Fig. 296 n Wire (+)
= cable colour blue
n Wire (-)
= cable colour yellow
Measuring at the CAN Signals transmitted through the bus line can generally not be
measured with simple measuring instruments. Testing is therefore
quite complicated for the user. Only the correct line connections
can be tested by means of a continuity test. For the fitter or user to
recognize faults or retrieve information from the BUS, BOMAG
connects display modules to the BUS.
BW 219 D-5 / BW 219 PD-5 447

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

120 Ohm. For an individual CAN bus device on a stub line, this
functions just like a single 60 Ohm resistor, which is installed at the
branch location.
6.1.8.3 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. Other-
wise components 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 procedure: 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 control unit.
448 BW 219 D-5 / BW 219 PD-5

Replacing the control unit Each control unit is clearly designated to the engine, in accordance
with the respective application. In case of a replacement the con-
trol unit therefore needs to be completed with the engine specific
data set. When ordering a new control unit you must not only
specify the part-number, but also the engine serial number (see
sticker on EMR-control unit).
The Deutz part-number specified on the EMR-con-

trol unit is the part number without software spe-
cific for the engine. The correct part number can
be found in the BOMAG spare parts catalogue.
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.
BW 219 D-5 / BW 219 PD-5 449

EDC17 CV52
Fig. 297
Electronic DCR up to 2000 bar

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. 298
450 BW 219 D-5 / BW 219 PD-5

Electronic DCR up to 1600 bar

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. 299: System overview

1 Engine side
2 Vehicle side
3 Service
4 Sensors and actuators
5 EMR
6 Diagnostics socket, X32 in central electrics
7 CAN-display
8 SerDia2010
BW 219 D-5 / BW 219 PD-5 451

Changes to the control units with respect to set-

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

B Battery minus (-)
F CAN2 low
G CAN1 low
H CAN1 high
K K-Line
M CAN2 high
Fig. 300: Diagnostic interface
CAN-display
A CAN display is available for showing measuring
values and fault messages of the EMR control unit.
BOMAG part-no.: 057 189 94
The following data can be displayed, as far as these are trans-

mitted by the control unit.
n Engine speed
n Engine torque (current)
n Coolant temperature
n Intake air temperature
n Exhaust gas temperature
Fig. 301: CAN-display n Lubrication oil pressure
n Coolant pressure
n Charge air pressure
n Fuel pressure
n Regeneration status of diesel particulate filter
n Operation monitoring of diesel particulate filter
n Fault in exhaust gas aftertreatment system
n Battery voltage
n Position of throttle pedal
n Fuel consumption
n Operating hours
Fault messages appear as plain text and audibly, the fault log of
the control unit can be read out.
452 BW 219 D-5 / BW 219 PD-5

Cable for diagnostics interface

The display is connected to the diagnostic inter-
face by means of a special cable.
Fig. 302: Cable for diagnostics inter-

face
6.1.8.4 EMR4 system components

6.1.8.4.1 Common Rail and electrics
Fig. 303: Injection system

2 Injectors
4 Rail
5 High pressure pump (2 pieces)
6 Camshaft
7 FCU (fuel control unit)
BW 219 D-5 / BW 219 PD-5 453

8 Fuel filter
9 Return line
10 Tank
11 Fuel pre-cleaner
12 Fuel pump
Fuel control unit (FCU)
Fig. 304: 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.
454 BW 219 D-5 / BW 219 PD-5

Injector
Fig. 305: 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.
BW 219 D-5 / BW 219 PD-5 455

6.1.8.4.2 Sensors and actuators
Fig. 306: 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
456 BW 219 D-5 / BW 219 PD-5

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 behind the fuel filter and
the pressure is normally between 5-7 bar.
Fig. 307
(3) Coolant temperature sensor
The coolant temperature has an effect on the calculated injection

quantity and the preheating behaviour of the glow plugs.
Fig. 308
(4) Charge air pressure sensor /

charge air temperature sensor
BW 219 D-5 / BW 219 PD-5 457

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. 309
(6) Crankshaft speed sensor
Determination of the top dead centre, emergency function in case

of a camshaft sensor failure.
Fig. 310
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. 311: Checking the gap dimension
(7) Rail pressure sensor This sensor serves the purpose of monitoring the injection pres-
sure.
458 BW 219 D-5 / BW 219 PD-5

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 off the cable plug.
WARNING!
After shutting down the engine wait 30 seconds,
before starting work in the fuel system.
Fig. 312: Disassembly 2. Unscrew the rail pressure sensor with a socket spanner.
3. Check thread and sealing edge (arrows) on the rail pressure

sensor visually.
Assembling the rail pressure sensor
Fig. 313
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. 314: Assembly
2. Turn in and tighten the rail pressure sensor (2).
Tightening torque: 40 + 5Nm
3. Plug in the cable plug
BW 219 D-5 / BW 219 PD-5 459

(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
lubrication oil system.
Thoroughly clean the area around the affected
component. 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 off the cable plug.

2. Unscrew oil pressure sensor.
Fig. 315: 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. 316: Installing the sensor
(10) Camshaft speed sensor The sensor has the function of determining top dead centre, emer-
gency function in case of a crankshaft sensor failure.
460 BW 219 D-5 / BW 219 PD-5

Disassembling the speed sensor
1. Unlock and pull out the cable plug (3).

2. Unscrew the screw (2).
3. Remove the speed sensor (1).
Fig. 317: Disassembly
4. Clean the sealing surfaces on the speed sensor and gear-

case cover.
5. Install the new O-ring (arrow).
6. Cover the O-ring slightly with oil.
Fig. 318
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. 319: Assembly
BW 219 D-5 / BW 219 PD-5 461

6.1.8.4.3 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. 320: Heating flange
The heating flange is controlled by the engine control unit via relay
K14.
Fig. 321: K14
6.1.8.4.4 Fuel pre-heating

Fuel pre-heating optional equipment
1 Water separator sensor connection (B124)
2 Fuel pre-heating connection (R79) 200 Watt (option)
The preheating system is not monitored by the

engine control unit.
In diesel engines the pre-heating of the fuel prevents malfunctions

caused by the formation of jelly (paraffin separation) in the fuel
under low temperatures.
Operating the ignition switch activates the heater, this should take
place at least 5 minutes before starting the engine.
The generated heat works directly under the filter element and
melts the wax crystals that have formed, so that the fuel can flow
through the filter element without restriction. The 200W heating is
supplied with 12V DC current.
Fig. 322
462 BW 219 D-5 / BW 219 PD-5

6.1.8.4.5 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 Elec-
trics.
6.1.9 Inspection and maintenance work

6.1.9.1 Maintenance Table

Checks prior to start up, exhaust classification STAGE V
6.1.9.2.1 Checking the engine oil level 464
6.1.9.2.2 Checking the AdBlue®/DEF level, topping up 465
6.1.9.2.3 Checking the coolant level 466
6.1.9.3.1 Cleaning the radiator module 467
6.1.9.3.2 Checking, tensioning the V-belt of the air conditioning compressor 468
Every 500 operating hours, exhaust classification 4f
6.1.9.4.1 Running regeneration at standstill 471
6.1.9.4.2 Change engine oil and oil filter cartridge 473
6.1.9.4.3 Replacing the fuel filter; bleeding the fuel system 475
6.1.9.4.4 Checking the anti-freeze concentration and the condition of the coolant 477
6.1.9.5.1 Renewing the AdBlue®/DEF filter 478
6.1.9.5.2 Checking the ribbed V-belt 479
6.1.9.5.3 Replacing the air conditioning compressor V-belts 481
6.1.9.5.4 Checking the engine mounts 481
6.1.9.6.1 Checking, adjusting the valve clearance 482
6.1.9.6.2 Changing the coolant 483
BW 219 D-5 / BW 219 PD-5 463


6.1.9.6.3 Checking, cleaning the components of the exhaust gas aftertreatment 485
system
6.1.9.7.1 Replace ribbed V-belt and idler pulley 486
As required, exhaust classification Tier 4f
6.1.9.8.1 Air filter maintenance 487
6.1.9.8.2 Checking and cleaning the water separator 490
6.1.9.8.3 Measures prior to extended shut-down period 490
As required, exhaust classification STAGE V
6.1.9.9.1 Air filter maintenance 493
6.1.9.9.2 Checking and cleaning the water separator 496
6.1.9.8.3 Measures prior to extended shut-down period 490
6.1.9.2 Checks prior to start up, exhaust classification STAGE V

6.1.9.2.1 Checking the engine oil level
NOTICE!
– If the engine is warm, shut it down and check
the oil level after five minutes. With a cold
engine the oil level can be checked immedi-
ately.
Ä Chapter 2.5.1 ‘Engine oil’ on page 81.
During the DPF-regeneration process part of the fuel may mix with
the engine oil. This increases the amount of engine oil in the
engine.
NOTICE!
– If the engine oil level is higher than the "MAX"-
mark, the engine oil must be changed immedi-
ately.
464 BW 219 D-5 / BW 219 PD-5


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. 323
6.1.9.2.2 Checking the AdBlue®/DEF level, topping up

Checking the AdBlue®/DEF level
1. Check the filling level on the AdBlue®/DEF level gauge.
2. Refuel as necessary, but only after shutting down the engine
and auxiliary heating.
B-DIS-0682
Fig. 324
A filling level, which is too low, is indicated by the AdBlue®/DEF

warning light.
If the AdBlue®/DEF level is not topped up in time,

the engine power will be reduced.
Fig. 325
BW 219 D-5 / BW 219 PD-5 465

Topping up AdBlue®/DEF
n Safety shoes
n Protective gloves
NOTICE!
Filling the AdBlue®/DEF tank with cleaning
agent or other operating media or fuels, mixing
in additives or diluting AdBlue®/DEF will
damage the exhaust gas aftertreatment system.
– Use only AdBlue®/DEF of the permitted specifi-
cation Ä Chapter 2.5.3 ‘AdBlue®/DEF’
on page 83.
– In case of incorrect filling inform our service
immediately.
NOTICE!
Minimum topping up quantity:
– 10 l (2.65 gal us)
– Fill up, if less than 10 l free tank volume is
available.
1. Clean the area around the filling port.

2. Unscrew the cap and fill with AdBlue®/DEF.
3. Close the cap.
AdBlue® /DEF
B-586-0533
Fig. 326
6.1.9.2.3 Checking the coolant level
NOTICE!
– If, during the daily inspection the coolant level
is found to have dropped, check all lines,
hoses and engine for leaks.
– Do not use radiator sealant to seal leaks.
– Use only coolant of the permitted specification
Ä Chapter 2.5.4 ‘Coolant’ on page 85.
466 BW 219 D-5 / BW 219 PD-5

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

warning light.
Fig. 327

n Protective gloves
n Safety goggles
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. For topping up, clean the area around the filling port.
Fig. 328 3. Unscrew the cap and fill in coolant up to the “MAX” mark.
4. Close the cap.
6.1.9.3 Every 250 operating hours

6.1.9.3.1 Cleaning the radiator module
NOTICE!
– Dirt on fan blades and oil coolers reduce the
cooling effect. Dirt deposits in these areas are
substantially supported by oil and fuel on these
surfaces. For this reason you should always
seal any oil or fuel leaks in the vicinity of the
cooling fan or the radiator and clean the
cooling fins after.
– Do not damage any cooling fins on the cooler
core when cleaning.
Cleaning with compressed air Protective equipment: n Working clothes

n Protective gloves
n Safety goggles
BW 219 D-5 / BW 219 PD-5 467

LUFT 3.
CAUTION!
AIR Danger of eye injuries caused by particles
flying around!
– Wear your personal protective equipment
(safety gloves, protective working
clothes, goggles).
Blow the radiator out with compressed air from the air dis-
B-586-0134 charge side.
Fig. 329 4. Blow the radiator out with compressed air from the air supply
side.
Cleaning with cold cleansing agent

NOTICE!
Electric components can be damaged by water
entering into the system!
– Protect electrical equipment such as generator,
regulator and starter against the direct water
jet.
1. Spray engine and radiator with a suitable cleansing agent,

e.g. cold cleansing agent, let it soak in for a while and spray it
off with a strong water jet.
2. Warm up the engine for a while to avoid corrosion.
6.1.9.3.2 Checking, tensioning the V-belt of the air conditioning compressor

468 BW 219 D-5 / BW 219 PD-5

Checking the condition of the V-belt

n Safety shoes
n Protective gloves
1. Check the entire circumference of the belt for damage and
cracks.
2. Replace a damaged or torn V-belt Ä Chapter 6.1.9.5.3
‘Replacing the air conditioning compressor V-belts’
on page 481.
B-870-0278
Fig. 330
Checking the V-belt tension

n Protective gloves
Tool: n Belt tension tester
1. Press the indicator arm (a) of the tester into the gap of the
measuring scale.
2. Place the meter in the middle between the V-belt pulleys on
the back of the belt.
Fig. 331
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. 332
BW 219 D-5 / BW 219 PD-5 469

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. 333
Tightening the V-belt

n Safety shoes
n Protective gloves
2. Turn the tensioning screw (2) to tighten the V-belt to the
2 specified value.
1 3. Retighten the screw (1).
B-870-0279
Fig. 334
470 BW 219 D-5 / BW 219 PD-5

6.1.9.4 Every 500 operating hours, exhaust classification 4f

6.1.9.4.1 Running regeneration at standstill
Preliminary remarks The combustion of diesel fuel produces soot particles, which are fil-
tered out of the exhaust gas in the DPF.
These soot particles are deposited in the DPF and under normal
conditions they are burned off to a great extent.
Short engine running times, low engine loads or long engine idle
times lead to the formation of soot in the DPF.
This load is monitored by the engine control unit. If the load is too
high,the regeneration warning light will flash and thus demand
regeneration at standstill.
If regeneration at standstill is not carried out or is interrupted and
the soot load continues to increase, the engine power will be
reduced and the warning buzzer will sound.
Fig. 335
If regeneration at standstill is still not carried out after the reduction
of engine power, the soot load will continue to increase. The
engine power is reduced further. The DPF is overloaded.
NOTICE!
DPF overload!
– In this case of a DPF overload, regeneration
must be activated by authorized Service Per-
sonnel, or regeneration of the DPF is no longer
possible.
Regeneration at standstill should be performed

after approx. 500 operating hours.
If the regeneration warning light does not light up,
regeneration at standstill can only be activated by
authorized service personnel with the help of the
engine diagnostics device.
Within the framework of regular maintenance, the regeneration at

standstill is performed before the engine oil change.
Regeneration at standstill takes up to 40 minutes.
Keep the engine hood closed until the regeneration at standstill is
finished and the exhaust gas temperature warning light has gone
out.
BW 219 D-5 / BW 219 PD-5 471

Regeneration at standstill
Prerequisites:
n Regeneration warning light flashing
n If the regeneration warning light is not flashing, you must con-
nect the engine diagnostics device to be able to start regenera-
tion at standstill.
Fig. 336 1.
WARNING!
Danger of burning by ignited materials!
– Keep a safe distance to combustible or
explosive materials.
Stop the machine in open terrain.

2. Engage the travel lever to the right (parking brake position).
ð The parking brake warning light lights up.
When the travel lever is disengaged out

of parking brake position to the left,
regeneration at standstill will be aborted.
3. Turn the rotary switch for engine speed to “Middle” position

(ECO mode).
Fig. 337
472 BW 219 D-5 / BW 219 PD-5

4. Hold the push button for regeneration for approx. 2 seconds.

ð As soon as regeneration at standstill starts, the engine
speed increases.
Regeneration at standstill runs automatically and takes
up to 40 minutes.
Fig. 338
The regeneration warning light lights up.
Fig. 339
The increased exhaust gas temperature is indicated by

the exhaust gas temperature warning light.
After the regeneration at standstill has been completed,
the regeneration warning light goes out.
After the exhaust gas temperature has dropped to its
Fig. 340 normal level, the exhaust gas temperature warning light
will also go out.
6.1.9.4.2 Change engine oil and oil filter cartridge

n Safety shoes
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
regeneration at standstill before changing the
engine oil.

one year.
BW 219 D-5 / BW 219 PD-5 473

NOTICE!
– Change the oil only with the engine at oper-
ating temperature.
Ä Chapter 2.5.1 ‘Engine oil’ on page 81.
lubricants’ on page 90

WARNING!
2. Unscrew the drain plug and collect any oil running out.
3. Screw the drain plug back in tightly.
B-586-0374
Fig. 341
4. Thoroughly clean the outside of the oil filter cartridge.

5. Unscrew the oil filter cartridge using an appropriate strap
wrench.
6. Remove any dirt from the sealing face of the filter carrier.
7. Thinly apply oil to the rubber seal of the new oil filter car-
tridge.
8. Screw on the new oil filter cartridge tightly by hand.
B-586-0155
Fig. 342
474 BW 219 D-5 / BW 219 PD-5

9. Fill with new engine oil.

10. After a short test run check the oil level on the dipstick; if nec-
essary, top up to the top dipstick mark.
11. Check oil filter cartridge and drain plug for leaks.
12. Dispose of the oil and oil filter cartridge in line with environ-
mental regulations.
B-586-0150
Fig. 343
6.1.9.4.3 Replacing the fuel filter; bleeding the fuel system

Preliminary remarks
NOTICE!
– Ensure strict cleanliness! Thoroughly clean the
area around the fuel filters.
– Air in the fuel system causes irregular running
of the engine, a drop in engine power, stalls the
engine and makes starting impossible.
– After work on the fuel system bleed the
system, perform a test run and check for leaks.
– Additional bleeding of the fuel system by a 5
minute test run in idle speed or low load is
mandatory.

Replacing the fuel filter

one year.
BW 219 D-5 / BW 219 PD-5 475


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. 344
Replacing the fuel pre-filter

one 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. 345 8. Push the plug on to the sensor on the water separator.
9. Dispose of fuel and filter environmentally.
476 BW 219 D-5 / BW 219 PD-5

Bleeding the fuel system

n Safety shoes
n Protective gloves
1. Slacken the bleeding screw (1) on the fuel pre-filter for 2 to 3
1 turns.
2. Unlock the bayonet lock of the fuel hand pump (2) by
pressing it down and turning it anticlockwise.
3. Operate the fuel hand pump manually, until fuel flows out of
the slackened bleeding screw without air bubbles.
4. Then tighten the bleeding screw while pumping.
2 5. Lock the bayonet lock of the fuel hand pump by pressing it

B-GEN-0066 down and turning it clockwise.
Fig. 346 6. Start the engine and run it for 5 minutes at idle speed.
7. Check the fuel pre-filter for leaks.
6.1.9.4.4 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 6.1.9.6.2 ‘Changing the coolant’ on page 483.
6. Screw the cap back on again.
Fig. 347
BW 219 D-5 / BW 219 PD-5 477


6.1.9.5.1 Renewing the AdBlue®/DEF filter

three years.
NOTICE!
– If AdBlue®/DEF comes into contact with spray
painted or aluminium surfaces while refilling,
you should rinse off the affected areas immedi-
ately with lots of water.
NOTICE!
– Ensure strict cleanliness! Thoroughly clean the
area around the filter housing.
– Take care that no dirt will enter into the filter
housing.

n Protective gloves
n Safety goggles
2. Allow the engine to cool down for at least five minutes.
3. Thoroughly clean the area around the filter housing.
4. Unscrew the filter cover.
Fig. 348
478 BW 219 D-5 / BW 219 PD-5

5. Pull out filter carrier (2) together with filter element (1).
6. Attach the new filter element to the filter carrier and reinsert it
into the filter housing.
7. Tighten the filter cover, tightening torque: 23 Nm (17 ft·lbf).
1
8. Dispose of the filter element in an environmentally friendly
way.
2
B-586-0138
Fig. 349
6.1.9.5.2 Checking the ribbed V-belt

n Protective gloves
3. Remove the air conditioning compressor V-belt Ä Chapter
6.1.9.5.3 ‘Replacing the air conditioning compressor V-belts’
on page 481.
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. 350
BW 219 D-5 / BW 219 PD-5 479

Fig. 351: 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 481.
Fig. 352
480 BW 219 D-5 / BW 219 PD-5

6.1.9.5.3 Replacing the air conditioning compressor V-belts

two years.

n Protective gloves
3. Loosen the screws (2, 3, 4) on the air conditioning com-
pressor.
4. Relieve the V-belt with the tensioning screw (1) and take it
off.
5. Install the new V-belt for the air conditioning compressor.
specified value Ä Chapter 6.1.9.3.2.2 ‘Checking the V-belt
tension’ on page 469.
7. Tighten screws (2, 3, 4) again.
Fig. 353
6.1.9.5.4 Checking the engine mounts

n Protective gloves
3. Check air intake and exhaust manifold fastenings for tight fit.
4. Check sockets and clamps between air filter, exhaust turbo-
charger and charge air line as well as the engine oil lines for
tight fit and leaks.
5. Check fastening screws on the engine oil sump and engine
mounts for tight fit.
6. Check condition and tight fit of engine pillow blocks.
BW 219 D-5 / BW 219 PD-5 481


6.1.9.6.1 Checking, adjusting the valve clearance
NOTICE!
We recommend to have this work carried out by
trained personnel or our after sales service.
– Before checking the valve clearance let the
engine cool down for at least 30 minutes. The
engine oil temperature must be below 80 °C
(176 °F).
Valve clearance adjustment

angle:
Intake valve 75° ±15°
Exhaust valve 120° ±15°
Valve Cylinder
overlapping 1 5 3 6 2 4
adjustment 6 2 4 1 5 3

n Protective gloves
Tool: n Rotation angle disc
3. Remove the valve cover.
4. Turn the crankshaft with the cranking device until the valves
are overlapping.
482 BW 219 D-5 / BW 219 PD-5

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. 354
1 Valve adjustment screw
2 Counter nut
3 Rotation angle disc
4 Socket
5 Magnet
6.1.9.6.2 Changing the coolant

two years.
Do not start the engine after draining off the coolant.

In case of lubrication oil entering into the cooling system or a suspi-
cious turbidity caused by corrosion residues or other suspended
matter, the coolant must be drained off and the complete cooling
system needs to be cleaned.
Oil can damage the sealing materials used in the cooling system.
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.
BW 219 D-5 / BW 219 PD-5 483

NOTICE!
– Use only coolant of the permitted specification
Ä Chapter 2.5.4 ‘Coolant’ on page 85.
– Do not mix different coolants and additives of
any other kind.
lubricants’ on page 90

n Safety shoes
n Protective gloves
n Safety goggles
3. Unscrew the cap from the compensation tank.
Fig. 355
4. Unscrew the plug.

5. Drain off and collect all coolant.
6. Screw the drain plug back in tightly.
7. Check the condition of the coolant.
8. Thoroughly flush the cooling system if the coolant is contami-
nated by corrosion residues or other suspended matter.
9. Remove the thermostat.
B-586-0378 10. Fill with clean water.
Fig. 356 11. Start the engine and run to operating temperature.
12. Allow the engine to cool down to approx. 50 °C (122 °F).
13. Drain off all water.
14. If using a cleaning agent, repeat the flushing process twice
with clear water.
15. Reinstall the thermostat.
484 BW 219 D-5 / BW 219 PD-5

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. 357
17. Set maximum cabin temperature.
Fig. 358
18. Set maximum fan speed.

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.
24. Check the coolant level again when the engine has cooled
Fig. 359 down; top up if necessary.
25. Dispose of coolant in line with environmental regulations.
6.1.9.6.3 Checking, cleaning the components of the exhaust gas aftertreatment system
This work must only be performed by authorized service per-
sonnel.
BW 219 D-5 / BW 219 PD-5 485

1. Check, clean the charge pressure sensor.

2. Check, clean the Venturi sensor and the exhaust gas recircu-
lation system adapter plate underneath.
3. Check, clean the differential pressure sensor of the DPF

6.1.9.7.1 Replace ribbed V-belt and idler pulley
n Protective gloves
3. Remove the air conditioning compressor V-belt Ä Chapter
on page 481.
4. Swing the idler pulley back and fixate it by inserting a locking
pin into the fixing hole.
5. Take the ribbed V-belt off the smallest pulley first.
6. Unscrew fastening screw and take off the idler pulley.
7. Attach the new idler pulley and tighten the fastening screw;
tightening torque of 80 Nm (59 ft·lbf).
B-DEU-0020
Fig. 360
8. Install the new ribbed V-belt.

9. Pull the locking pin out of the fixing hole and slowly release
the idler pulley.
10. Check the correct seat of the ribbed V-belt on the V-belt pul-
leys.
11. Install the air conditioning compressor V-belt Ä Chapter
on page 481.
Fig. 361
486 BW 219 D-5 / BW 219 PD-5

6.1.9.8 As required, exhaust classification Tier 4f

6.1.9.8.1 Air filter maintenance
NOTICE!
– Do not start the engine after having removed
the air filter.
– If necessary, the air filter may be cleaned up to
six times. After one year at the latest it must be
replaced together with the safety element.
– Cleaning does not make sense if the air filter
element is covered with a sooty deposit.
– Do not use gasoline or hot fluids to clean the
filter element.
– After cleaning, the air filter must be inspected
for damage using a torch.
– Do not continue to use a damaged air filter ele-
ment. If in doubt use a new air filter.
– If the air filter is damaged, the safety element
must be replaced as well.
– The safety element must not be cleaned.
We generally recommend to renew the air filter. A

new filter element is far less expensive than a pos-
sible engine damage.

n Protective gloves
n Safety goggles
1. Maintenance of the air filter is due when the air filter warning
light lights up, but at the latest after one year.
Fig. 362
4. Loosen both locking hooks on the housing cover and take the
cover off.
5. Clean housing cover and dust discharge valve.
Fig. 363
BW 219 D-5 / BW 219 PD-5 487

6. Pull out the air filter with light turning movements.
CAUTION!
Danger of eye injuries caused by particles
flying around!
(safety gloves, protective working clothes, gog-
gles).
Fig. 364
7. Blow the air filter out with dry compressed air (max. 2.1 bar
(30 psi)) from inside to outside by moving the gun up and
down inside the element, until it is free of dust.
Fig. 365
8. Examine the air filter with a torch for cracks and holes in the
paper bellows.
9. In case of damage replace the air filter and the safety ele-
ment.
Fig. 366
10. Slide the air filter carefully into the housing.
NOTICE!
– The dust discharge valve must point vertically
downwards.
– Make sure that the cover locks engage cor-
rectly.
11. Reassemble the housing cover.

Fig. 367
488 BW 219 D-5 / BW 219 PD-5

Replacing the safety element
NOTICE!
The safety element must not be cleaned and
should not be used again after it has been
removed.
The safety element must be replaced:
– if the air filter is damaged.
– at the latest after one year.
– if the air filter warning light comes on again
after the air filter has been cleaned.
1. Remove the housing cover and pull the air filter element off.
2. Pull the safety element out by turning it lightly.
3. Push in a new safety element.
4. Insert the air filter and reassemble the housing cover.
Fig. 368
BW 219 D-5 / BW 219 PD-5 489

6.1.9.8.2 Checking and cleaning the water separator
The service intervals for the water separator

depend on the water content in the fuel and can
therefore not be determined precisely.
After taking the engine into operation you should
check for signs of water and dirt initially every day.

n Protective gloves
1. If the “water in fuel” warning light lights up when starting or
during operation, drain the water from the fuel pre-filter
immediately.
Fig. 369
3. Loosen the drain plug and drain the fluid until pure diesel fuel
starts to run out.
4. Collect running out fluid.
5. Screw the drain plug tightly back in. Check for leaks, if nec-
essary use a new seal ring.
ð Once the water separator is empty, the warning light for
water in fuel must go out.
Fig. 370
6.1.9.8.3 Measures prior to extended shut-down period

Measures before shutting down
If the machine is shut down for a longer period of time, e.g. winter
season, the following work must be carried out:
1. Clean the machine thoroughly.
2. After shutting down store the machine under cover in a dry
and well ventilated room. The room temperature should
thereby not drop below -10 °C (14 °F), to prevent freezing of
the AdBlue®/DEF.
3. Grease the bare piston rods of all hydraulic cylinders well
and pull them in as far as possible.
4. Spray a thin oil film onto to all lever joints and bearing points
without lubrication.
5. Repair damaged paint; preserve bare areas thoroughly with
anti-corrosive agent.
6. Clean the water separator.
7. Fill the fuel tank with diesel fuel to prevent the formation of
condensation water in the tank.
490 BW 219 D-5 / BW 219 PD-5

8. Change engine oil and oil filter if the oil has been changed
more than 300 hours ago, or if the oil is older than 12
months.
9. Check the anti-freeze concentration and the coolant level.
10. Completely fill the AdBlue®/DEF tank to prevent crystallisa-
tion of the AdBlue®/DEF.
11. Disconnect the ground strap from the battery (this avoids
self-discharge caused by closed-circuit consuming devices).
Battery service during prolonged machine downtimes
WARNING!
ture!
the battery.
the battery.

n Protective gloves
n Safety goggles
charged to 50%.
charging.
the last discharge.
clamps.
BW 219 D-5 / BW 219 PD-5 491

Measures before restarting

1. Replace the fuel filter.
2. Replace the air filter.
3. Change the engine oil and oil filter.
4. For storage periods exceeding four months, empty the
AdBlue®/DEF tank and fill it completely with new AdBlue®/
DEF.
5. In case of storage periods exceeding four months you should
renew the AdBlue®/DEF filter.
6. Check the coolant level.
7. Check the charge condition of the batteries, recharge if nec-
essary. Check the battery fluid level before and after
charging.
8. Connect the ground straps to the batteries.
9. Check the function of the electric system.
10. Check cables, hoses and lines for cracks and leaks.
11. Check the service life of hydraulic hoses and replace if nec-
essary.
12. Start the engine and run it for 15 to 30 minutes with idle
speed.
13. While the engine is running keep an eye on the gauges for
engine oil pressure and coolant temperature.
14. Check the oil levels.
15. Check the function of electric system, steering and brakes.
492 BW 219 D-5 / BW 219 PD-5

6.1.9.9 As required, exhaust classification STAGE V

6.1.9.9.1 Air filter maintenance
NOTICE!
– Do not start the engine after having removed
the air filter.
– If necessary, the air filter may be cleaned up to
six times. After one year at the latest it must be
replaced together with the safety element.
– Cleaning does not make sense if the air filter
element is covered with a sooty deposit.
– Do not use gasoline or hot fluids to clean the
filter element.
– After cleaning, the air filter must be inspected
for damage using a torch.
– Do not continue to use a damaged air filter ele-
ment. If in doubt use a new air filter.
– If the air filter is damaged, the safety element
must be replaced as well.
– The safety element must not be cleaned.
We generally recommend to renew the air filter. A

new filter element is far less expensive than a pos-
sible engine damage.

n Protective gloves
n Safety goggles
1. Maintenance of the air filter is due when the air filter warning
lamp lights up, but at the latest after one year.
Fig. 371
4. Loosen both locking hooks on the housing cover and take the
cover off.
5. Clean housing cover and dust discharge valve.
Fig. 372
BW 219 D-5 / BW 219 PD-5 493

6. Pull out the air filter with light turning movements.
CAUTION!
flying around!
(safety gloves, protective working clothes, gog-
gles).
Fig. 373
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. 374
8. Examine the air filter with a torch for cracks and holes in the
paper bellows.
9. In case of damage replace the air filter and the safety ele-
ment.
Fig. 375
10. Slide the air filter carefully into the housing.
NOTICE!
– The dust discharge valve must point vertically
downwards.
– Make sure that the cover locks engage cor-
rectly.
11. Reassemble the housing cover.

Fig. 376
494 BW 219 D-5 / BW 219 PD-5

Replacing the safety element
NOTICE!
The safety element must not be cleaned and
should not be used again after it has been
removed.
The safety element must be replaced:
– if the air filter is damaged.
– at the latest after one year.
– if the air filter warning light comes on again
after the air filter has been cleaned.
1. Remove the housing cover and pull the air filter element off.
2. Pull the safety element out by turning it lightly.
3. Push in a new safety element.
4. Insert the air filter and reassemble the housing cover.
Fig. 377
BW 219 D-5 / BW 219 PD-5 495

6.1.9.9.2 Checking and cleaning the water separator
The service intervals for the water separator

depend on the water content in the fuel and can
therefore not be determined precisely.
After taking the engine into operation you should
check for signs of water and dirt initially every day.

n Safety shoes
n Protective gloves
1. If the “water in fuel” warning light lights up when starting or
during operation, drain the water from the fuel pre-filter
immediately.
Fig. 378
3. Loosen the drain plug and drain the fluid until pure diesel fuel
starts to run out.
4. Collect the escaping fluid.
5. Screw the drain plug back in tightly. Check for leaks; if neces-
sary, use a new seal ring.
ð Once the water separator is empty, the warning light for
water in fuel must go out.
B-GEN-0025
Fig. 379
6.1.9.9.3 Measures prior to extended shut-down period

Measures before shutting down
If the machine is shut down for a longer period of time, e.g. winter
season, the following work must be carried out:
2. After shutting down store the machine under cover in a dry
and well ventilated room. The room temperature should
thereby not drop below -10 °C (14 °F), to prevent freezing of
the AdBlue®/DEF.
3. Grease the bare piston rods of all hydraulic cylinders well
and pull them in as far as possible.
4. Spray a thin oil film onto to all lever joints and bearing points
without lubrication.
5. Repair damaged paint; preserve bare areas thoroughly with
anti-corrosive agent.
6. Clean the water separator.
496 BW 219 D-5 / BW 219 PD-5

7. Fill the fuel tank with diesel fuel to prevent the formation of
condensation water in the tank.
8. Change engine oil and oil filter if the oil has been changed
more than 300 hours ago, or if the oil is older than 12
months.
9. Check the anti-freeze concentration and the coolant level.
10. Completely fill the AdBlue®/DEF tank to prevent crystallisa-
tion of the AdBlue®/DEF.
11. Disconnect the ground strap from the battery (this avoids
self-discharge caused by closed-circuit consuming devices).
Battery service during prolonged machine downtimes
WARNING!
ture!
the battery.
the battery.

n Protective gloves
n Safety goggles
charged to 50%.
charging.
the last discharge.
clamps.
BW 219 D-5 / BW 219 PD-5 497


Measures before restarting

1. Replace the fuel filter.
2. Replace the air filter.
3. Change the engine oil and oil filter.
4. For storage periods exceeding four months, empty the
AdBlue®/DEF tank and fill it completely with new AdBlue®/
DEF.
5. In case of storage periods exceeding four months you should
renew the AdBlue®/DEF filter.
6. Check the coolant level.
7. Check the charge condition of the batteries, recharge if nec-
essary. Check the battery fluid level before and after
charging.
8. Connect the ground straps to the batteries.
9. Check the function of the electric system.
10. Check cables, hoses and lines for cracks and leaks.
11. Check the service life of hydraulic hoses and replace if nec-
essary.
12. Start the engine and run it for 15 to 30 minutes with idle
speed.
13. While the engine is running keep an eye on the gauges for
engine oil pressure and coolant temperature.
14. Check the oil levels.
15. Check the function of electric system, steering and brakes.
498 BW 219 D-5 / BW 219 PD-5

Machine assemblies – Drum
6.2 Drum
6.2.1 Repair overview for drum....................................... 500
6.2.2 Dismantling the drum............................................. 503
6.2.3 Dismantling and assembling the change-over
weight.................................................................... 517
6.2.4 Assembling the drum............................................. 521
6.2.5 Changing the rubber buffers, adjusting the preten-
sion........................................................................ 543
6.2.6 Smooth drum scraper; installation and removal.... 548
6.2.7 Pad foot scraper; installation and removal............. 552
BW 219 D-5 / BW 219 PD-5 499

6.2.1 Repair overview for drum

1 Vibration motor
2 Exciter unit
3 Clutch
4 Travel gear
5 Travel motor
6 Drum shell
7 Rubber buffer
9 Travel bearings
500 BW 219 D-5 / BW 219 PD-5

2 SILICON
1 59 1 2
OIL 47V
Nm 1000 CST
4
0,6 ... 1,8 mm
9
SAE
15W40
3 4 120
8
Nm
7
6 5
S-586-0478
Fig. 381: Repair overview for drum
NOTICE!
Ensure strict cleanliness!
– Thoroughly clean work place and components.
BW 219 D-5 / BW 219 PD-5 501

NOTICE!
Notes on repair
– 1
Install the O-ring with some grease.
– 2
Fitting and contact surfaces of the connection
must be absolutely dry and free of grease, oil,
paint and conserving agent.
– 3
Grease radial seals + running surface on shaft
before assembling.
– 4
Install the dowel pins with the grooves offset by
180° to each other, but in line with the shaft
axis.
– 5
The thread must be free of grease, oil, paint
and conserving agents.
– 6
To ease assembly of the mechanical seal, wet
the elastomer part + bore in flanged hub with
spirit (not with oil).
– Clean the sliding surfaces on the seal and
apply a thin film of oil.
– During assembly fill the cavity up to 1/3 with
grease.
– 7
Fill the bearing completely with grease.
– Bearing chamber to 1/3 filled with grease.
– 8
Ventilation bore in cover pointing down.
– 9
Check the axial clearance of the shaft: Nom-
inal value 0.6 to 1.8 mm.
502 BW 219 D-5 / BW 219 PD-5

6.2.2 Dismantling the drum

Removing the travel motor
DANGER!
Danger to life caused by suspended loads!
– Do not step or stand under suspended loads.
WARNING!
Danger of crushing caused by heavy compo-
nents!
– Be extremely cautious when working in the
danger zone
gloves, protective clothing).
1. Attach the lifting tackle to travel drive (3).

2. Unscrew all nuts (1) from the rubber buffers.
3. Take drive disc (2) with travel drive off the rubber buffers and
lay it down.
Fig. 382
4. Unscrew fastening screws (3) and take off gearbox bracket

(4).
5. Unscrew fastening screws (1) and take off drive disc (2).
Fig. 383
Removing the exciter unit (travel

motor side)
DANGER!
BW 219 D-5 / BW 219 PD-5 503

WARNING!
nents!
danger zone
1. Unscrew both socket head cap screws from the flange.
Fig. 384
2. Mount bracket (1) for the lifting device to the flange.

3.
NOTICE!
The four short fastening screws (drawn with
thin lines) must remain installed.
Unscrew screws (2) from the flange.
Fig. 385
4. Slide the lifting device over the bracket.

5. Force the exciter unit off with two forcing screws.
Fig. 386
504 BW 219 D-5 / BW 219 PD-5

6. Pull the exciter unit out of the drum .

7. Take the coupling element off the coupling half.
Fig. 387
Disassembling the exciter unit

(travel motor side)
1. Unscrew fastening screws (1) for the fan.
2. Loosen the clamping screw (2).
3. Pull the coupling hub off the shaft.
Fig. 388
4. Unscrew all other fastening screws (1) from the flange.

5. Press the flange off the flanged housing with forcing screws
(2).
Fig. 389
6. Lift the flange off the flanged housing.

7. Take the O-ring out of the groove in the flanged housing.
Fig. 390
BW 219 D-5 / BW 219 PD-5 505

8. Unclip the circlip from the groove in the flange.
Fig. 391
9. Press the cylinder roller bearing with forcing screws out of

the flange.
Fig. 392
10. Lift the exciter unit out of the flanged housing.
Fig. 393
11. Knock the radial seal out of the flanged housing.
Fig. 394
506 BW 219 D-5 / BW 219 PD-5

12. Unclip the circlip from the groove in the flanged housing.
Fig. 395
the flanged housing.
Fig. 396
14. Extract inner ring (1) for the radial seal and inner bearing
races (2).
Fig. 397
15.
If the rings are very tight, heat them up with a
torch.
WARNING!
Danger of burning!
Wear safety gloves.
Unclip the circlip from the basic weight.

Fig. 398
BW 219 D-5 / BW 219 PD-5 507

16. To change shaft (1) knock out dowel pins (2 and 3) and press
the shaft out of the basic weight.
Fig. 399
508 BW 219 D-5 / BW 219 PD-5

Removing the exciter unit (vibra-

tion motor side)
DANGER!
WARNING!
nents!
danger zone
1.
Perform work steps Ä Fig. 400 or
Ä Fig. 401 on both sides of the side plate.
– BW 213
4 rectangular rubber buffers
– BW 216
– BW 219
– BW 226
Fig. 400: shows BW 213-5 8 rectangular rubber buffers
2. Take up spacer block with rectangular rubber buffers

Ä Fig. 400 or Ä Fig. 401 with lifting tackle and unscrew fas-
tening screws (1).
3. Take rectangular rubber buffer (2) with spacer block (3) off
the side plate.
Fig. 401: shows BW 216-5
BW 219 D-5 / BW 219 PD-5 509

4. Unscrew fastening screws (1).

5. Force cover (2) together with the attached vibration motor off
the side plate (4) with forcing screws (3).
Fig. 402: On -4 machines the vibra-

tion motor is installed with a 180° rota-
tion
6. To change the vibration motor loosen clamping screw (1) and

pull off coupling half (2).
Fig. 403

8. Take the vibration motor off the cover.

tion
510 BW 219 D-5 / BW 219 PD-5

9. Take off coupling element (1).
Fig. 405
10. Fasten the lifting device.
NOTICE!
The four short fastening screws (2) must remain
screwed in (the two others are not visible).
Fig. 406
12. Press the exciter unit out of the drum with forcing screws.
The second forcing screw is covered by the

side plate.
Fig. 407
BW 219 D-5 / BW 219 PD-5 511

13. Pull the exciter unit out of the drum .
Fig. 408
Removing, dismantling the side

plate DANGER!
WARNING!
nents!
danger zone
1. Remove the V-ring (1).
Fig. 409
2. Unscrew fastening screws (2) and remove clamping ring (1).
Fig. 410
512 BW 219 D-5 / BW 219 PD-5

3. Attach the disassembly device to the side plate and force off
the side plate.
Fig. 411
4. Lift the side plate off the flanged hub.
Fig. 412
5.
New version with reinforced travel bear-
ings
On the new reinforced version, two self-
aligning roller bearings are installed.
Drive both bearings (new reinforced version has two self-

aligning roller bearings, the old version has one self-aligning
roller bearing and one grooved ball bearing) out of the side
plate and take out the spacer ring.
Fig. 413
BW 219 D-5 / BW 219 PD-5 513

6. Take the mechanical seal off the flanged hub.
Fig. 414
Dismantling the exciter unit (vibra-

tion motor side) WARNING!
nents!
danger zone
1. Unscrew the fastening from the coupling hub.

2. Pull the coupling hub off the shaft with a puller.
Fig. 415
3. Loosen the clamping screw (1).

4. Pull coupling hub (2) off the shaft.
Fig. 416
514 BW 219 D-5 / BW 219 PD-5

5. Unscrew all other fastening screws (1) and press the flanged
hub off the flanged housing with forcing screws (2).
6. Take off the flanged hub.
7. Take the O-ring out of the groove in the flanged housing.
Fig. 417
8. Unclip the circlip from the groove in the flanged hub.
Fig. 418
9. Knock the cylinder roller bearing out of the flanged hub.
Fig. 419
10. Lift the exciter unit out of the flanged housing.
Fig. 420
BW 219 D-5 / BW 219 PD-5 515

11. Knock the radial seal out of the flanged housing.
Fig. 421
12. Unclip the circlip from the groove in the flanged housing.
Fig. 422
the flanged housing.
Fig. 423
14. Extract inner rings (1) for the radial seals and inner bearing
races (2) from the shafts.
Fig. 424
516 BW 219 D-5 / BW 219 PD-5

15.
If the rings are very tight, heat them up with a
torch.
WARNING!
Danger of burning!
Wear protective gloves.
Unclip the circlip from the basic weight and remove the cover.
Fig. 425
The shafts cannot be pressed out. If dam-

aged they must be replaced with basic
weight and cover.
If necessary disassemble, assemble the
change-over weight (see corresponding
chapter).
6.2.3 Dismantling and assembling the change-over weight

Dismantling the change-over
weight ENVIRONMENT!
Environmental damage!
Catch running out oil and dispose of environmen-
tally.
1. Unscrew all screws.
Fig. 426
BW 219 D-5 / BW 219 PD-5 517

2. Force the cover off the basic weight with forcing screws.
Fig. 427
3. Take the change-over weight out of the basic weight.
Fig. 428
4. Pull O-rings (1 and 2) out of the grooves.
Fig. 429
518 BW 219 D-5 / BW 219 PD-5

Assembling the change-over

weights NOTICE!
Ensure strict cleanliness.
1. Install new O-rings (1 and 2) with grease.
Fig. 430
2. Insert the change-over weight into the basic weight.
Fig. 431
3. Fill silicon oil 47 V 1000 cst up to the upper edge of the

change-over weight (approx. 2.3 litres) into the basic weight.
Fig. 432
BW 219 D-5 / BW 219 PD-5 519

4. Attach the cover, so that the raised areas are in line.

5. Turn in screws with screw retention agent (e.g. Loctite blue
243) and tighten with 120 Nm.
6. Check the end float of the shaft.
ð
There must be play.
Fig. 433
520 BW 219 D-5 / BW 219 PD-5

6.2.4 Assembling the drum

Assembling the exciter unit (vibra-
tion motor side)
WARNING!
nents!
danger zone
WARNING!
WARNING!
Danger of body parts freezing due to liquid
nitrogen!
Wear your personal protective outfit (face protec-
tion, protective gloves, protective clothing).
Avoid skin contact.
WARNING!
Danger of body parts freezing on cold sur-
faces!
Wear your personal protective outfit (protective
NOTICE!
1. Close the bore in the shaft with a screw.

2. Cool the shaft down with liquid oxygen.
3. Remove the screw from the shaft again.
4. Align and insert the cooled shaft with the bores into the basic
weight until it bottoms.
Fig. 434
BW 219 D-5 / BW 219 PD-5 521

5.
NOTICE!
Assemble the dowel pins with the grooves
offset by 180° to each other, but in line with
the axis of the shaft.
Secure the shaft (1) with the dowel pins (2 and 3).
Fig. 435

9. Align and insert the cooled shaft with the bores into the cover
until it bottoms.
Fig. 436
10.
NOTICE!
Secure the shaft (2) with the dowel pins (1 u. 3).
Fig. 437
11. Insert the feather key into the groove of the respective shaft.
Fig. 438
522 BW 219 D-5 / BW 219 PD-5

12. Insert the circlip into the groove on the basic weight and the
cover.
Fig. 439
13. Heat the inner bearing race up to approx. 100° C and slide it
on the basic weight with the bigger outer diameter facing for-
ward until it bottoms.
Fig. 440
14. Heat the shaft collar up to approx. 50° C and slide it on the
shorter shaft with the longer chamfer facing outward until it
bottoms.
Fig. 441
on the cover with the bigger outer diameter facing forward
until it bottoms.
Fig. 442
BW 219 D-5 / BW 219 PD-5 523

longer shaft with the longer chamfer facing outward.
Fig. 443
17. Press the cylinder roller bearing (1) into the flanged housing
until it bottoms using pressing plate (2).
Fig. 444
18. Insert the circlip into the groove of the flanged housing.
Fig. 445
19. Insert the new O-ring with grease into the groove of the
flanged housing.
20. Fill approx. 1.2 l of SAE 15W-40 oil into the flanged housing.
Fig. 446
524 BW 219 D-5 / BW 219 PD-5

21. Insert the exciter unit into the flanged housing with the longer
shaft facing forward.
Fig. 447
22. Press the cylinder roller bearing (1) into the flanged hub until
it bottoms using pressing plate (2).
Fig. 448
23. Insert the circlip into the groove of the flanged hub.
Fig. 449
24.
NOTICE!
Fitting and contact surfaces must be abso-
lutely dry and free of grease, paint and con-
serving agents.
Place the flanged hub on the flanged housing.

25. Unscrew the eye bolts (1) and screw in the short screws
instead.
26. Screw in and tighten four short screws (2) into the tapped
Fig. 450 bores of the flanged housing.
BW 219 D-5 / BW 219 PD-5 525

27. Slightly lubricate the sealing lip of the radial seal (1).
28. Insert the radial seal into the flanged hub with the sealing lip
pointing down and press it until it bottoms using pressing
plate (2).
Fig. 451
29. Heat the coupling hub up to approx. 80° C and slide it on the
shaft until it bottoms.
Fig. 452
31. Slide the radial seal onto the shaft with the sealing lip
pointing forward and drive it into the flanged housing with a
suitable pipe (2) until it bottoms.
Fig. 453
32. Apply screw retention agent (Loctite CVX strong, blue, 582)
to the thread of the screw (1).
33. Slide on the new U-seal ring (2), insert and tighten the screw.
Fig. 454
526 BW 219 D-5 / BW 219 PD-5

34. Heat the coupling hub (1) with the code letter “L“ up to
approx. 80° C and slide it on the shaft until it bottoms.
35. Turn in and tighten the clamping screw (2).
Fig. 455
Assembling and installing the side

plate WARNING!
nents!
danger zone
1.
New version with reinforced travel bear-
ings
On the new reinforced version, two self-
aligning roller bearings are installed.
Fill grooved ball bearing/self-aligning roller bearing (1) on

both sides with grease.
2. Press the grooved ball bearing/self-aligning roller bearing
completely in using the pressing plate (2).
Fig. 456
3. Apply a thick coat of grease to the spacer ring on both sides

and insert it into the side plate.
Fig. 457
BW 219 D-5 / BW 219 PD-5 527

4.
NOTICE!
Inserting the outer ring with adhesive
Insert the outer ring with LOCTITE 603, high-
strength fitted connection.
Fill the self-aligning roller bearing (1) with grease.

5. Press the self-aligning roller bearing completely in using
pressing plate (2).
Fig. 458
6. Clean the sliding surfaces of the mechanical seal and cover

them lightly with oil.
7. Insert the O-ring into the mechanical seal.
Fig. 459
8.
Wet the elastomer part + bore with spirit (no
oil) to make the assembly easier.
Lay one half of the mechanical seal on the flanged hub with
the sliding surface pointing up.
Fig. 460
9. Lay the second half of the mechanical seal on top with the
sliding surface pointing down.
10. Fill the cavity of the mechanical seal up to 1/3 with grease.
Fig. 461
528 BW 219 D-5 / BW 219 PD-5

11. Bolt the threaded section of the assembly device to the

flanged hub.
Fig. 462
12. Lay the side plate on the flanged hub.
Fig. 463
13. Attach bushing (2) of the assembly device and turn on nut
(1).
Fig. 464
14.
NOTICE!
During assembly make sure that the
mechanical seal slides correctly into the side
plate and the loop rings are not damaged .
Pull the side plate with the assembly device onto the flanged
hub.
15. Remove the assembly device.
Fig. 465
BW 219 D-5 / BW 219 PD-5 529

16.
Tighten the fastening screws crosswise.
Assemble the clamping ring (1) with screws and washers (2).
Fig. 466
530 BW 219 D-5 / BW 219 PD-5

Assembling the exciter unit (travel

motor side)
WARNING!
nents!
danger zone
WARNING!
WARNING!
Danger of body parts freezing due to liquid
nitrogen!
Wear your personal protective outfit (face protec-
tion, protective gloves, protective clothing).
Avoid skin contact.
WARNING!
Danger of body parts freezing on cold sur-
faces!
Wear your personal protective outfit (protective
NOTICE!

4. Align and insert the cooled shaft with the bores into the basic
weight until it bottoms.
Fig. 467
BW 219 D-5 / BW 219 PD-5 531

5.
NOTICE!
Secure the shaft (1) with the dowel pins (2 and 3).
Fig. 468
6. Insert the circlip into the groove on the basic weight and the
cover.
Fig. 469

on the basic weight with the bigger outer diameter facing for-
ward until it bottoms.
Fig. 470

shaft with the longer chamfer facing outward until it bottoms.
Fig. 471
532 BW 219 D-5 / BW 219 PD-5


on the cover with the bigger outer diameter facing forward
until it bottoms.
Fig. 472
10. Press the cylinder roller bearing (1) into the flanged housing
until it bottoms using pressing plate (2).
Fig. 473
11. Insert the circlip into the groove of the flanged housing.
Fig. 474
12. Insert the new O-ring with grease into the groove of the
flanged housing.
13. Fill approx. 1.2 l of SAE-15W/40 oil into the flanged housing.
Fig. 475
BW 219 D-5 / BW 219 PD-5 533

14. Insert the exciter unit into the flanged housing.
Fig. 476
15. Press the cylinder roller bearing (1) into the flange until it bot-
toms using pressing plate (2).
Fig. 477
16. Insert the circlip into the groove of the flange.
Fig. 478
17.
NOTICE!
Fitting and contact surfaces must be abso-
lutely dry and free of grease, paint and con-
serving agents.
Lift the flange to the flanged housing and align it with the
boreholes.
Fig. 479
534 BW 219 D-5 / BW 219 PD-5

18. Turn in and tighten the screws into the tapped bores of the
flanged housing.
Fig. 480
20. Slide the radial seal onto the shaft with the sealing lip
pointing forward and drive it into the flanged housing with a
suitable pipe (2) until it bottoms.
Fig. 481
21. Apply screw retention agent (Loctite CVX strong, blue, 582)
to the thread of the screws (1).
22. Slide on the new U-seal ring (2), insert and tighten the screw.
Fig. 482
23. Insert the feather key into the groove of the shaft.
Fig. 483
BW 219 D-5 / BW 219 PD-5 535

24. Slide the fan blade with the mounting disc on the shaft.
25. Heat the coupling hub (1) with the code letter “R“ up to
approx. 80° C and slide it on the shaft until it bottoms.
26. Turn in and tighten the clamping screw (2).
27. Mount the fan blade to the coupling hub .
Fig. 484
Installing the exciter unit (travel

motor side) DANGER!
WARNING!
nents!
danger zone
NOTICE!
between exciter unit and drum must be absolutely
dry and free of grease, oil, paint and conserving
agent.
1. Check coupling elements , replace if necessary.

2. Insert the coupling element into the coupling hub.
Fig. 485
536 BW 219 D-5 / BW 219 PD-5

3. Fasten the lifting device to the exciter unit.

4. Insert the vibrator unit into the drum.
Fig. 486
5.
Insert the exciter unit so that oil filler plug 1 is
in line with bore (2) in the drum.
Fig. 487
6.
NOTICE!
The thread must be free of oil, grease and
conserving agents.
Turn in and tighten screws (2).

7. Remove bracket (1) for the lifting device.
Fig. 488
8. Cover the thread of screws with a screw retention agent (e.g.

Loctite green 270).
9. Slide on the new U-seal ring, turn in and tighten the screws.
Fig. 489
BW 219 D-5 / BW 219 PD-5 537

Installing the travel motor

DANGER!
WARNING!
nents!
danger zone
1. Assemble drive disc (2) and gearbox bracket (4) with screws
(3).
Fig. 490
2. Attach drive disc (2) with assembled travel drive (3) to the
rubber buffers. Turn on and tighten the nuts (1).
Fig. 491
538 BW 219 D-5 / BW 219 PD-5

Installing the exciter unit (vibration

motor side) DANGER!
WARNING!
nents!
danger zone
NOTICE!
between exciter unit and drum must be absolutely
dry and free of grease, oil, paint and conserving
agent.
1. Fasten the lifting tackle to the exciter unit and insert it into the
drum.
Fig. 492
2.
NOTICE!
Ensure correct engagement of coupling and
alignment of shaft .
If the shafts are not correctly in line deter-
mine the cause, if necessary measure the
drum.
Fig. 493
BW 219 D-5 / BW 219 PD-5 539

3.
NOTICE!
The thread must be free of oil, grease and
conserving agents.
Turn in and tighten screws (1).

4. Remove the lifting gear.
5. Fit cover (2) to the drum.
Fig. 494
6. Check the end float of the exciter shafts.

ð
Nominal value: 0.6...1.8 mm
Fig. 495
7. Attach washer (1), turn in and tighten the fastening screw (2).
8. Fill the self-aligning roller bearing with grease.
Fig. 496
540 BW 219 D-5 / BW 219 PD-5

9.
Check coupling element (1), replace if neces-
sary.
Insert the coupling element into the coupling hub.

10. Assemble V-ring (2).
Fig. 497
11. Install a new O-ring (1) and apply a thin coat of oil.
Fig. 498: Vibration motor
12.
Ventilation bore (3) in cover pointing down.
Mount vibration motor (1) to cover (2).

13. Turn in fastening screws with ball disc and ball socket and
tighten.

tion
BW 219 D-5 / BW 219 PD-5 541

14. Slide on coupling half (2) and secure with clamping screw
(1).
Fig. 500
15. Install a new O-ring (1) and apply a thin coat of oil.
Fig. 501
16. Attach cover (2) with the assembled vibration motor,

assemble screws (1) with washers and tighten.

tion
542 BW 219 D-5 / BW 219 PD-5

17.
Perform work steps Ä Fig. 503 or
Ä Fig. 504 on both sides of the side plate.
– BW 213
– BW 216
– BW 219
– BW 226
Fig. 503: shows BW 213-5 8 rectangular rubber buffers
18. Take rectangular rubber buffers (2) with attached spacer

block (3) with lifting tackle mount to the side plate with
screws and washers (1).
Fig. 504: shows BW 216-5
6.2.5 Changing the rubber buffers, adjusting the pretension
BW 211/212/213/214 = 4 rectangular rubber buf-

fers
BW 216 = 6 rectangular rubber buffers
BW 219/226 = 8 rectangular rubber buffers
BW 219 D-5 / BW 219 PD-5 543

Fig. 505: BW 211/212/213/214 D/PD

1 Weld-on nuts
Fig. 506: BW 211/212 DH/PDH

1 Weld-on nuts
544 BW 219 D-5 / BW 219 PD-5

Fig. 507: BW 213 DH/PDH

1 Weld-on nuts
Fig. 508: BW 215/216 D/PD, BW216/219/226 DH/PDH

1 Weld-on nuts
BW 219 D-5 / BW 219 PD-5 545

Relieve the rubber buffers

1. Lift the front frame up on both sides, until rubber buffers and
rectangular buffers are relieved of any load.
2. Loosen all fastening screws.
Fig. 509
3. Turn the screws into the weld-on nuts.
Fig. 510: Picture shows BW216
4. Remove the compensation plates.
Fig. 511
5. Unscrew the screws from the welded nuts.
546 BW 219 D-5 / BW 219 PD-5

6.
NOTICE!
Check the rectangular rubber buffers,
replace if necessary
Observe the assembly direction, arrow up.
Fig. 513
Changing the rubber buffers

1. Unscrew nut (1) and remove the washer.
2. Unscrew screws (2).
3. Take off rubber buffer (3).
4. Attach the new rubber buffer to the drive disc and align the
bores to the tapped bores in the drum.
5. Turn in and tighten the screws.
6. Install the washer, turn on and tighten the nut.
Fig. 514
Adjusting the pretension

1. Measure distance “X” between spacer block and side plate.
2. Calculate the thickness of the compensation plates.
ð Nominal value: Distance “X” + 2 mm
3. Turn in screws into each welded nut and create sufficient

space to insert the compensation plates.
BW 219 D-5 / BW 219 PD-5 547

4. Install the compensation plates.
Fig. 517
5. Unscrew the screws from the welded nuts.
6. Tighten the fastening screws.

7. Lower the front frame again.
Fig. 519
6.2.6 Smooth drum scraper; installation and removal

6.2.6.1 Removing the scrapers....................................... 549
6.2.6.2 Attaching the scrapers........................................ 551
548 BW 219 D-5 / BW 219 PD-5

6.2.6.1 Removing the scrapers

n Safety shoes
n Protective gloves
Front scraper
1. Remove all nuts (1) from the fastening bolts between the
1 front scraper and drum.
WARNING!
Danger of injury caused by heavy component!
– When removing the bolts make sure nobody is
within the swivel range of the scraper!
– Persons may only stand to the side of the
crossbar.
Fig. 520
2. Remove the rear bolts (1) on both sides.

1
Fig. 521
3. Attach the lifting tackle to the front scraper as perpendicularly

as possible and secure with suitable lifting tackle.
4. Remove the remaining bolts on both sides.
5. Lower the front scraper to the ground or onto a pallet and pull
to the side.
Fig. 522
BW 219 D-5 / BW 219 PD-5 549

Rear scraper
6.
NOTICE!
– Make sure no components of the driver’s
stand get damaged.
– Particularly in the case of machines with
cabs, make sure that the windows do not
get damaged.
If necessary, protect the window (e.g.
with a board).
Fig. 523 Attach the lifting tackle to the rear scraper as perpendicularly
7. Remove all nuts (1) from the fastening bolts between the rear
1 scraper and drum.
WARNING!
crossbar.
Fig. 524
8. Remove the front bolts on both sides.

1
10. Lower the rear scraper to the ground or onto a pallet and pull
to the side.
Fig. 525
550 BW 219 D-5 / BW 219 PD-5

6.2.6.2 Attaching the scrapers

n Safety shoes
n Protective gloves
Front scraper
1. Position the scraper in front of the drum.
Fig. 526
3. Carefully lift the scraper until it is in installation position.

1
4. Insert the fastening bolts, screw the nuts (1) on and tighten.
Fig. 527
Rear scraper
6.
NOTICE!
stand get damaged.
get damaged.
Fig. 528 with a board).
Attach the lifting tackle to the rear scraper as perpendicularly

BW 219 D-5 / BW 219 PD-5 551


1
Fig. 529
6.2.7 Pad foot scraper; installation and removal

6.2.7.1 Removing the scrapers....................................... 552
6.2.7.2 Attaching the scrapers........................................ 554

n Safety shoes
n Protective gloves
Front scraper
Fig. 530
2. Remove the two lower bolts (1) from the half shells on both
sides.
3. Carefully set the scraper down on the floor.
B-586-0370
Fig. 531
552 BW 219 D-5 / BW 219 PD-5

4. Remove all three nuts (1) on both sides.

5. Remove the bolts (2) and the upper half shells.
B-586-0364
Fig. 532
Rear scraper
6.
NOTICE!
stand get damaged.
get damaged.
with a board).
sides.
out from under the machine.
B-586-0371
Fig. 534

B-586-0362
Fig. 535
BW 219 D-5 / BW 219 PD-5 553


n Safety shoes
n Protective gloves
Front scraper
1. Attach both of the upper half shells of the padfoot scraper to
the front right and left of the machine.
Fig. 536

4. Carefully lift the scraper until it is in the upper retainer half.
Fig. 537
5. Attach the lower half shells, insert the screws with copper
paste (OKS 240, BOMAG 009 700 03) and secure them.
Fig. 538
554 BW 219 D-5 / BW 219 PD-5

6. Slide the scraper onto the drum leaving approx. 25 mm (1 in).

7. Tighten the bolts on the half shells using tightening torque:
463 Nm (341 ft·lbf).
Fig. 539
Rear scraper
8. Attach both of the upper half shells of the scraper rear right
and left.
B-586-0349
Fig. 540

10.
NOTICE!
stand get damaged.
get damaged.

11. Carefully lift the scraper until it is in the upper half shells.
BW 219 D-5 / BW 219 PD-5 555

Fig. 542
463 Nm (341 ft·lbf).
Fig. 543


6.2.8.2.1 Checking the oil level in the exciter housing 557
6.2.8.2.2 Checking the oil level in the drum drive reduction gear 557
6.2.8.3.1 Change the oil in the exciter housing 558
6.2.8.3.2 Change the oil in the drum drive reduction gear 560
As required
6.2.8.4.1 Retightening the padfoot shell 561
6.2.8.4.2 Adjust the scrapers 561
556 BW 219 D-5 / BW 219 PD-5


6.2.8.2.1 Checking the oil level in the exciter housing
NOTICE!
– Use only gear oil of the permitted specification
Ä Chapter 2.5.6 ‘Gear oil SAE 75W-90’
on page 88.

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. 544
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. 545
6.2.8.2.2 Checking the oil level in the drum drive reduction gear
NOTICE!
on page 88.
BW 219 D-5 / BW 219 PD-5 557


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. 546 bore.
4. If necessary clean the area around the upper level inspection
plug and unscrew the plug.
5. Fill in oil through the opening of the upper level inspection
plug, until it starts to run out through the horizontal inspection
plug.
6. Retighten both inspection plugs again.

6.2.8.3.1 Change the oil in the exciter housing
NOTICE!
– Drain gear oil only at operating temperature.
on page 88.

one year.
558 BW 219 D-5 / BW 219 PD-5


n Protective gloves
1. Before changing the oil level run the machine warm for about
1/2 hour with vibration.
2. Move the drum, until the drain plug is in bottom position.
4. Clean the area around the drain plug.
WARNING!
Fig. 547 – Avoid touching hot components.
5. Unscrew the drain plug and catch any oil running out.
6. Turn the drain plug tightly back in.
7. Clean the area around the oil level inspection plug.
8. Unscrew the oil level inspection plug.
Fig. 548
9. Unscrew the oil filler plug and fill in new oil through the oil
filler bore, until oil starts to drip out through the inspection
bore.
10. Retighten the filler and level inspection plugs.
11. Change the oil on both sides.
12. Dispose of oil in an environmentally friendly way.
Fig. 549
BW 219 D-5 / BW 219 PD-5 559

6.2.8.3.2 Change the oil in the drum drive reduction gear
NOTICE!
on page 88.

one year.

n Protective gloves
1. There are three plugs arranged around the circumference of
the reduction gear, always offset to each other by 90°.
Move the machine so that one plug is in horizontal position
and the two other plugs are facing vertically upwards and
vertically downwards.
3. Clean the area around the plugs.
WARNING!
Fig. 550
6. Unscrew the filler and oil level inspection plugs.
7. Fill in oil through the filler plug, until it starts to run out
through the oil level inspection plug.
8. Retighten the filler and oil level inspection plugs.
560 BW 219 D-5 / BW 219 PD-5

6.2.8.4 As required
6.2.8.4.1 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. 551
6.2.8.4.2 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. 552
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. 553
BW 219 D-5 / BW 219 PD-5 561

Machine assemblies – Padfoot shell
6.3 Padfoot shell

6.3.1 Attaching the padfoot shells................................... 562
6.3.2 Removing the padfoot shells................................. 574
6.3.1 Attaching the padfoot shells

6.3.1.1 Preliminary remarks and safety notes
Loads are only to be attached and hoisted by an expert/qualified
person.
Do not use lifting points that are damaged or impaired in any other
way.
Only use lifting and lashing tackle with sufficient load bearing
Always use appropriate lifting and lashing tackle at the lifting and
lashing points.
Use lifting tackle only in the specified loading direction.
When lifting the machine, avoid uncontrolled movements of the
load. If necessary, hold the load with guide ropes.
At least two people are required when attaching and detaching the
segments.
Weights
Padfoot shell segment Scraper
Approx. 425 kg (937 lbs) each Approx. 138 kg (304 lbs) each
During production, 1, 2 or 3 weld seams are

applied to the individual segments as identification
in order to ensure that the individual segments stay
together.
Fig. 554
1 Weld seam identification
562 BW 219 D-5 / BW 219 PD-5

6.3.1.2 Preparations
n Safety shoes
n Protective gloves
n Safety goggles
1. Drive the machine onto level, firm ground.
Make sure there is sufficient space to drive

the machine for at least one full turn of the
drum.
2. Apply the parking brake.

4. Clean the drum.
B-ELE-0069
Fig. 555
5. Check all three segments for damage to the lifting points.

ð Do not use lifting points that are damaged or impaired in
any way.
6. Check all three segments for deformation.
ð Do not use damaged or badly bent segments.
7. Clean all three segments.
8. Clean screw connection points of disconnected bolts, nuts
and dirt.
Fig. 556
If necessary, use a drill with wire brush
attachment to clean the screw connection
points.
BW 219 D-5 / BW 219 PD-5 563


n Safety shoes
n Protective gloves
Front scraper
1. Remove all nuts (1) from the fastening bolts between the
1 front scraper and drum.
WARNING!
crossbar.
Fig. 557
2. Remove the rear bolts (1) on both sides.

1
Fig. 558

5. Lower the front scraper to the ground or onto a pallet and pull
to the side.
Fig. 559
564 BW 219 D-5 / BW 219 PD-5

Rear scraper
6.
NOTICE!
stand get damaged.
get damaged.
with a board).
7. Remove all nuts (1) from the fastening bolts between the rear
1 scraper and drum.
WARNING!
crossbar.
Fig. 561
8. Remove the front bolts on both sides.

1
to the side.
Fig. 562
BW 219 D-5 / BW 219 PD-5 565

6.3.1.4 Attaching segments

n Safety shoes
n Protective gloves
To fasten the segments together first use

M20 x 135 bolts.
Once all segments are attached to the drum,
replace those bolts with M20 x 85 bolts.
Use new bolts and nuts!
NOTICE!
Fig. 563 – When fastening, always turn the screw itself.
1 Hexagon bolt M20 x 85 (BOMAG – The cap nut is fitted with a knurl which holds
071 320 37) the nut in the retainer.
2 Cap nut M20 with knurl (BOMAG If the retainer on the cap is turned, the knurl
580 038 44) may get damaged which means the required
tightening torque cannot be achieved.
1. Segment
1. Attach suitable lifting tackle to the lifting eyes of the first seg-
ment.
CAUTION!
Danger of crushing when positioning the indi-
vidual segments!
– Never put your hands between the segment
and drum or machine parts.
Fig. 564
2. Lift the first segment using suitable lifting tackle, position as

centrally as possible on the drum and set down.
Fig. 565
566 BW 219 D-5 / BW 219 PD-5

3. Fix the segment to the drum both right and left with a vice.
If there are four vices available, it is useful to

fix the segment front and back with a vice.
4. Start the engine and move the machine back as far as nec-
essary to be able to set down the next segment on the drum
from above.
Fig. 566
B-ELE-0069
Fig. 567
2. Segment 6. Select the right segment.
CAUTION!
vidual segments!
7. Lift the second segment using suitable lifting tackle, position

as centrally as possible on the drum and set down.
8. Loosely connect the two segments using bolts of length
M20 x 135 (4 to 5 thread turns).
Fig. 568
BW 219 D-5 / BW 219 PD-5 567

9. Fix the second segment to the drum both right and left with a
vice.
essary to be able to set down the next segment on the drum
from above.
Fig. 569
B-ELE-0069
Fig. 570
3. Segment
CAUTION!
vidual segments!
12. Lift the third segment using suitable lifting tackle, position on
the drum and set down.
13. Loosely connect the segments using bolts of length
M20 x 135 (4 to 5 thread turns).
Fig. 571
568 BW 219 D-5 / BW 219 PD-5

Tightening segments 1 and 3

14. Replace bolts of length M20 x 135 with length M20 x 85 and
tighten using tightening torque: 578 Nm (426 ft·lbf).
15. Start the engine and move the machine forward as far as
necessary to allow the bolts in the next segment to be
replaced and tightened.
Fig. 572
B-ELE-0069
Fig. 573

18. Start the engine and move the machine forward as far as
necessary to allow the bolts in the next segment to be
replaced and tightened.
Fig. 574
B-ELE-0069
Fig. 575
BW 219 D-5 / BW 219 PD-5 569


21. Start the engine and test drive for approx. two minutes with
vibration.
Fig. 576
23. Retighten all fastening screws.
24. After approx. 60 minutes work, retighten all fastening screws
again.
B-ELE-0069
Fig. 577

n Safety shoes
n Protective gloves
Front scraper
1. Attach both of the upper half shells of the padfoot scraper to
the front right and left of the machine.
Fig. 578
570 BW 219 D-5 / BW 219 PD-5


4. Carefully lift the scraper until it is in the upper retainer half.
Fig. 579
Fig. 580

463 Nm (341 ft·lbf).
Fig. 581
Rear scraper
8. Attach both of the upper half shells of the scraper rear right
and left.
B-586-0349
Fig. 582
BW 219 D-5 / BW 219 PD-5 571


10.
NOTICE!
stand get damaged.
get damaged.

11. Carefully lift the scraper until it is in the upper half shells.
Fig. 584
463 Nm (341 ft·lbf).
Fig. 585
572 BW 219 D-5 / BW 219 PD-5

6.3.1.6 Installing the access steps

n Safety shoes
n Protective gloves
Repositioning the steps
1. Remove all four nuts of the upper step.
1
2. Remove the screws and position the step one bore higher
(1).
3. Insert the bolts, screw the nuts on and tighten them.
4. Likewise, install the lower step one bore higher.
1
B-586-0420
Fig. 586
Installing an additional step

5. Place two rubber plates with profiles on the lower bores.
B-586-0422
Fig. 587
7. Position the step with the profiles on the rubber plates.

B-586-0423
Fig. 588
BW 219 D-5 / BW 219 PD-5 573

6.3.2 Removing the padfoot shells

6.3.2.1 Preliminary remarks and safety notes
Loads are only to be attached and hoisted by an expert/qualified
person.
Do not use lifting points that are damaged or impaired in any other
way.
Only use lifting and lashing tackle with sufficient load bearing
Always use appropriate lifting and lashing tackle at the lifting and
lashing points.
Use lifting tackle only in the specified loading direction.
When lifting the machine, avoid uncontrolled movements of the
load. If necessary, hold the load with guide ropes.
At least two people are required when attaching and detaching the
segments.
6.3.2.2 Preparations
n Safety shoes
n Protective gloves
1. Drive the machine onto level, firm ground.
Make sure there is sufficient space to drive

the machine for at least one full turn of the
drum.
2. Apply the parking brake.

B-ELE-0069
Fig. 589
574 BW 219 D-5 / BW 219 PD-5


n Safety shoes
n Protective gloves
Front scraper
Fig. 590
sides.
3. Carefully set the scraper down on the floor.
B-586-0370
Fig. 591

B-586-0364
Fig. 592
BW 219 D-5 / BW 219 PD-5 575

Rear scraper
6.
NOTICE!
stand get damaged.
get damaged.
with a board).
sides.
out from under the machine.
B-586-0371
Fig. 594

B-586-0362
Fig. 595
576 BW 219 D-5 / BW 219 PD-5

6.3.2.4 Removing segments

n Safety shoes
n Protective gloves
n Safety goggles
1. Attach suitable lifting tackle to the lifting eyes of the first seg-
ment.
2. Secure the segment with suitable lifting tackle.
3.
CAUTION!
flying around!
clothes, goggles).
Fig. 596
Sever the fastening screws from the segments using a flame
cutter or cutting disc.
4. Lift the segment and set aside safely.
essary to attach lifting tackle to the next segment.
Fig. 597
B-ELE-0069
Fig. 598
BW 219 D-5 / BW 219 PD-5 577

7. Attach suitable lifting tackle to the lifting eyes of the second

segment.
9. Sever the fastening screws from the segments using a flame
cutter or cutting disc.
Fig. 599
Fig. 600
11. Fix the third segment to the drum both right and left with a
vice.
essary to attach lifting tackle to the next segment.
Fig. 601
B-ELE-0069
Fig. 602
578 BW 219 D-5 / BW 219 PD-5

14. Attach suitable lifting tackle to the lifting eyes of the third seg-
ment.
16. Undo the vices.
Fig. 603

n Safety shoes
n Protective gloves
Front scraper
Fig. 604

1
Fig. 605
BW 219 D-5 / BW 219 PD-5 579

Rear scraper
6.
NOTICE!
stand get damaged.
get damaged.

1
Fig. 607
6.3.2.6 Removing the access steps

n Safety shoes
n Protective gloves
Removing an additional step
1. Remove all four nuts of the lowest step.
2. Remove the screws and the remove the step with the pro-
files.
B-586-0423
Fig. 608
580 BW 219 D-5 / BW 219 PD-5

3. Unscrew all four nuts on the frame.

4. Remove the screws and the remove the rubber plates with
the profiles.
B-586-0422
Fig. 609
Repositioning the steps

5. Remove all four nuts of the upper step.
1 6. Remove the screws and position the step one bore lower (1).
8. Likewise, install the lower step one bore lower.
B-586-0421
Fig. 610
BW 219 D-5 / BW 219 PD-5 581

Machine assemblies – Oscillating articulated joint
6.4 Oscillating articulated joint

6.4.1 Overview................................................................ 582
6.4.2 Dismantling the oscillating articulated joint............ 583
6.4.3 Assembly of oscillating articulated joint................. 584
6.4.1 Overview
Fig. 611
1 Oscillating articulated joint
2 Bearing cover
3 Housing
4 Cover
5 Carrier
6 Console
582 BW 219 D-5 / BW 219 PD-5

6.4.2 Dismantling the oscillating articulated joint

1. Unscrew screw (1) and screws (2).
Fig. 612
2. Force the bearing cover (1) off using the thread (2).
3. Disassemble the opposite bearing cover in the same way.
Fig. 613
4. Remove the console (1).
Fig. 614
5. Unscrew screws (1).
Fig. 615
BW 219 D-5 / BW 219 PD-5 583

6. Remove the housing (1).
Fig. 616
7. Take off the carrier (1).
Fig. 617
6.4.3 Assembly of oscillating articulated joint

1. Lay the cover (3) on a level base.
2. Apply anti-friction paint to the mating faces of cover and
rocker bearings (2).
3. Knock the rocker bearing into the bore hole.
4. Install the seal ring (1).
Fig. 618
5. Apply anti-friction paint to the mating faces of rocker bearings

(1) and carrier (2).
6. Assemble the rocker bearings.
Fig. 619
584 BW 219 D-5 / BW 219 PD-5

7. Place the carrier (1) in mounting position on the cover (2).
Fig. 620

Fig. 621
10. Stand the housing (6) on a level base.

11. Insert shims (5) into the bearing bore as per spare parts cata-
logue.
12. Insert the backing disc (4) into the bearing bore.
13. Insert the Belleville springs (3) into the bearing bore. Ensure
correct alignment!
(2) and housing.
Fig. 622 16. Install the seal ring (1).
17. Position the housing (1) above the carrier (2).
18. Check whether the Belleville sprigs are correctly positioned.
If necessary, reposition the Belleville springs.
19. Lower the housing.
20. Bolt housing and cover together.
Fig. 623
BW 219 D-5 / BW 219 PD-5 585


Fig. 624

Fig. 625

(2) and bearing cover (3).
Fig. 626
28. Stand the bearing cover (1) on a level base.

29. Insert shims (2) into the bearing bore as per spare parts cata-
logue.
30. Insert the backing disc (3) into the bearing bore.
31. Insert the Belleville springs (4) into the bearing bore. Ensure
correct alignment!
(5) and bearing housing.
Fig. 627
586 BW 219 D-5 / BW 219 PD-5

35. Put the console (1) into place and align it to the carrier (2).
Fig. 628
36. Apply anti-friction paint to the mating faces of console (1) and
bearing cover (3).
37. Turn the guide pins (2) into the threaded bores.
38. Align and assemble the bearing cover.
39. Fasten the bearing cover.
40. Remove the guide pins.
41. Tighten the fastening screws on the bearing cover.
42. Repeat this procedure with two further bearing covers on the
opposite side.
Fig. 629
43. Assemble screws (2).
Fig. 630
BW 219 D-5 / BW 219 PD-5 587

Machine assemblies – Drive axle
6.5 Drive axle


Checks prior to start up
6.5.2.1 Checking wheels and tyres 588
6.5.3.1 Checking the oil level in the drive axle 589
6.5.3.2 Checking the oil level in the drive axle reduction gear 590
6.5.3.3 Checking the oil level in the wheel hubs 591
6.5.4.1 Change the oil in the drive axle 591
6.5.4.2 Changing the oil in the drive axle reduction gear 592
6.5.4.3 Changing the oil in the wheel hubs 593
6.5.4.4 Retightening the fastening of the axle on the frame 594
6.5.4.5 Retightening the wheel nuts 595
As required
6.5.5.1 Adjust the parking brake 595
6.5.2 Checks prior to start up

6.5.2.1 Checking wheels and tyres
WARNING!
Danger of being injured by bursting tyres!
(safety shoes, gloves, goggles, hard hat).
– When checking the tyre pressure stand in the
extended path of the tyre track.
– Use an air hose with a length of min. 6 meters.
– Never exceed the permitted maximum pres-
sure.
588 BW 219 D-5 / BW 219 PD-5

The tire pressure can be adapted to the operating

conditions within the specified limits.
A reduced tire pressure improves the traction
especially on sandy soils.
Higher tires pressures improve the driving stability
of the machine.
The total height of the machine can also be influ-
enced by changing the tire pressure.
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. 631 Ensure equal pressure in all tires.
Tire pressure, nominal value Ä Chapter 2

‘Technical data’ on page 67
6. Screw the valve caps back on again.

6.5.3.1 Checking the oil level in the drive axle
NOTICE!
on page 88.
BW 219 D-5 / BW 219 PD-5 589


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. 632
5. After filling in oil wait until the oil has evenly distributed inside
the axle.
6. Retighten level inspection and filler plugs.
6.5.3.2 Checking the oil level in the drive axle reduction gear
NOTICE!
on page 88.

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. 633
590 BW 219 D-5 / BW 219 PD-5

6.5.3.3 Checking the oil level in the wheel hubs
NOTICE!
on page 88.

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

6.5.4.1 Change the oil in the drive axle
NOTICE!
on page 88.

one year.
BW 219 D-5 / BW 219 PD-5 591


n Protective gloves
2. Clean the area around the drain plug.
WARNING!
Fig. 635
5. Clean the area around the filler plug (2) and the level inspec-
tion plug (1).
A second inspection plug is located on the

left front side of the drive axle.
7. Unscrew the filler plug.

Fig. 636 through the level inspection bore.
9. After filling in oil wait until the oil has evenly distributed inside
the axle, if necessary fill in some more oil.
10. Retighten level inspection and filler plugs.
6.5.4.2 Changing the oil in the drive axle reduction gear
NOTICE!
on page 88.

one year.
592 BW 219 D-5 / BW 219 PD-5


n Protective gloves
2. Clean the area around drain plug and level inspection plug.
WARNING!
Fig. 637

6. Fill in oil through the inspection bore, until it starts to run out
Fig. 638
6.5.4.3 Changing the oil in the wheel hubs
NOTICE!
on page 88.

one year.
BW 219 D-5 / BW 219 PD-5 593


n Protective gloves
1. Move the drum, until the oil level inspection plug is in bottom
position.
3. Clean the area around the oil level inspection plug.
WARNING!
Fig. 639
4. Unscrew the level inspection plug and catch any oil running
out.
5. Move the drive wheel, until the oil level inspection plug is in
horizontal position.
6. Fill in oil through the inspection bore, until it starts to run out
8. Change the oil in both wheel hubs.
Fig. 640
6.5.4.4 Retightening the fastening of the axle on the frame

1. Check all fastening nuts on axle mounting bolts for tight fit,
retighten if necessary, tightening torque: 800 Nm (590 ft·lbf).
Fig. 641
594 BW 219 D-5 / BW 219 PD-5

6.5.4.5 Retightening the wheel nuts

n Protective gloves
1. Tighten the wheel nuts cross-wise, tightening torque: 550 Nm
(405 ft·lbf).
Fig. 642
6.5.5 As required
6.5.5.1 Adjust the parking brake
NOTICE!
Have adjustment work on the brakes only carried
out by a specialist! Always adjust both sides.
1. Secure the machine with wheel chocks against rolling.

2. Start the diesel engine to relieve the brake.
1. Disengage the travel lever Ä Fig. 643 to the left, but do not
move to position "I" or "II".
The parking brake is released
Fig. 643
BW 219 D-5 / BW 219 PD-5 595

1. Unscrew locking plate 2 Ä Fig. 644.

2. Turn the square (1) in anti-clockwise direction against the
stop.
Fig. 644
1. In order to adjust the brake clearance turn the square 1

Ä Fig. 645 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. 645
596 BW 219 D-5 / BW 219 PD-5

Machine assemblies – Air conditioning
6.6 Air conditioning

6.6.1 Overview of air conditioning system...................... 597
6.6.2 Physical principles................................................. 600
6.6.3 Refrigerant R134a................................................. 602
6.6.4 Compressor oil / refrigeration oil............................ 604
6.6.5 Working principle of the air conditioning system.... 606
6.6.6 Monitoring devices................................................. 607
6.6.7 Description of components.................................... 608
6.6.8 Compressor........................................................... 613
6.6.9 Emptying in case of repair..................................... 615
6.6.10 Drying and evacuation......................................... 616
6.6.11 Filling instructions................................................. 616
6.6.12 Steam table for R134a......................................... 619
6.6.13 Inspection and maintenance work....................... 623
6.6.1 Overview of air conditioning system
3 2 1
S-586-0456
Fig. 646
1 Compressor
2 Condenser
3 Drier / collector
4 HKL module
BW 219 D-5 / BW 219 PD-5 597

Optional equipment
598 BW 219 D-5 / BW 219 PD-5

Fig. 647
1 Compressor
2 Condenser
3 Drier / collector
4 HKL module
BW 219 D-5 / BW 219 PD-5 599

6.6.2 Physical principles

In order to understand the working principle of an air conditioning
system one must first become familiar with the physical basics of
such a system.
The four well known physical conditions of water apply also for the
refrigerant in the air conditioning system.
1. gaseous (invisible)
2. vaporous
3. liquid
4. solid
If the water in a container is heated up (absorption of heat), the
rising steam is visible. If the steam is heated up further, due to the
absorption of heat, the visible steam will turn into invisible gas. This
process is reversible. When withdrawing the heat contained in gas-
eous water, the gas will turn into steam, then into water and finally
into ice.
Fig. 648
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. 649
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.
600 BW 219 D-5 / BW 219 PD-5

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. 650: Steam pressure curve 3. Condensing gas dissipates a lot of heat energy.
4. If a fluid evaporates it requires a lot of heat, i.e. the fluid thereby
cools down the surrounding environment (e.g. alcohol on skin)
At absolute pressure 0 bar correspond with an

absolute vacuum. The normal ambient pressure
(overpressure) corresponds with 1 bar absolute
pressure. On the scales of most pressure gauges
0 bar corresponds with an absolute pressure of 1
bar (indicated by the statement -1 bar below the 0).
In the pressure - temperature diagram for the refrigerant the drawn

in closed curve shows the cycle of the refrigerant. This cycle per-
manently continues in direction of the arrow.
The characters A, B, C, D stand for:
A - compression
B- condensation
C- relaxation
D- evaporation.
Fig. 651: 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
BW 219 D-5 / BW 219 PD-5 601

Saturation temperature Overpressure (pressure gauge Absolute pressure (pamb = 1 bar P

reading Pe in bar) in bar)
0 1,93 2,93
10 3,15 4,15
20 4,72 5,72
6.6.3 Refrigerant R134a

General
The evaporation and condensation process is the method com-
monly used in mobile air conditioning systems. The system in this
case works with a substance that boils at low temperature, a sub-
stance referred to a refrigerant. The refrigerant used is tetrafluoro-
ethane R134a, which boils at a temperature of -26.5°C and under a
steam pressure of 1 bar.
Although the refrigerant circuit is a hermetically closed loop, the
system loses approx. 100g of refrigerant over the course of 1 year
by diffusion through hoses, pipes and seals, even though the
system is free of leaks. If too much refrigerant is lost the cooling
power of the system will drop.
Physical data of the refrigerant R134a
Chemical formula:
CH2F-CF3 or CF3-CH2F
Chemical designation:
Tetrafluoroethane
Boiling point at 1 bar:

- 26.5 °C
Solidification point:
-101.6 °C
Critical temperature:
100,6 °C
Critical pressure:
40.56 bar (absolute)
Critical point:
Critical point (critical temperature and critical pressure) means that
above this point there is no separating interface between liquid and
gas. Above its critical point any substance is gaseous. At tempera-
tures below the critical point all refrigerant types in pressure con-
tainers have a liquid and a gaseous phase, i.e. a gas cushion is
above the liquid. As long as gas is in the container, besides the
liquid, the pressure depends on the ambient temperature.
602 BW 219 D-5 / BW 219 PD-5

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:
BW 219 D-5 / BW 219 PD-5 603

Refrigerant is not inflammable. On the contrary, it has fire inhibiting

or fire extinguishing properties. Refrigerant is decomposed by
flames or glowing surfaces. Ultraviolet light also cracks refrigerant
(caused by electric welding). This results in toxic fission products,
these must not be inhaled. However, irritation of the mucous mem-
branes is an early and in-time warning.
Filling factor:
In a container there must be a steam space above the liquid space.
The liquid expands with increasing temperature. The steam filled
space becomes smaller. From a certain time on the container will
be filled with just liquid. After this only a minor temperature
increase is enough to generate very high pressures in the con-
tainer, because the liquid would like to expand, but there is no
more room. The related forces are high enough to cause the con-
tainer to burst. In order to avoid overfilling of a container the pres-
sure gas directive clearly specifies how many kilograms of refrig-
erant may be filled into the container per litre volume. Multiplied
with the internal volume this "filling factor" determines the permis-
sible filling capacity For refrigerants used in motor vehicles it is
1.15 kg/l.
Environmental aspects The contribution of R134a to the greenhouse effect is by factor 10

smaller than the contribution of R12.
Since approx. 1992 the air conditioning systems for newly pro-
duced construction equipment were successively converted to
refrigerant R134a. This refrigerant does not contain any chlorine
and is thus harmless for the ozone layer. Until approx. 1992 air
conditioning systems were filled with refrigerant R12. Due to its
chlorine atoms this CFC has a high ozone decomposition potential
and also a potential to amplify the greenhouse effect. Conversion
programs for existing old systems with the ozone damaging R12
are in effect. For reasons of protecting the environment refrigerant
must not be discharged into the atmosphere.
6.6.4 Compressor oil / refrigeration oil

General
The compressor oil lubricates the movable parts in the compressor,

seals e.g. the gap between piston and cylinder inside the com-
pressor to prevent refrigerant loss and prevents other seals in the
system from drying up.
Part of the compressor oil dissolves in the refrigerant until satura-
tion is reached, so that a gas mixture of refrigerant, water steam,
compressor oil and contrast agent circulates through the system.
Compressor oil (the oil quantity should be 10 % of the refrigerant
weight) mixes with the refrigerant and circulates permanently
through the system.
604 BW 219 D-5 / BW 219 PD-5

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
BW 219 D-5 / BW 219 PD-5 605

Reason of oil loss Amount of oil lost

Replacement of evaporator approx. 30 gr
Replacement of liquid container approx. 30 gr
Replacement of expansion valve approx. 15 gr
NOTICE!
Compressor replacement
New compressors are delivered with an approx.
250 gr.compressor oil filling. To avoid excessive oil
in the A/C-system and thus a poor cooling effect,
the oil level in the A/C-system must be adjusted
accordingly.
The quantity depends on the amount of oil that
may have been lost in connection with the possible
replacement of other components.
The compressor oil quantity must be 10% of the
refrigerant quantity in the complete system.
With a refrigerant filling of 1100 gr. the system
requires a compressor oil / refrigerant oil filling of
110 gr.
Procedure
– Drain and measure the compressor oil from the

old compressor.
– Drain the compressor oil from the new com-
pressor and only fill in the exact quantity that
had been drained out of the old compressor.
The compressor oil from the new compressor
can be used for this purpose.
Topping up compressor oil / refrigeration oil is pos-

sible on a pressureless compressor directly into
the oil pan, in a pressureless refrigeration system
directly into the pressure side, but it is also pos-
sible to draw it into the pressure side of the refrig-
eration system during the evacuation process.
6.6.5 Working principle of the air conditioning system

All air conditioning systems are based on the same principle. They
extract heat from the surrounding environment. Everybody knows
the effect: if a sweating body is exposed to wind it will cool down,
because heat is extracted. For this purpose a refrigerant circulates
in a closed circuit inside the vehicle. This refrigerant thereby con-
tinuously changes its physical state between liquid and gaseous.
606 BW 219 D-5 / BW 219 PD-5

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. 652: Principle sketch of an air The expansion valve (4) regulates the flow rate from the dryer /
conditioning system liquid container (3) back to the evaporator (5) and the circuit starts
again.
6.6.6 Monitoring devices

Pressure switch, B105 The pressure switch (8) is used as monitoring feature for too high
and too low pressures. The switching contacts (4 and 5) effect the
magnetic clutch of the compressor via a relay (6).
If the system pressure increases excessively, e.g. because of a
excessively soiled condenser, a failed fan or a defective expansion
valve, the high pressure contact (5) will cut off the electric power
supply to the magnetic clutch when the set pressure is reached.
When the system pressure drops below the cut-off pressure by the
set differential pressure, the magnetic clutch of the compressor is
switched on again.
The low pressure contact (4) interrupts the electric power supply to
the magnetic clutch when the set pressure is fallen short of (pos-
sible causes: lack of refrigerant, defective expansion valve, too low
heat load, defective evaporator fan, ...). Since the refrigerant
R134a has an evaporation temperature of 0 °C at an overpressure
of 2 bar, the low pressure contact (4) is set to approx. 1.5 bar to
avoid icing. The switch on pressure is 0.5 to 2 bar higher than the
shut-off pressure (depending on system, see description of compo-
nents).
Thermostat A frost protection thermostat (3) protects the evaporator against

icing. Similar to the pressure switch, the thermostat activates or
deactivates the magnetic clutch for the compressor. Depending on
the design, the feeler of the temperature control is mounted
between the fins of the evaporator or attached to the evaporator
outlet (suction side). With fixed temperature controls the control
switches the compressor off at about 1 °C and back on again at
about 2.5°C to 5.5 °C (depending on system, see description of
components.)
With adjustable temperature regulators the switching point can be
changed so that the compressor is already shut down at higher
temperatures. This enables regulation of the air temperature.
BW 219 D-5 / BW 219 PD-5 607

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. 653: Monitoring chain
6.6.7 Description of components

Condenser
The condenser is located in front of the radiator for the machine. It
emits heat energy from the system into the surrounding air and liq-
uefies the gaseous refrigerant.
WARNING!
Danger of injury caused by exploding compo-
nent!
– Do not clean the condenser in the air condi-
tioning system with a hot water jet.
Fig. 654
The fins must be free of dirt and damage.
NOTICE!
or condenser, any compressor oil lost by
exchanging the components, must be replaced
with fresh oil.
Dryer / filter / fluid container /

inspection glass
Dryer / filter
The fluid container collects the fluid drops and passes these then
as a constant flow to the expansion valve. Moisture that has
entered during assembly of the refrigerant circuit is absorbed by a
dryer in the fluid container.
At evaporation temperatures below zero the refrigerant will deposit
previously absorbed moisture on the expansion valve, where this
water turns into ice and thus adversely affects the controllability of
the expansion valve. Moreover, moisture in the refrigerant circuit
causes corrosion, forms acids and enters into chemical composi-
tions.
Fig. 655
608 BW 219 D-5 / BW 219 PD-5

Inside the refrigerant container the heavy liquid refrigerant collects

in the lower part of the container, flows through a rising pipe to the
outlet marked "A" and thus ensures bubble free operation of the
expansion valve.
Since the absorbing capacity of this filter/dryer is

limited, it must be changed within certain service
intervals. We recommend to replace it 1 x per
years, before the start of the season.
NOTICE!
The filter/dryer must generally be replaced when-
ever opening the refrigerant circuit, because mois-
ture will enter in such a case.
This requires emptying the air conditioning system!
Installation position:
The arrow marks on the filter/dryer must point in
flow direction, i.e. towards the expansion valve.
Filter/dryer cannot be treated for further use!
Pressure relief valve

The fluid container is equipped with a safety valve.
Response pressure 32 +/- 4 bar
Tightening torque 10 - 15 Nm
Fig. 656
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. 657 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.
BW 219 D-5 / BW 219 PD-5 609

Air in the system is characterized by high pres-

sures and temperatures.
On R134a refrigeration systems from KONVEKTA the inspection

glasses are equipped with moisture indicators. In addition to the
float, the dryer/collector/inspection glass combination has an indi-
cator pearl integrated in the inspection glass, which changes its
colour when absorbing moisture.
The refrigerant level should be inside the inspection glass and
should only be checked after approx. 5 minutes continuous opera-
tion, because the refrigerant must first evenly distribute all over the
system.
WARNING!
In case of mechanical damage or corrosion on this
pressure container this collector unit must be
replaced, to avoid bursting and further damage.
Expansion valve
The expansion valve is mounted inside the HKL-module in the

cabin. The expansion valve always allows a small amount of the
high pressure liquefied refrigerant to flow into the evaporator, which
has a much lower pressure. This lower pressure causes these
liquid refrigerant to expand and to evaporate to gaseous state. The
heat required for this evaporation process is taken from the
ambient air through the lamellas and supplied to the refrigerant.
This is the so-called cooling effect.
The thermostatic expansion valve operates with an external pres-
sure compensation. This type of expansion valve works with high
accuracy, because it uses pressure and temperature at the evapo-
rator outlet and adjusts and overheating of approx. 7 K. The
already installed expansion valves and the ones delivered as spare
parts have this overheating value pre-set. In order to prevent a loss
Fig. 658 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.+
610 BW 219 D-5 / BW 219 PD-5

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. 659 filter condensation water may flow into the inside of the vehicle.
NOTICE!
or condenser, any compressor oil lost by
exchanging the components, must be replaced
with fresh oil.
Thermostat
Thermostat with fixed setting

The feeler of a defroster thermostat to switch off the magnetic
clutch in case of icing up or to switch the clutch back on after
defrosting, is mounted on the evaporator.
With fixed temperature controls the control switches the com-
pressor off at about +1 °C and back on again at about +2.5°C to
+5.5 °C.
Fig. 660
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.
BW 219 D-5 / BW 219 PD-5 611

The adjusted temperature must be below the

actual temperature inside the cabin, so that the
compressor will be switched on.
Fig. 661: adjustable temperature con-

troller
Pressure switch
Pressure switch B104

After a minimum pressure is reached on the low pressure side or a
maximum pressure on the high pressure side, the pressure switch
will switch off the magnetic clutch of the compressor to avoid
destruction of system components caused either by excessive
pressure or by drawing in external gases and foreign matter due to
a pressure which is too low.
Working pressure:
Low pressure off: 1.5 ± 0.5 bar
Low pressure on: 3.5 bar
Overpressure off: 25.0 ± 1.5 bar
Fig. 662
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
612 BW 219 D-5 / BW 219 PD-5

Thread Spanner width Torque

5/8“ 17 or 19 13.6 - 20.3 Nm
3/4“ 32.5 - 39.3 Nm
7/8“ 27 35.3 - 42.0 Nm
1 1/16“ 32 40.7 - 47.5 Nm
M30X2 36 105.0 - 115.0 Nm
M36X2 41 165.0 - 175.0 Nm
Bending radii for air conditioning hoses
Hose type Nominal width Bending radius

GH 134 NW8 min. 50 mm
GH 134 NW16 min. 100 mm
GH 494 NW20 min. 160 mm
GH 494 NW25 min. 194 mm
GH 494 NW32 min. 225 mm
6.6.8 Compressor
Structure
Fig. 663: Refrigerant compressor
BW 219 D-5 / BW 219 PD-5 613

1 Refrigerant compressor 7 Pressure plate

2 Belt pulley 8 Driver disc
3 Melting fuse 9 Swash disc
4 Refrigerant compressor shaft 10 Piston (7 pieces, uniformly distributed over the entire circumference)
5 Ball bearing 11 Slipper pad
6 Magnetic coil 12 Swash plate chamber
A Suction valve B Pressure valve
Magnetic clutch The belt pulley (2) runs on a bearing on the refrigerant compressor
housing. It is driven by the ribbed V-belt and rotates on the ball
bearing (5) around the magnetic coil (6), which is mounted to the
refrigerant compressor housing. The pressure plate (7) is con-
nected to the shaft of the refrigerant compressor (4) by means of a
splined connection. It consists of 2 rings, which are connected by a
resilient plate.
The magnetic coil (6) is energized to start up the refrigerant com-
pressor (1). The magnetic force pulls the outer ring of the pressure
plate (7) against the belt pulley (2) and holds it in position. This
causes a positive connection between pressure plate (7) and belt
pulley (2).
Once the magnetic coil (6) is de-energized, spring force will return
the outer ring of the pressure plate (7) back to its rest position and
the flow of force is interrupted. This ensures switching off of the
refrigerant compressor in case of a mechanical defect.
Delivery process Once the magnetic coupling of the refrigerant compressor (1) has
caused the frictional connection, the shaft of the refrigerant com-
pressor (4) will drive the swash plate (9) via the driver disc (8). The
revolving slanted swash plate (9) causes a stroke movement of the
7 pistons (10), which are evenly distributed along the circumfer-
ence.
The pistons (10) are thereby actuated by slipper pads (11).
During the suction stroke gaseous refrigerant flows through the
suction valve (A) into the corresponding cylinder. When the stroke
of the piston (10) is reversed, it compresses the gaseous refrig-
erant, until the pressure inside the cylinder becomes so high, that
the pressure valve (B) opens and allows the refrigerant to flow
through the compressor outlet and thus into the refrigerant circuit.
The refrigerant compressor (1) has integrated chambers both on
the suction and on the pressure side, which have the function to
dampen resonances, which are generated by suction and com-
pression.
Displacement control The refrigerant compressor (1) is designed in such a way, that
already has sufficient flow rate to keep up the refrigerant circuit,
even at a slow vehicle speed and low engine speed.
614 BW 219 D-5 / BW 219 PD-5

Since the flow rate of the refrigerant compressor (1) rises with
increasing engine and travel speed, the flow rate needs to be
reduced or regulated.
This is to avoid that the refrigerant compressor (1) unnecessarily
uses engine power.
The flow rate is controlled by switching the magnetic coupling on
and off.
Safety contgrol of the refrigerant To prevent the ribbed V-belt jumping off in case of a mechanical
compressor (1) defect of the refrigerant compressor (1), the magnetic coupling will
disengage automatically.
In case of a mechanical defect the refrigerant compressor (1) will
be harder to turn or may even block completely. The heat created
on the friction surface of the V-belt (2) blows a meting fuse (3) in
the magnetic coil (6). This interrupts the power supply to the mag-
netic coil (6) and releases the frictional connection.
Service valves The service valves are installed directly on the compressor. These
are used to e.g. evacuate and fill the system.
6.6.9 Emptying in case of repair

For repair work the air conditioning systems must very often be
emptied of all refrigerant.
Especially with expensive refrigerants and larger amounts of oil it
may be necessary to keep the refrigerant for later use.
For later use these refrigerants must be drawn out with suitable
equipment and intermediately stored in collecting containers.
ENVIRONMENT!
Contaminated refrigerant must be disposed of
environmentally
Releasing refrigerant into the atmosphere is pro-
hibited (see restrictive injunction concerning CFC,
day of enforcement 01. 08. 1991, § 8)
WARNING!
For draining refrigeration systems you should not
simply use any delivery containers, but only appro-
priate pressure bottles, which must be specially
marked and should comply with the pressure gas
directive.
When transferring refrigerant you must make sure
that the bottle does not contain more than the per-
mitted amount of refrigerant in litres and has suffi-
cient gas space for expansion (filling factor: 0,7).
BW 219 D-5 / BW 219 PD-5 615

In order to reduce the evacuation period in case of short repairs,

you may fill the refrigerant circuit with approx. 0.5 bar nitrogen
when opening. This ensures that nitrogen will flow out of the refrig-
erant circuit while it is open and no air or moisture can enter. How-
ever, the necessity for vacuum generation and a dryer change
remains.
6.6.10 Drying and evacuation

Evacuation of air conditioning systems using R-type refrigerants
not only has the purpose of emptying the system of all air before
filling in refrigerant, but also to verify the leak tightness over a
longer lifetime in the achieved vacuum. However, the most impor-
tant factor in this work step is the drying of the system.
Any water residues in the refrigerant circuit will combine with the
refrigerant, which will lead to the previously described consequen-
tial damage.
Vacuum pumps with a capacity of more than 100 l/min and a final
pressure of less than 30 micron, i.e. 0.039 mbar should be used to
evacuate the refrigeration system.
The refrigerant compressor is not suitable for the purpose of evac-
uation, because it is not able to achieve a sufficient final vacuum
and, apart from this, may be mechanically damaged because of a
lack of lubrication when running empty during evacuation.
It is common practice to evacuate the refrigeration system to a final
vacuum of 1 Torr, i.e. 1.33 mbar.An exact time for evacuation and
drying cannot be predicted. It can only be determined by means of
a vacuum meter. However, if there is no vacuum meter at hand it is
generally better to evacuate 1 hour longer than 1 hour too less.
Function drying:
Under normal ambient pressure (1.013 mbar) evaporates absolute
at 100° C. If the pressure is reduced, water will already evaporate,
e.g. under a pressure of 10 mbar, at an ambient temperature of
almost 7°C, but the water will not evaporate all at once. Since it is
very difficult to separate the steam from the vacuum in the system,
the evacuation process is supported by the co-called vacuum
breaking (filling the circuit with dried nitrogen). With vacuum
breaking the filled in dried nitrogen absorbs the moisture in the
refrigerant circuit, which can then be easily discharged together
with the nitrogen.
6.6.11 Filling instructions

Filling of refrigerant into the dried, vented and oil filed machines
takes place under various conditions.
In most large series production facilities highly complicated equip-
ment is available for this purpose, whereas individual machines at
the place of installation must be filled directly from the refrigerant
container.
616 BW 219 D-5 / BW 219 PD-5

Liquid refrigerant is only used to pre-fill the pressure side of the

evacuated refrigeration system (protective filling).
After switching the refrigeration system on and watching the
inspection glass, gaseous refrigerant can be filled into the system
while the engine is running, if the refrigerant level is found to be too
low (gas bubbles in the inspection glass).
NOTICE!
Liquid refrigerant in the suction side of the com-
pressor should generally be avoided during filling
and operation of the refrigeration system, since
this could damage the compressor..
When filling the air conditioning system directly from the refrigerant
bottle care must be taken not to overfill the system. As an addi-
tional control and for statistical purposes, e.g. for refilling, it is
important to write down the weight of the filled in refrigerant.
With correct operation of the air conditioning the refrigerant con-
tainer should be about 1/3 filled with liquid refrigerant, the evapo-
rator should be maximally filled at the calculated evaporation tem-
perature, i.e. the suction line should only be a few degrees warmer
than the evaporation temperature indicated by the pressure gauge.
White frost on the suction line is no measure for

assessing the filling.
BW 219 D-5 / BW 219 PD-5 617

Fig. 664
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
618 BW 219 D-5 / BW 219 PD-5

Pos Designation Pos Designation

11 Collecting container 23 Pressure gauge bar
12 Capacitor
Filling instructions
6.6.12 Steam table for R134a

Tempera- Pressure Density spec. volume spec. enthalpy Evapora-
ture tion heat
of the of the of the of the of the of the
fluid steam fluid steam fluid steam
t p p' p'' v' v'' h' h'' r
°C bar kg/dm3 kg/dm3 dm3/kg dm3/kg kJ/kg kJ/kg kJ/kg
-60 0.16 1.469 0.92 0.681 1082.6 123.17 359.85 236.68
-55 0.22 1.456 1.24 0.687 803.83 129.49 362.99 233.5
-50 0.29 1.443 1.65 0.693 606.45 135.75 366.14 230.39
-45 0.39 1.429 2.15 0.7 464.29 141.98 369.28 227.3
-40 0.51 1.415 2.78 0.707 360.3 148.21 372.41 224.19
-35 0.66 1.401 3.53 0.714 283.08 154.47 375.52 221.05
-30 0.84 1.387 4.45 0.721 224.97 160.78 378.61 217.84
-25 1.06 1.373 5.53 0.728 180.67 167.14 381.68 214.55
-24 1.11 1.37 5.78 0.73 173.12 168.42 382.29 213.88
-23 1.16 1.367 6.03 0.732 165.95 169.7 382.9 213.2
-22 1.22 1.364 6.28 0.733 159.14 170.98 383.51 212.53
-21 1.27 1.361 6.55 0.735 152.66 172.27 384.12 211.85
-20 1.33 1.358 6.83 0.736 146.5 173.56 384.72 211.16
-19 1.39 1.355 7.11 0.738 140.64 174.86 385.33 210.47
-18 1.45 1.352 7.4 0.74 135.06 176.15 385.93 209.78
-17 1.51 1.349 7.71 0.741 129.75 177.45 386.53 209.08
-16 1.57 1.346 8.02 0.743 124.68 178.75 387.13 208.38
-15 1.64 1.343 8.34 0.745 119.86 180.06 387.73 207.67
-14 1.71 1.34 8.68 0.746 115.26 181.37 388.33 206.96
-13 1.78 1.337 9.02 0.748 110.87 182.68 388.93 206.25
-12 1.85 1.334 9.37 0.75 106.68 183.99 389.52 205.53
BW 219 D-5 / BW 219 PD-5 619


ture tion heat
t p p' p'' v' v'' h' h'' r
-11 1.93 1.331 9.74 0.752 102.68 185.31 390.11 204.8
-10 2.01 1.328 10.12 0.753 98.86 186.63 390.71 204.07
-9 2.09 1.324 10.5 0.755 95.21 187.96 391.3 203.34
-8 2.17 1.321 10.9 0.757 91.73 189.28 391.88 202.6
-7 2.26 1.318 11.31 0.759 88.39 190.61 392.47 201.86
-6 2.34 1.315 11.74 0.76 85.21 191.94 393.06 201.11
-5 2.43 1.312 12.17 0.762 82.16 193.28 393.64 200.36
-4 2.53 1.309 12.62 0.764 79.24 194.62 394.22 199.6
-3 2.62 1.305 13.08 0.766 76.44 195.96 394.8 198.84
-2 2.72 1.302 13.56 0.768 73.77 197.3 395.38 198.08
-1 2.82 1.299 14.04 0.77 71.2 198.65 395.96 197.31
0 2.93 1.296 14.55 0.772 68.75 200 396.53 196.53
28 7.27 1.196 35.66 0.836 28.04 238.96 411.71 172.75
29 7.48 1.192 36.73 0.839 27.22 240.4 412.21 171.81
30 7.7 1.189 37.83 0.841 26.44 241.83 412.71 170.87
31 7.93 1.185 38.95 0.844 25.67 243.28 413.2 169.92
32 8.16 1.181 40.1 0.847 24.94 244.72 413.69 168.97
33 8.39 1.177 41.28 0.85 24.22 246.17 414.18 168
34 8.63 1.173 42.49 0.853 23.53 247.63 414.66 167.03
35 8.87 1.169 43.74 0.856 22.86 249.08 415.14 166.05
36 9.12 1.164 45.01 0.859 22.22 250.55 415.61 165.07
37 9.37 1.16 46.31 0.862 21.59 252.01 416.08 164.07
38 9.63 1.156 47.65 0.865 20.99 253.48 416.55 163.07
39 9.9 1.152 49.02 0.868 20.4 254.96 417.01 162.05
40 10.17 1.148 50.43 0.871 19.83 256.44 417.47 161.03
41 10.44 1.143 51.87 0.875 19.28 257.92 417.92 160
42 10.72 1.139 53.35 0.878 18.74 259.41 418.37 158.96
43 11.01 1.135 54.87 0.881 18.23 260.9 418.81 157.9
44 11.3 1.13 56.42 0.885 17.72 262.4 419.24 156.84
45 11.6 1.126 58.02 0.888 17.24 263.91 419.68 155.77
620 BW 219 D-5 / BW 219 PD-5


ture tion heat
t p p' p'' v' v'' h' h'' r
46 11.9 1.121 59.65 0.892 16.76 265.42 420.1 154.68
47 12.21 1.117 61.33 0.895 16.3 266.94 420.52 153.58
48 12.53 1.112 63.06 0.899 15.86 268.46 420.93 152.47
49 12.85 1.108 64.82 0.903 15.43 269.99 421.34 151.35
50 13.18 1.103 66.64 0.907 15.01 271.53 421.74 150.21
51 13.51 1.098 68.5 0.91 14.6 273.07 422.14 149.06
52 13.85 1.094 70.41 0.914 14.2 274.62 422.52 147.9
53 14.2 1.089 72.38 0.919 13.82 276.18 422.9 146.72
54 14.55 1.084 74.39 0.923 13.44 277.75 423.28 145.53
55 14.91 1.079 76.47 0.927 13.08 279.32 423.64 144.32
56 15.28 1.074 78.59 0.931 12.72 280.91 424 143.09
57 15.66 1.069 80.78 0.936 12.38 282.5 424.35 141.85
58 16.04 1.064 83.03 0.94 12.04 284.1 424.69 140.58
59 16.42 1.059 85.34 0.945 11.72 285.71 425.02 139.3
60 16.82 1.053 87.72 0.949 11.4 287.34 425.34 138
61 17.22 1.048 90.16 0.954 11.09 288.97 425.65 136.68
62 17.63 1.043 92.68 0.959 10.79 290.61 425.95 135.34
63 18.04 1.037 95.27 0.964 10.5 292.26 426.24 133.97
64 18.47 1.032 97.94 0.969 10.21 293.93 426.51 132.58
65 18.9 1.026 100.69 0.975 9.93 295.61 426.78 131.17
66 19.34 1.02 103.53 0.98 9.66 297.3 427.03 129.74
67 19.78 1.014 106.45 0.986 9.39 299 427.27 128.27
68 20.24 1.009 109.46 0.992 9.14 300.72 427.5 126.78
69 20.7 1.003 112.58 0.997 8.88 302.45 427.71 125.26
70 21.17 0.996 115.79 1.004 8.64 304.19 427.9 123.71
71 21.65 0.99 119.11 1.01 8.4 305.95 428.08 122.13
72 22.14 0.984 122.55 1.016 8.16 307.73 428.25 120.52
73 22.63 0.977 126.11 1.023 7.93 309.52 428.39 118.87
74 23.13 0.971 129.79 1.03 7.7 311.33 428.51 117.19
75 23.65 0.964 133.6 1.037 7.48 313.15 428.62 115.46
BW 219 D-5 / BW 219 PD-5 621


ture tion heat
t p p' p'' v' v'' h' h'' r
76 24.17 0.957 137.56 1.045 7.27 315 428.7 113.7
77 24.7 0.95 141.67 1.052 7.06 316.86 428.76 111.9
78 25.23 0.943 145.95 1.06 6.85 318.74 428.79 110.05
79 25.78 0.936 150.4 1.069 6.65 320.64 428.8 108.15
80 26.34 0.928 155.03 1.078 6.45 322.57 428.77 106.21
81 26.9 0.92 159.87 1.087 6.26 324.51 428.72 104.21
82 27.48 0.912 164.92 1.096 6.06 326.48 428.63 102.15
83 28.06 0.904 170.22 1.106 5.87 328.47 428.5 100.04
84 28.66 0.895 175.77 1.117 5.69 330.48 428.34 97.86
85 29.26 0.887 181.6 1.128 5.51 332.52 428.12 95.61
86 29.88 0.878 187.75 1.14 5.33 334.58 427.86 93.29
87 30.51 0.868 194.25 1.152 5.15 336.67 427.55 90.88
88 31.14 0.858 201.14 1.165 4.97 338.78 427.17 88.39
89 31.79 0.848 208.48 1.179 4.8 340.92 426.72 85.8
90 32.45 0.837 216.31 1.195 4.62 343.09 426.2 83.1
91 33.12 0.826 224.73 1.211 4.45 345.29 425.58 80.29
92 33.8 0.813 233.84 1.229 4.28 347.53 424.86 77.33
93 34.49 0.801 243.77 1.249 4.1 349.79 424 74.21
94 35.19 0.787 254.71 1.271 3.93 352.08 422.99 70.91
95 35.91 0.771 266.92 1.296 3.75 354.41 421.78 67.37
96 36.64 0.755 280.84 1.325 3.56 356.77 420.3 63.53
97 37.39 0.736 297.17 1.359 3.37 359.17 418.44 59.27
98 38.14 0.714 317.43 1.4 3.15 361.6 415.97 54.37
99 38.92 0.687 346.24 1.455 2.89 364.07 412.16 48.09
100 39.71 0.65 636.32 1.537 1.57 366.58 375.04 8.46
101.06 40.56 0.515 515.3 1.941 1.94 390.05 390.05 0
622 BW 219 D-5 / BW 219 PD-5



6.1.9.3.2 Checking, tensioning the V-belt of the air conditioning compressor 468
6.6.13.2.2 Changing the fresh air filter in the cabin 625
6.6.13.3.1 Servicing the air conditioning system 626
6.1.9.5.3 Replacing the air conditioning compressor V-belts 481
6.6.13.4.2 Cleaning the circulation air filter of the heating 629
As required
6.6.13.5.1 Checking the compressor oil level / refrigeration oil level 630

6.6.13.2.1 Checking, tensioning the V-belt of the air conditioning compressor
Checking the condition of the V-belt

n Safety shoes
n Protective gloves
1. Check the entire circumference of the belt for damage and
cracks.
2. Replace a damaged or torn V-belt Ä Chapter 6.1.9.5.3
‘Replacing the air conditioning compressor V-belts’
on page 481.
B-870-0278
Fig. 665
BW 219 D-5 / BW 219 PD-5 623

Checking the V-belt tension

n Protective gloves
Tool: n Belt tension tester
1. Press the indicator arm (a) of the tester into the gap of the
measuring scale.
2. Place the meter in the middle between the V-belt pulleys on
the back of the belt.
Fig. 666
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. 667
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. 668
624 BW 219 D-5 / BW 219 PD-5

Tightening the V-belt

n Safety shoes
n Protective gloves
2 specified value.
1 3. Retighten the screw (1).
B-870-0279
Fig. 669
6.6.13.2.2 Changing the fresh air filter in the cabin

n Protective gloves
2. Pull the fastening pins out of the left cover and remove the
cover.
Fig. 670
3. Loosen the fastening screw.

4. Also remove the cover from the right hand side and loosen
the fastening screw.
Fig. 671
BW 219 D-5 / BW 219 PD-5 625

5. Tilt the console towards the front screen and hold it.
Fig. 672
6. Take out the filter.

7. Insert the new filter and fold the console down again.
8. Tighten the left and right fastening screws and reinstall the
covers.
Fig. 673

6.6.13.3.1 Servicing the air conditioning system
Cleaning the condenser
n Protective gloves
n Safety goggles
626 BW 219 D-5 / BW 219 PD-5

The air conditioning condenser is located in front of

the radiator.
LUFT 3.
CAUTION!
AIR Danger of eye injuries caused by particles
flying around!
clothes, goggles).
Clean the condenser fins with compressed air or water.

B-586-0134
Fig. 674
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. 675
a Adjust the air distribution
b Regulate the cabin temperature
c Air conditioning on/off
d Fan on/off
Checking the condition of the drier/collector unit
Have the drier/collector unit replaced by our cus-

tomer service once every year before the operating
season.
BW 219 D-5 / BW 219 PD-5 627

1. Check the drier/collector unit for mechanical damage or rust.

2. In case of mechanical damage or rust, have the drier/
collector unit immediately replaced by our customer service.
4. Switch the air conditioning on.
B-920-0067
Fig. 676
5. Check the moisture indication pearl inside the inspection

glass of the drier/collector unit.
orange The degree of moisture in the drying

agent is correct.
colourless Moisture level of drying agent too
high
6. If the moisture level of the drying agent is too high, have the
drier/collector unit replaced by our customer service.
B-920-0068
Fig. 677
7. Check the white floating ball inside the inspection glass of the
drier/collector unit.
Ball floats right on top The refrigerant level is cor-

rect.
Ball floats at bottom The refrigerant level is not
correct.
8. If the refrigerant level is too low, have the air conditioning

system inspected by our customer service.
B-920-0069
Fig. 678

6.6.13.4.1 Replacing the air conditioning compressor V-belts

two years.

n Protective gloves
628 BW 219 D-5 / BW 219 PD-5

3. Loosen the screws (2, 3, 4) on the air conditioning com-

pressor.
4. Relieve the V-belt with the tensioning screw (1) and take it
off.
5. Install the new V-belt for the air conditioning compressor.
specified value Ä Chapter 6.1.9.3.2.2 ‘Checking the V-belt
tension’ on page 469.
7. Tighten screws (2, 3, 4) again.
Fig. 679
6.6.13.4.2 Cleaning the circulation air filter of the heating

n Safety shoes
n Protective gloves
2. Loosen the locks and remove the cover.
3. Take out the filter.
4. Clean the filter, replace if necessary.
5. Insert the filter and reinstall the cover.
B-GEN-0073
Fig. 680
BW 219 D-5 / BW 219 PD-5 629

6.6.13.5 As required
6.6.13.5.1 Checking the compressor oil level / refrigeration oil level
NOTICE!
The compressor oil level must be checked after
replacing a system component or if a leak in the
system is suspected. Use only compressor oil /
refrigeration oil PAG SP-20 (H14-003-404).
1. Run the compressor for 10 minutes at engine idle speed.

2. remove the refrigerant from the air conditioning system.
3. Turn the compressor, as shown in Ä Fig. 681, 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. 681
630 BW 219 D-5 / BW 219 PD-5

Machine assemblies – Auxiliary heating, AIRTRONIC
6.7 Auxiliary heating, AIRTRONIC

6.7.1 Description of function........................................... 632
6.7.2 Fuse assignment................................................... 635
6.7.3 Control panel......................................................... 635
2 3
1
S-586-0459
Fig. 682
1 Heater unit, E30
2 Air filter
3 Timer (S28) and fuses (F320 and F321)
4 Fuel filter and pump for heating unit, Y14/M57
Optional equipment
BW 219 D-5 / BW 219 PD-5 631

6.7.1 Description of function
9
8
1 2 3 4 5 6 7
10
W
F
B
19 15 14 13
12 11
V 17
18
A
16
S-586-0260
Fig. 683
1 Hot air fan wheel
2 Control unit
3 Combustion air fan wheel
4 Glow plug
5 Cover
6 Heat exchanger
7 Combined sensor (overheating/flame sensor)
8 Control element, module clock (S28)
9 Fuses (F320 & F321)
10 Air outlet
11 Cup filter, installed in fuel dosing pump
12 Fuel dosing pump (Y14)
13 Air outlet hood
14 Combustion chamber
15 Flange gasket
16 Exhaust silencer
17 Exhaust pipe
18 Combustion air hose
19 Fan motor
A Exhaust gas
B Fuel
632 BW 219 D-5 / BW 219 PD-5

F Fresh air
V Combustion air
W Heating air
n The fan motor (19) Ä Fig. 683 and the combustion air impeller
(3) deliver combustion air into the combustion chamber (14).
n Fuel is pumped out of the vehicle’s tank.
n The fuel dosing pump (12) delivers fuel into the combustion
chamber (14).
n The glow pin (4) evaporates this fuel as it enters the combus-
tion chamber (14) and, in combination with the combustion air
(V), a combustible fuel-air mix is generated.
n Once a flame is present, the glow pin (4) is switched off, the
heat exchanger (6) transfers the heat to the heating air (W) and
exhaust gas (A) is discharged through the exhaust gas silencer
(16).
n The fan motor (19) and the heating air impeller (1) supply the
heating with cool fresh air (F), which is then heated up by the
heat exchanger (6) and finally blown into the inside of the
vehicle.
Switching on
DANGER!
Danger of suffocation caused by exhaust
fumes!
– Always ensure sufficient ventilation and extrac-
tion.
When switching on, the operation indicator in the control element

(8) Ä Fig. 683 lights up. The glow pin (4) is switched on and the
fan motor (19) starts with low speed.
Residual heat
If the heat exchanger (6) still contains too much
residual heat from the previous heater operation,
only the fan motor (19) will initially run (blow out of
cold air). Once the residual heat has dissipated,
the system will start.
Start The delivery of fuel starts approx. 60 seconds later and the fuel-air
mix in the combustion chamber (14) Ä Fig. 683 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°.
BW 219 D-5 / BW 219 PD-5 633

Control of heater operation During heater operation the room temperature or the temperature
of the drawn in heated air is permanently measured. If the temper-
ature is higher than the temperature pre-selected by the control
element, the control process starts. The system has been designed
with 4 control stages, so that the heat flow provided by the heater
can be accurately adapted to the heat requirements. Fan speed
and fuel quantity thereby match the corresponding control stage.
Should the adjusted temperature still be exceeded in the lowest
control stage, the AIRTRONIC will change to control stage “OFF”
with the fan running on for another 4 minutes for cooling. After this
the fan will continue to run with minimum speed (circulation air
operation) or is switched off (fresh air operation), until the next
start.
Fan operation For fan operation you must first operate the change over switch
“Heating / Ventilation” and then switch on the AIRTRONIC.
Switching off When switching off the AIRTRONIC, the control light will go out
and the fuel supply is shut off.
The fan will continue running for approx. 4 minutes for cooling rea-
sons.
While the fan is still running, the glow pin is switched on for
cleaning, either for 40 sec. (AIRTRONIC D2) or 30 sec. (AIR-
TRONIC D4 / D4S).
Exceptional case
If no delivery of fuel (start phase) takes place until
the system is switched off, or if the AIRTRONIC is
in control stage “OFF”, the AIRTRONIC is shut
down without any overrun.
Heater operation at high altitudes n up to 1500 m: unlimited heater operation possible.

n above 1500 m: short term operation (e.g. crossing a pass or
having a rest) is generally possible. Longer periods require a
height adaptation of the fuel supply.
634 BW 219 D-5 / BW 219 PD-5

6.7.2 Fuse assignment
B-586-0424
Fig. 684

6.7.3 Control panel

Control panel, old version
Fig. 685: Old version

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 for auxiliary heating on/off
6 Push button to reduce the heating period
7 Push button to extend the heating period
Optional equipment
BW 219 D-5 / BW 219 PD-5 635

Control panel, new version
1 4
2
3 17:30 21°C
6 5
B-DIS-0523
Fig. 686

1 [◀] button Navigating in the menu levels
Setting/changing numerical values
2 Menu bar Display of available menus
3 Status section Time
Cabin temperature
Information on active functions
Fault indicator
4 [▶] button Navigating in the menu levels
5 [ ] button Selecting menu levels and functions
Switching functions on
6 [ ] button Switching functions on and off
Returning to the main menu
Optional equipment
636 BW 219 D-5 / BW 219 PD-5

In case of malfunctions you should The electronic control unit is able to store up to 5 faults, which can
check the following then be read out with the control panel and displayed.
If the AIRTRONIC does not start after being switched on:
n Switch the AIRTRONIC off and on again, but not more than 2
times in succession.
If the AIRTRONIC still does not start, please check if:
n Fuel in tank?
n Fuses ok?
n Electric cables, connections, terminals ok?
n Hot air duct, combustion air duct or exhaust duct congested?
n If the AIRTRONIC remains in “Ventilation” condition after
switching on, check the control element for short circuits.
In this case no fault code will be submitted.
Ä Chapter 7.7 ‘Troubleshooting the auxiliary heating’

on page 783.


Monthly
6.7.4.2.1 Notes on maintenance 637
Heating season
6.7.4.3.1 Notes on maintenance 638
6.7.4.4.1 Servicing the auxiliary heating 638
6.7.4.2 Monthly
6.7.4.2.1 Notes on maintenance
n Switch the auxiliary heating on every month for about ten
minutes.
After longer periods of rest one check and prob-

ably clean the openings on heating air duct, the
combustion air duct and the exhaust duct.
BW 219 D-5 / BW 219 PD-5 637

6.7.4.3 Heating season

6.7.4.3.1 Notes on maintenance
n Before the heating season the heater should be thoroughly
tested.
NOTICE!
In case of excessive of smoke over a longer period
of time or unusual combustion noises or if a dis-
tinct smell of fuel can be noticed, or electric / elec-
tronic components are overheating, the heater
must be switched off and taken out of service by
removing the fuse.

6.7.4.4.1 Servicing the auxiliary heating
Replacing the fuel filter for the auxiliary heating
n Safety shoes
n Protective gloves
2. Loosen the hose clamps (1) on the fuel filter (2) and pull the
1 hoses off the fuel filter.
3. Take off the fuel filter.
4. Install the new fuel filter by observing the flow direction.
5. Dispose of the used fuel filter environmentally.
2
B-586-0401
Fig. 687
638 BW 219 D-5 / BW 219 PD-5

Replacing the air filter for the auxiliary heating

n Protective gloves
2. Unscrew the housing cover (1).
3. Take out the air filter (2).
4. Slide the new air filter carefully into the housing (3).
5. Close the housing cover again.
Fig. 688
BW 219 D-5 / BW 219 PD-5 639

Machine assemblies – Cabin assembly
6.8 Cabin assembly

6.8.1 Safety..................................................................... 640
6.8.2 Preparations.......................................................... 641
6.8.3 Cabin assembly..................................................... 642
6.8.4 Final function tests and checks.............................. 647
6.8.1 Safety
General safety regulations for When installing the cabin to your BOMAG machine you must
assembly strictly comply with the valid accident prevention instructions
or the country specific regulations. However, dangers for per-
sons and property may still arise, if:
n the lifting gear used has a too low bearing capacity
n damaged or worn lifting tackle is used
n unqualified personnel is entrusted with the installation
Each person involved in the installation of the cabin must
therefore read and comply with these safety regulations. If
necessary, the customer must demand a written confirmation
with signature.
Moreover, the following instructions and regulations must obviously
also be adhered to:
n country specific safety regulations. It is the duty of the operator
to be acquainted with these instructions and to apply these
accordingly. This applies also for local regulations concerning
different types of handling work. Should the recommendations
in these instructions be different from the regulations valid in
your country, you must comply with the safety regulations valid
in your country.
Changes and conversions to the Unauthorized changes to the cabin are prohibited for safety rea-
cabin/machine sons.
this machine. We wish to make explicitly clear that we have not
tested or approved any parts or accessories not supplied by us.
effect on the active and/or passive driving safety.
The manufacturer explicitly excludes any liability for damage
caused by the use of non-original parts or accessories.
Notes on safety in the assembly

instructions WARNING!
Paragraphs marked like this highlight possible dan-
gers for persons.
640 BW 219 D-5 / BW 219 PD-5

NOTICE!
gers for machines or parts of the machine.
Paragraphs marked like this contains technical

information and hints for optimal assembly.
ENVIRONMENT!
Paragraphs marked like this point out practices for
safe and environmental disposal of fuels and lubri-
cants as well as replacement parts.
Strictly observe the national regulations for the pro-
tection of the environment.
Information and safety stickers/ Keep stickers/decals in good and legible condition (see spare parts
decals on the cabin catalogue) and comply with their meaning.
Replace damaged stickers/decals
Working on electric parts of the Before starting to work on electric parts of the machine disconnect
machine the battery and cover it with insulating material.
Do not use fuses with higher ampere ratings and do not repair
fuses with a piece of wire. Fire hazard.
6.8.2 Preparations
WARNING!
Danger of accident!
For transport purposes the driver's seat must be
tied down with cable straps thus to operate the
seat contact switch. Before resuming operation of
the machine these cable straps must strictly be
removed to ensure safe and reliable function of the
seat contact switch.
Check the 4 lifting eyes on the cabin roof for tight
fit.
Fasten the lifting gear to all four lifting eyes.
Use lifting gear (chains or ropes) of sufficient load
bearing capacity. The minimum load bearing
capacity of the crane must be 1000 kg.
Do not stand or step under loads being lifted.
BW 219 D-5 / BW 219 PD-5 641

1. Make sure that all fastening screws, washers, spacers and

nuts are available to fasten the cabin.
2. Check whether rear rack, foot mat, step plate and fastening
kit are available.
Fig. 689
3. Fasten the lifting tackle to the four lifting eyes 1.

4. Undo any fastenings on the transport pallet.
5. Slowly lift the cabin with a crane.
WARNING!
Danger of accident!
Fig. 690
6.8.3 Cabin assembly
WARNING!
Danger of accident!
NOTICE!
After the cabin installation the fault code “9109” will
no longer be displayed.
642 BW 219 D-5 / BW 219 PD-5

1. Remove dirt, oil and moisture from the driver's stand.

2. Check the condition of the seals on the driver's stand.
Fig. 691
3.
NOTICE!
When lifting the cabin, observe the weight
distribution. In any case the cabin must be
lowered vertically onto the driver's stand.
Lower the cabin slowly and vertically onto the driver's stand
until only approx. 20 cm distance remains.
Fig. 692
4. Plug in the cables for the heating.

5. Set down the cabin completely on the driver's stand.
Fig. 693
6.
NOTICE!
Take care that none of the hoses and electric
cables become squashed .
Run cables and hoses from inside the cabin frame through
the driver's stand to the outside.
Fig. 694
BW 219 D-5 / BW 219 PD-5 643

If the bores do not match, the cabin can be moved

into position by means of a crow bar.
7. Turn in the fastening screws (M 16x35) and tighten.

8. Repeat this measure on the opposite side.
Fig. 695
9. Insert screws from below and tighten the nuts (M10) with
washers.
Fig. 696
10. Attach the cover, insert expanding rivet and knock it in with a
plastic mallet.
Fig. 697
644 BW 219 D-5 / BW 219 PD-5

11. Insert a distance plate between driver's stand and cabin and
tighten the fastening screw.
Fig. 698
13. Connect the hoses for the heating and, if available, for the air
conditioning.
Fig. 699
14. Insert the wiring loom into the control cabinet and install a
bulkhead bushing.
Fig. 700
15. Connect ground cable X8B (2), + potential 30 X8A (3) and
wiring loom plug X4E (1) to the circuit board.
Fig. 701
BW 219 D-5 / BW 219 PD-5 645

16. Install the protective covering.
Fig. 702
17. Push the hoses for the front and rear windscreen washers
through the opening and connect them to the check valves.
Fig. 703
18. Fasten the wiring loom of the cabin and hoses with cable
ties.
Fig. 704
19. Turn nuts with washers onto both studs and tighten.
Fig. 705
646 BW 219 D-5 / BW 219 PD-5

20. Assemble the guard.
Fig. 706
21. Remove the lifting tackle, unscrew the lifting eyes and close
the openings with plugs.
Fig. 707
6.8.4 Final function tests and checks
NOTICE!
Make sure that all screws have been tightened
with the specified torque.
After the cabin assembly the following tests must

be performed to assure that all cables and lines
are correctly connected.
1. Insert the ignition key and turn clockwise to position "1".

2. Operate the switches fpr headlights, direction indicators and
interior light to check their function.
If the function of the windscreen washer system is

reversed, the two washing water hoses must be
interchanged.
3. Operate the switches for front and rear windscreen washer

system and check their correct function.
5. Switch the air conditioning on by the switch. After a five
minute operation the cabin must become noticeably cooler.
6. Switch the air heater on by the switch. After a five minute
operation the cabin must become noticeably warmer.
BW 219 D-5 / BW 219 PD-5 647

NOTICE!
The machine must not be operated if the seat con-
tact switch is not functioning correctly.
7. Function of the seat contact switch.

8. Check the adjustment of the doors, re-adjust if necessary
648 BW 219 D-5 / BW 219 PD-5

Machine assemblies – ROPS/FOPS assembly
6.9 ROPS/FOPS assembly

6.9.1 Safety..................................................................... 649
6.9.2 Preparations.......................................................... 650
6.9.3 ROPS/FOPS assembly.......................................... 651
6.9.4 Final work.............................................................. 655
6.9.1 Safety
General safety regulations for When carrying out assembly work on your machine you must
assembly strictly comply with the valid accident prevention instructions
or the country specific regulations. However, dangers for per-
sons and property may still arise, if:
n the lifting gear used has a too low bearing capacity
n damaged or worn lifting tackle is used
n unqualified personnel is entrusted with the installation
Each person involved in such assembly work must therefore
read and comply with these safety regulations.
Moreover, the following instructions and regulations must obviously
also be adhered to:
n country specific safety regulations. It is the duty of the operator
to be acquainted with these instructions and to apply these
accordingly. This applies also for local regulations concerning
different types of handling work. Should the recommendations
in these instructions be different from the regulations valid in
your country, you must comply with the safety regulations valid
in your country.
Changes and conversions to the Unauthorized changes to the ROPS/FOPS or the machine are pro-
cabin/machine hibited for safety reasons.
this machine. We wish to make explicitly clear that we have not
tested or approved any parts or accessories not supplied by us.
effect on the active and/or passive driving safety.
The manufacturer explicitly excludes any liability for damage
caused by the use of non-original parts or accessories.
Notes on safety in the assembly

instructions WARNING!
gers for persons.
BW 219 D-5 / BW 219 PD-5 649

NOTICE!
gers for machines or parts of the machine.
Paragraphs marked like this contains technical

information and hints for optimal assembly.
ENVIRONMENT!
Paragraphs marked like this point out practices for
safe and environmental disposal of fuels and lubri-
cants as well as replacement parts.
Strictly observe the national regulations for the pro-
tection of the environment.
Information and safety stickers/ Keep stickers/decals in good and legible condition (see spare parts
decals on the cabin catalogue) and comply with their meaning.
Replace damaged stickers/decals
Working on electric parts of the Before starting to work on electric parts of the machine disconnect
machine the battery and cover it with insulating material.
Do not use fuses with higher ampere ratings and do not repair
fuses with a piece of wire. Fire hazard.
6.9.2 Preparations
WARNING!
Danger of accident!
Check the 4 lifting eyes on the ROPS/FOPS for
tight fit.
Fasten the lifting gear to all four lifting eyes of the
ROPS/FOPS.
650 BW 219 D-5 / BW 219 PD-5

1. Make sure that all fastening screws, washers, and nuts are
available.
Fig. 708
2. Fasten the lifting gear to the four lifting eyes.

3. Loosen possible fastening on the transport pallet.
4. Slowly lift the ROPS/FOPS using a crane.
WARNING!
Danger of accident!
Fig. 709
6.9.3 ROPS/FOPS assembly
WARNING!
Danger of accident!
1. Remove dirt, oil and moisture from the driver’s stand.

2. Check the condition of the seals on the driver’s stand.
Fig. 710
BW 219 D-5 / BW 219 PD-5 651

3.
NOTICE!
When lifting the ROPS/FOPS take care of
the weight distribution. In any case the
ROPS/FOPS must be lowered vertically onto
the driver’s stand.
Slowly lower the ROPS/FOPS vertically onto the driver’s

stand.
Fig. 711 If the bores do not match, the ROPS/FOPS can be

moved into position by means of a crow bar.
4. Turn in and tighten the fastening screws (M16x35).

Fig. 712
6. Insert the screws (M10x30) and tighten the nuts with

washers.
Fig. 713
7. Cover the fastening screws for the railings with screw reten-
tion agent and tighten them.
Fig. 714
652 BW 219 D-5 / BW 219 PD-5

8. Tighten the fastening screws of the railings at the bottom.
Fig. 715
9. Insert the wiring loom into the control cabinet and install a
bulkhead bushing.
Fig. 716
10. Connect ground cable X8B (2), + potential 30 X8A (3) and
wiring loom plug X4E (1) to the circuit board.
Fig. 717
11. Install the protective covering.
Fig. 718
BW 219 D-5 / BW 219 PD-5 653

12. Fasten the wiring loom of the cabin and hoses with cable
ties.
Fig. 719
13. Turn nuts with washers onto both studs and tighten.
Fig. 720
14. Remove the lifting tackle and unscrew the lifting eyes.
15. Turn in and tighten the fastening screws (M16x30) for the
FOPS plate.
Fig. 721
16. Place the roof shells on the FOPS plate.

17. Screw in the fastening screws (M10x25), tighten them and
press on the protective caps (1).
Fig. 722
654 BW 219 D-5 / BW 219 PD-5

18. Hook the safety catch (1) into the front of the FOPS plate.
U-586-0261
Fig. 723
19. Fasten the safety catch to the roof shells.
U-586-0262
Fig. 724
6.9.4 Final work

1. Function test of sockets and working lights.
BW 219 D-5 / BW 219 PD-5 655

656 BW 219 D-5 / BW 219 PD-5

Troubleshooting
7 Troubleshooting
BW 219 D-5 / BW 219 PD-5 657

Troubleshooting
7.1 Preliminary remarks............................................... 659

7.2 Emergency procedures.......................................... 660
7.2.1 Actuating the emergency stop switch.................... 660
7.2.2 Machine stops in case of faults.............................. 661
7.2.3 Disconnecting the battery...................................... 662
7.2.4 Emergency exit...................................................... 662
7.2.5 Towing the machine............................................... 662
7.2.6 After towing............................................................ 667
7.3 Troubleshooting, electrical systems..................... 671
7.3.1 Preliminary remarks............................................... 671
7.3.2 Starting the engine with jump leads....................... 674
7.3.3 Servicing the battery, checking the main battery
isolation.................................................................. 675
7.3.4 Fuse assignment................................................... 676
7.3.5 ESX, checking the electric power supply............... 680
7.3.6 Diagnostics concept............................................... 688
7.3.7 Fault code display.................................................. 691
7.4 Trouble shooting, diesel engine............................ 692
7.4.2 Engine malfunctions.............................................. 692
7.4.3 SCR system warning strategy............................... 696
7.4.4 Deutz DTC fault code list, EMR4........................... 699
7.5 Trouble shooting, hydraulics................................. 745
7.5.2 Insufficient hydraulic power................................... 746
7.5.3 Troubleshooting axial piston pumps...................... 749
7.5.4 Troubleshooting axial piston motors...................... 751
7.5.5 Troubleshooting table for hydraulic components... 753
7.6 Troubleshooting the air conditioning system...... 761
7.6.1 Basic principles...................................................... 761
7.6.2 Troubleshooting..................................................... 768
7.6.3 Leak test................................................................ 781
7.6.4 Checking the magnetic clutch ............................... 782
7.7 Troubleshooting the auxiliary heating.................. 783
7.7.1 Fuse assignment................................................... 783
7.7.2 Components.......................................................... 784
7.7.3 Control and safety elements.................................. 785
7.7.5 Diagnostics of control panel, old version............... 786
7.7.6 Diagnostics of control panel, new version............. 794
7.7.7 Check the fuel supply............................................ 797
7.7.8 Circuit diagram, AIRTRONIC D2/D4...................... 799
658 BW 219 D-5 / BW 219 PD-5

Troubleshooting – Preliminary remarks
7.1 Preliminary remarks

Malfunctions are frequently caused by incorrect operation of the
machine or insufficient maintenance. Whenever a fault occurs you
should therefore thoroughly read these instructions on correct
operation and maintenance.
If you cannot locate the cause of a fault or rectify it yourself by fol-
lowing the trouble shooting chart, you should contact our customer
service department.
BW 219 D-5 / BW 219 PD-5 659

Troubleshooting – Emergency procedures
7.2 Emergency procedures

7.2.1 Actuating the emergency stop switch
1. In events of emergency and in case of danger actuate the
emergency stop switch immediately.
ð The engine is shut down and the parking brake is closed.
Fig. 725
660 BW 219 D-5 / BW 219 PD-5

7.2.2 Machine stops in case of faults

If serious faults occur during operation, the control unit prevents
further operation.
The machine is stopped and the parking brake is applied irrespec-
tive of the travel lever position (safe condition).
B-SYM-0222
The central warning light lights up and the warning buzzer sounds.
Fig. 726
1. Shift the travel lever to position “Middle” and engage it to the

right.
NOTICE!
– Do not shut down the engine all of a sudden
from full load speed, but let it idle for about two
minutes.
Fig. 727

B-ELE-0069
Fig. 728
4. Turn the main battery switch anticlockwise and pull it out.

5. Close the engine hood and lock it if necessary.
6. Inform our Customer Service.
7. Only operate the machine after it has been properly repaired.
Fig. 729
BW 219 D-5 / BW 219 PD-5 661

7.2.3 Disconnecting the battery

1. In events of emergency, e.g. in case of a cable fire, discon-
nect the battery from the vehicle network. For this purpose
turn the main battery switch anticlockwise and pull it out or
pull the battery terminal off the battery.
Fig. 730
7.2.4 Emergency exit

If a machine has turned over and the cabin door is jammed, the
cabin windows can be used as emergency exits.
1. Take the emergency hammer out of its bracket and smash
the cabin window.
Fig. 731
7.2.5 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.
662 BW 219 D-5 / BW 219 PD-5


n Protective gloves
WARNING!
Danger of injury caused by uncontrolled
machine movement!
– Always secure the machine against unintended
rolling.
Preparing for towing

1. Fasten the towing device reliably to the towing points.
Fig. 732
Access to the travel pumps

4. Unscrew the screw on the upper exhaust pipe bracket.
Fig. 733
5. Loosen both clamps (1) on the exhaust pipe.

6. Unscrew the screw (2) on the exhaust pipe bracket.
7. Take off the exhaust tube with the two seals.
Fig. 734
BW 219 D-5 / BW 219 PD-5 663

8. Unscrew four screws (1) from the main fuse box and lay the
main fuse box to the side.
Fig. 735
9. Pull off plug (1).

10. Unscrew four screws (2) from the hydraulic oil filter and lay
the hydraulic oil filter to the side.
Fig. 736
11. Unscrew the two screws (1) from the engine oil filter
mounting bracket and lay the engine oil filter with bracket to
the side.
Fig. 737
12. Unscrew three screws (1) from the AdBlue®/DEF dosing unit.
13. Lay the AdBlue®/DEF dosing unit to the side.
Fig. 738
664 BW 219 D-5 / BW 219 PD-5

14. Unscrew the screw (1) on the exhaust pipe bracket.

15. Loosen the clamp (2) on the exhaust pipe and take off the
exhaust pipe.
Fig. 739
16. Loosen the cable straps on the wiring loom.
Fig. 740
17. Pull off the plug.
Fig. 741
18. Unscrew the pipe to the sensor and lay it to the side.
Fig. 742
BW 219 D-5 / BW 219 PD-5 665

19. Unscrew the two screws (1) from the left side of the cross-
member.
Fig. 743
20. Unscrew the two outer screws (1) from the right side of the
cross-member.
21. Tilt the cross-member to the right.
Fig. 744
Releasing the parking brake

22. Loosen the high pressure relief valves (1) on the travel pump
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. 745
23. Press the emergency operation button completely in.

24. Insert a suitable pump lever extension and operate the pump,
until the brake is released.
ð The machine can now be towed.
Fig. 746
666 BW 219 D-5 / BW 219 PD-5

7.2.6 After towing
WARNING!
Danger of injury caused by uncontrolled
machine movement!
– Always secure the machine against unintended
rolling.
1. If the engine cannot be started, pull the emergency operation

button completely out after towing.
After starting the engine the emergency oper-

ation button is pushed out by hydraulic pres-
sure.
Fig. 747
2. Retighten the high pressure limiting valves (1) on the travel

pump again, tightening torque: 70 Nm (52 ft·lbf).
3. Return the cross-member to the installation position.
B-586-0178
Fig. 748
4. Screw in and tighten the two outer screws (1) on the right
1 side of the cross-member.
B-586-0172
Fig. 749
BW 219 D-5 / BW 219 PD-5 667

5. Screw in and tighten the two screws (1) on the left side of the
1 cross-member.
B-586-0221
Fig. 750
6. Screw on the pipe to the sensor and tighten it.
B-586-0220
Fig. 751
7. Plug on the plug to the sensor.
B-586-0219
Fig. 752
8. Position the wiring loom and fasten with cable straps.
B-586-0218
Fig. 753
668 BW 219 D-5 / BW 219 PD-5

9. Push on the exhaust end pipe.

10. Install and tighten clamp (2).
1 11. Install the bracket and tighten the screw (1).
2
B-586-0217
Fig. 754
12. Fasten the AdBlue®/DEF dosing unit and tighten the three
1 screws (1).
B-586-0216
Fig. 755
13. Attach the engine oil filter bracket in installation position and
tighten both screws (1).
1
B-586-0215
Fig. 756
14. Attach the hydraulic oil filter and tighten four screws (2).
1 15. Plug on the plug (1) to the sensor.

2
B-586-0214
Fig. 757
BW 219 D-5 / BW 219 PD-5 669

16. Attach the main fuse box and tighten the four screws (1).
1
1
B-586-0213
Fig. 758
17. Return the exhaust tube to the installation position.

1
18. Mount the two clamps (1) on the exhaust tube with seals and
tighten.
2 1 19. Install the bracket and tighten the screw (2).
B-586-0212
Fig. 759
20. Install the upper bracket and tighten the screw.
B-586-0211
Fig. 760
670 BW 219 D-5 / BW 219 PD-5

Troubleshooting – Troubleshooting, electrical systems
7.3 Troubleshooting, electrical systems

7.3.3 Servicing the battery, checking the main battery
isolation.................................................................. 675
7.3.4 Fuse assignment................................................... 676
7.3.5 ESX, checking the electric power supply............... 680
7.3.6 Diagnostics concept............................................... 688
7.3.7 Fault code display.................................................. 691
7.3.1 Preliminary remarks

service department.
Due to the fast technical development electric and electronic

vehicle systems become more intelligent and more comprehensive
day by day, and can hardly be dispensed with in hydraulic and
mechanical vehicle systems.
Diagnostics according to plan
Well structured trouble shooting procedures can save time and
money.
Random tests have revealed that purely electronic components or
control units only very rarely are the actual cause of failures:
n In approx. 10 % of the examined cases the problems were
caused by control units.
n In approx. 15 % sensors and actuators were the cause of the
problems.
By far the highest proportion of all faults could be traced back to
wiring and connections (plugs, etc.).
General:
Before changing any expensive components, such as control units,
you should run a systematic trouble shooting session to eliminate
any other possible fault sources. Knowledge in basic electrics is
required for this purpose. If a fault was diagnosed without having
pulled the plug of the control unit or inspected the wiring, this
should be done before changing any parts.
Check for good cable and ground contacts, therefore keep all
mechanical transition points between electric conductors (termi-
nals, plugs) free of oxide and dirt, as far as this is possible.
BW 219 D-5 / BW 219 PD-5 671

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.
672 BW 219 D-5 / BW 219 PD-5

A leakage current can be located by a amperage

measurement with a multimeter.
Measuring fault Whenever the electrical system of the vehicle behaves in an unex-
pected way, one should first consider that there may be a ground
problem! The older the electrical system and the lower the voltage,
the more likely this will be the cause.
As we all know, being able to utilize electric current requires the
existence of a closed electric circuit, the electrons leaving the bat-
tery must be able to return to the battery. In vehicles numerous
existing metal parts can be used for this purpose. The negative
pole of the battery is connected with the metal of the frame. The
current then flows through an insulated cable to e.g. a lamp should
light, and instead of a return line, the socket of the lamp is also, in
some way, connected to the frame, through which the current can
flow back to the battery. However, should the connection between
lamp and frame corrode causing a high electrical resistance at that
point, the current will try to find a different way. If no other way can
be found, the component will simply not work, even if the meter
shows that voltage arrives. Very often the current finds a different
way back to the battery, sometimes through other consumers.
Measuring sensors and actuators

Sensor signals are best checked where they are
needed, i.e. on the control unit. If the correct signal
is received you can be sure that not only the
sensor, but also the wiring to the control unit is in
good working order.
It is a common procedure to pick up the signals
with a break-out-box, the Y-cable of which is fas-
tened between control unit and control unit plug. If
no break-out-box is available, the measurement
takes place directly on the sensor, or one must try
to gain access to the back of the plug.
Trouble shooting procedure:

n First check the corresponding actuator, in case of a faulty
signal the output signal must be checked directly on the control
unit.
n If the output signal is correct, check the wiring to the actuator.
n In case of an incorrect output signal, check the corresponding
input signals after.
n In case of incorrect input signals check the signal on the
sensor itself.
n If the sensor signal is correct, check the wiring to the control
unit for continuity and against ground (short circuit).
n If the sensor delivers a correct signal, the sensor itself may be
the cause of the problem, or the sensor may be affected by
other incorrectly working components.
BW 219 D-5 / BW 219 PD-5 673

n However, the voltage supply and the ground connection of the

control unit as well as the power supply for sensors and actua-
tors must also be checked. Because an incorrect voltage value
can distort the input and output signals.
n If the action steps described above do not deliver a result, the
periphery is OK and the fault must be in the control unit, but be
cautious, most faults are caused by poor contacts in the plug
connections.
If the battery is empty If the battery is empty, the fault is normally quite quickly identified.
There are the following possibilities:
n because it is no longer charged by the generator
n because one of the consumers (light, radio, etc.) has not been
switched off
n because a hidden consumer “surreptitiously” empties the bat-
tery
n because the battery is defective
n generator or regulator are defective
n wiring between generator, starter and battery in poor condition
Check and measure the charge

system for faults It makes sense to be familiar with the working prin-
ciple of the charge system.
Necessary if:
n the battery is permanently discharged
n the battery has boiled over and acid has escaped
n the headlights light considerably brighter when accelerating
n light bulbs burn out frequently at irregular intervals
7.3.2 Starting the engine with jump leads
NOTICE!
battery.
674 BW 219 D-5 / BW 219 PD-5

NOTICE!
Fig. 761

tive poles after.
7.3.3 Servicing the battery, checking the main battery isolation

7.3.3.1 Battery service

need to be checked.
ranty!
BW 219 D-5 / BW 219 PD-5 675


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. 762
7.3.3.2 Checking the main battery shutoff

out.
2. Check by turning the ignition key, whether the battery is dis-
connected from the electric system of the machine.
Fig. 763

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

F05 20 A 12-V socket
F07 10 A Hazard light
F08 10 A Direction indicators
676 BW 219 D-5 / BW 219 PD-5


F09 10 A Parking and tail light, left
F10 10 A Parking and tail light, right
F11 15 A Head lights, front
F13 15 A Starter switch
F19 15 A Working head lights, front
F22 15 A Working head lights, rear
F23 15 A Warning horn
F24 10 A Instrument cluster
F29 15 A Compressor - air suspended seat, seat heating
F39 80 A Main fuse for cabin
F40 30 A Heating, air conditioning, fan
F84 10 A Control (contact 54)
F91 5A Sensors
F124 25 A Fuel pre-heating
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
BW 219 D-5 / BW 219 PD-5 677

7.3.4.3 Main fuses

The main fuse box is located in the engine compartment.
Fig. 764

F164 150 A (B+) charge line
F00 125 A Main fuse (potential 30)
Fig. 765

F48 150 A Preheating system
678 BW 219 D-5 / BW 219 PD-5

7.3.4.4 Exhaust gas aftertreatment system

The fuse box for the exhaust gas aftertreatment system is located
in the engine compartment under the battery cover.

F238 15 A Exhaust gas recirculation
F250 30 A SCR control
F251 10 A NOx sensors
(NOx: Nitric oxides)
F310 5A Sensor for AdBlue®/DEF quality
F312 20 A Spare
F313 20 A Spare
7.3.4.5 Control console cabin
Fig. 766

1 F17 5A Radio
2 F264 10 A BCM
3 F271 10 A BCM net
4 F150 5A GPS
5 F266 10 A Radio/Tachograph
6 F143 20 A Rear windscreen heating
7 F28 15 A Rear windscreen wiper
8 F27 15 A Front windscreen wiper
BW 219 D-5 / BW 219 PD-5 679


9 F279 15 A Spare
10 F272 5A Control console cabin
7.3.4.6 Auxiliary heating
B-586-0424
Fig. 767

7.3.5 ESX, checking the electric power supply

Power supply All electronic switching and control units require an electric power
supply to be able to work. If the plus or minus supply is faulty, the
control unit will work incorrectly or fail.
The following describes the electric power supply

for the ESX-control.
shows a simplified representation of how the con-
trol unit (ESX, 68 pole) is connected. The complete
representation can be found in the wiring diagram
of the machine.
The procedure can also be used for other controls.
Pin assignment and voltage supply may be dif-
ferent, but the procedures for line testing are gen-
erally the same.
680 BW 219 D-5 / BW 219 PD-5

Fig. 768: 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.
BW 219 D-5 / BW 219 PD-5 681

Fig. 769: 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. 770 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.
682 BW 219 D-5 / BW 219 PD-5

4. 4. Check with multimeter. If a setpoint is not reached, pro-

ceed step by step to identify the weak spot. Repair as neces-
sary. Repeat the measurement.
NOTICE!
The plug must not be pulled off or plugged on while
the ignition is switched on. Switch off the ignition
first and then pull off or plug on the plug.
Only plug the wiring loom onto the control unit,
when the actual value corresponds with the set-
point.
Fig. 770: Pinbox for 68 pole ESX control
BW 219 D-5 / BW 219 PD-5 683

General measuring setup to check

a supply line (plus side)
Fig. 771: 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.
684 BW 219 D-5 / BW 219 PD-5

General measuring setup to check

a return line (minus side)
Fig. 772: 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.
BW 219 D-5 / BW 219 PD-5 685

Connection example to check the

plus line between battery and plug
pin 28
Fig. 773
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. 774
P Multimeter
X Wiring loom plug disconnected from control unit or Pinbox
E Nominal value: E is bright. UV max. 0.5 Volt
686 BW 219 D-5 / BW 219 PD-5

Test protocol for ESX
Plug pin Note Nominal values

28 Ignition ON
E is bright,
E between plug pin 28 and battery minus
UV max. 0.5 Volt
P between battery plus and plug pin 28
28 Ignition OFF
E is dark,
E between plug pin 28 and battery plus
UV = 0 Volt
P between battery minus and plug pin 28
54 Ignition OFF, emergency stop not operated
E is bright,
UV max. 0.5 Volt
54 Ignition OFF, emergency stop operated
E is dark,
UV = 0 Volt
55 Ignition OFF
E is bright,
UV max. 0.5 Volt
56, 57, 58, 59, 60 Ignition OFF
E is bright,
E between plug pin 56, 57, 58, 59, 60 and battery minus
UV max. 0.5 Volt
P between battery plus and plug pin 56, 57, 58, 59, 60
If one or several setpoint(s) is (are) exceeded, one

must make considerations which are related to the
wiring diagram.
Example 1:
In all supply lines to the pins 56, 57, 58, 59 and 60 the voltage drop
is too high. There are two possible reasons. All contacts are either
corroded, or the supply line between battery and fuse Fxx has poor
contact.
Example 2:
Only one measuring value exceeds the setpoint. In this case the
fault must be located between the last branch and the corre-
sponding plug pin.
BW 219 D-5 / BW 219 PD-5 687

7.3.6 Diagnostics concept

Introduction A correct and reliable diagnose is a general prerequisite for the
detection of faults in system. For this to count as a rule several
points must be fulfilled. One of these points is the ability of the
engine to run a systematic trouble shooting procedure. However,
this is only possible when a diagnostics concept is available and in
practice. Trouble shooting can generally be performed in various
ways.
Fault description and questioning After the customer has explained his complaint(s) the engineer has
of the customer to ask further questions to track down the cause of the fault. If the
complaint is additionally related to electric/electronic components,
the visual examination and a possible test drive must be subse-
quently followed by an interrogation of the error log. The further
procedure in this case depends on the outcome of this interroga-
tion.
Fig. 775
(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.
688 BW 219 D-5 / BW 219 PD-5

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. 776
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
BW 219 D-5 / BW 219 PD-5 689

Sequence after the fault is found
Fig. 777
690 BW 219 D-5 / BW 219 PD-5

7.3.7 Fault code display

If the warning buzzer sounds and the central warning light lights up
or flashes, read out the fault code and inform our Customer
Service Department.
1. Press the [F2] button on the travel lever until the ‘fault code
display’ appears.
B-DIS-0680
Fig. 778
2. Read out and note the fault code (1).

1 3. If necessary, read out and note further fault codes.
ð If there are other incoming fault codes, these will also be
shown in the INFO 2 display field (2).
In this case, the display will automatically switch to the
next fault code after approx. 4 seconds.
4. Inform our Customer Service Department.
2
B-DIS-0809
Fig. 779
BW 219 D-5 / BW 219 PD-5 691

Troubleshooting – Trouble shooting, diesel engine
7.4 Trouble shooting, diesel engine

7.4.2 Engine malfunctions.............................................. 692
7.4.3 SCR system warning strategy............................... 696
7.4.4 Deutz DTC fault code list, EMR4........................... 699
7.4.1 Starting the engine with jump leads
NOTICE!
battery.
NOTICE!
Fig. 780

tive poles after.
7.4.2 Engine malfunctions

Fault Possible cause Remedy
Engine does not Fuel tank empty Refuel, bleed the fuel system
start or starts poorly
Temperature below starting limit Check
Cold starting device Check, replace if necessary
Engine oil with wrong SAE viscosity class Changing the engine oil
692 BW 219 D-5 / BW 219 PD-5


The fuel quality does not meet the Change the fuel
requirements
Battery defective or not charged Check
Cable connection to starter loose or oxi- Check cable connection
dized
Starter defective or pinion does not Check starter
engage
Incorrect valve clearance Check, adjust if necessary
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
High pressure pump defective Check, replace if necessary
Engine does not Engine electronics prevent starting Check fault code, repair as necessary
start and central
warning light is
flashing
Engine starts but V-belt/ribbed V-belt (fuel pump in belt Check if torn or loose
runs irregularly or drive)
misfires
Cold starting device Check, replace if necessary
Air in the fuel system Bleeding the fuel system
Fuel pre-filter soiled Check, clean the water separator, replace
the fuel pre-filter
requirements
Injector defective Replace
Engine wiring loom defective Check, replace if necessary
Speed changes are Engine electronics detected a system Check fault code, repair as necessary
possible and cen- fault and activates a substitute speed
tral warning light
flashes
The engine over- Ventilation line to the coolant compensa- Clean
heats, the coolant tion tank clogged
temperature
warning light Incorrect valve clearance Check, adjust if necessary
flashes
BW 219 D-5 / BW 219 PD-5 693


Coolant radiator soiled Clean
Coolant pump defective (V-belt torn or Check if torn or loose
loose)
Lack of coolant Check the coolant level, refill if necessary
Resistance in cooling system too high / Check the cooling system
flow rate too low
Fan defective / V-belt torn or loose Check fan / V-belt, replace if necessary
Intercooler soiled Clean
defective
Throttle valve defective Check, replace if necessary
Coolant temperature sensor Check, replace if necessary
Coolant thermostat defective Check, replace if necessary
Coolant cover defective Check, replace if necessary
Insufficient engine Engine oil level too high Check, drain off if necessary
power
Throttle valve defective Check, replace if necessary
Exhaust gas recirculation, actuator defec- Check, replace if necessary
tive
Fuel intake temperature too high Check the system
requirements
defective
Fan defective / V-belt torn or loose Check fan / V-belt, replace if necessary
Charge air line leaking Check
Intercooler soiled Clean
Exhaust gas counter-pressure too high Check, clean if necessary
Exhaust turbo charger defective Replace
Insufficient engine Engine electronics reduce the power Check fault code, repair as necessary
power and central
warning light
flashes
Engine does not Injection line leaking Check
work with all cylin-
ders Injector defective Check, replace if necessary
694 BW 219 D-5 / BW 219 PD-5


Engine wiring loom defective Check, replace if necessary
Engine has too low Engine oil level too low Check, refill if necessary
or no oil pressure
Lubrication oil pressure sensor defective Check, replace if necessary
Lubrication oil control valve jammed Check, clean if necessary
Lubrication oil suction pipe blocked Check, clean if necessary
Engine has exces- Engine oil level too high Check, drain off if necessary
sive lubrication oil
consumption Crankcase ventilation Check, replace if necessary
Valve shaft seals defective Check, replace if necessary
Piston rings worn Check, replace if necessary
Exhaust turbo charger defective Check, replace if necessary
Blue engine Engine oil level too high Check, drain off if necessary
exhaust smoke
Crankcase ventilation Check, replace if necessary
Valve shaft seals defective Check, replace if necessary
Piston rings worn Check, replace if necessary
Exhaust turbo charger defective Check, replace if necessary
White engine Coolant in exhaust gas Check
exhaust smoke
Condensation water Warm up the engine to evaporate water
residues
Black engine Diesel particulate filter (DPF) defective Check, replace if necessary
exhaust smoke
Fault in the SCR- AdBlue®/DEF-tank empty/level indicator Check filling level sensor
system (exhaust shows full
gas aftertreatment)
SCR does not work Check plug-in connections of cables on
feed pump and injector.
Check plugs and lines of feed pump, NOx
sensor and exhaust gas temperature
sensor.
Frequent regenera- Air filter clogged/exhaust turbocharger Check, replace if necessary
tion at standstill defective
Charge air line leaking Check
BW 219 D-5 / BW 219 PD-5 695


Differential pressure flow meter defective Replace
NOx sensor defective Replace
7.4.3 SCR system warning strategy

Overview
Fig. 781
1 Control and warning lamps
5 Engine rpm-meter
6 AdBlue®/DEF level gauge
7 Fuel level gauge
8 not used
696 BW 219 D-5 / BW 219 PD-5

Control and warning lamps
Designation Note
Warning lamp AdBlue®/DEF Lights up if the AdBlue®/DEF filling level is low, if the
AdBlue®/DEF quality is insufficient or if there is a fault in the
exhaust gas after-treatment system.
Flashes in case of an extremely low AdBlue®/DEF filling level.
Fill up AdBlue®/DEF or have the exhaust gas after-treatment
system checked immediately.
Central warning lamp Flashes in case of system faults, warnings and for information.
Monitoring the SCR-functionality During operation the SCR-system is monitored by the installed
sensors. This monitoring thereby covers the following areas:
n Tank level monitoring
n Malfunction, defect
n Manipulation (incorrect filling, manipulation of sensors, etc.)
If all warnings concerning filling level, malfunction

and manipulation are ignored, an entry will be
made in the error log and the SCR-system is sub-
sequently shut down. Apart from this, further coer-
cive measures in the form of engine power reduc-
tion are then applied. The power reduction takes
place to such an extent, that normal operation of
the machine is no longer possible.
Torque limitation / power reduction In case of severe faults or if faults are not properly rectified, the
system will respond with an engine power reduction. Depending on
the type of fault the power will be reduced in one or two stages.
Warning of a too low tank level

the torque curve
Once the tank filling level has dropped below 15%, the warning will
be issued.
BW 219 D-5 / BW 219 PD-5 697


the torque curve
n If the tank is still not filled up and the filling level drops below
10%, the system will change to the next warning stage.
n Once the tank contents drops below 5%, the next warning
stage is activated. Moreover, a reduction related to the max-
imum power of the engine is activated after a certain count-
down time (Step 1)
n If no filling of the SCR-tank has been recognized, another
power reduction (Step 2) will be activated after a certain count-
down time.

> 15% None None None
< 15% None None
Level < 15%

< 10% None None
Level < 10%

< 5% Power reduction after Power reduction Step 1
countdown
Power reduction
< 5% Power reduction Step 2 Power reduction Step 2
after countdown
Power reduction
empty Power reduction Step 2 Power reduction Step 2
Power reduction
Test with the Service & Diagnostics With the Service and Diagnostics program SERDIA 2010 it is pos-
Tool SERDIA 2010 sible to test the SCR system.
698 BW 219 D-5 / BW 219 PD-5

Fig. 782
The SERDIA 2010 operating instructions contain a

detailed description of the procedure for using this
function.
7.4.4 Deutz DTC fault code list, EMR4
BW 219 D-5 / BW 219 PD-5 699

700
DTC-List-EMR4 Revision date: 03.12.2018
Diagnoses- and ErrorCodes Overview of all active EMR4 KWP error codes
regardless of engine series
Code SPN FMI Blink code Fehlerbescheibung Error Identification
8 132 1 2-2-6 Der Luftmassenmesswert AFS_dm ist größer als The air mass flow AFS_dm is greater than or equal to
AFS_PhysRng.Min_C. AFS_PhysRng.Min_C.
Physikalische Bereichsüberprüfung für Luftmassensensor. Physical range check is low for air mass flow sensor.
9 172 2 2-2-6 Ansauglufttemperatursensor unplausibles Signal. Air inlet filter temperature, plausibility error.
26 523891 14 2-6-3 Wenn AirHt_ctDefSRCLoOn_mp niedriger als When AirHt_ctDefSRCLoOn_mp is lower than
AirHt_ctMaxDef_C ist. AirHt_ctMaxDef_C.
DFC zu SRC Low Fehler, wenn der Heizer angeschaltet ist. DFC to SRC Low error when heater is on.
28 523953 2 7-2-8 Selbstheilung tritt ein, wenn Fehlerursache behoben ist. Healing takes place if the condition for error detection is not
Ladelufttemperaturüberwachung. present.
Air temprature monitoring plausibility check array.
30 523955 2 7-2-8 Selbstheilung tritt ein, wenn die Fehlerbedingung nicht mehr Healing takes place if the condition for error detection is not
erfüllt ist. present.
Ladelufttemperaturüberwachung Plausibilitätscheck. Air temperature monitoring plausibility check array.
36 523923 3 7-2-9 Detailinformationen nicht verfügbar.
37 523924 3 1-6-7 Batteriekurzschluss Aktuatorrelais 2 Short circuit to battery error of actuator relay 2.
38 523925 3 7-3-1 Batteriekurzschluss Aktuatorrelais 3. Short circuit to battery of actuator relay 3.
40 523927 3 7-3-3 Batteriekurzschluss Aktuatorrelais 6. Short circuit to battery of actuator relay 6.
41 523923 4 7-2-9 Kurzschluss nach Masse Fehler. Short circuit to ground error.
Detailinformationen nicht verfügbar. Detailinformation not available.
42 523924 4 1-6-7 Kurzschluss gegen Masse Aktuatorrelais 2. Short circuit to ground of actuator relay 2.
43 523925 4 7-3-1 Kurzschluss gegen Masse Aktuatorrelais 3 Short circuit to ground of actuator relay 3.
BW 219 D-5 / BW 219 PD-5

44 523926 4 7-3-2 Kurzschluss gegen Masse Aktuatorrelais 4. Short circuit to ground of actuator relay 4.
45 168 3 3-1-8 Sensorfehler Batteriespannung; Signalbereich überschritten. Sensor battery voltage error; signal range check is high.
46 168 4 3-1-8 Sensorwert des Batteriespannungssensors unter Grenzwert. Sensor battery voltage error; signal range check is low.
47 168 2 3-1-8 Batteriespannunug zu hoch; Warnschwelle erreicht. High battery voltage; warning threshold is 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
Revision 1.0 Page 1 / 45

56 524013 7 8-5-6 Brenner Kontrolle. Burner Control.
Brenner startet nicht nach mehreren Versuchen. Burner does not start after several trials (burner flame lost
Brennerflamme unbeabsichtigt gelöscht. detection).
Burner flame unintentional deleted.
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 Burner dosing valve (DV2); Short circuit to battery.
(DV2).
62 523911 4 7-2-3 Massekurzschluss einer Leistungsstufe des Burner dosing valve (DV2); Short circuit to ground.
Brennerdosierventil (DV2).
63 523911 11 7-2-3 Brennerdosierventil (DV2); Kurzschluss Leistungsstufe Burner dosing valve (DV2); Short circuit high side
plusseitig. powerstage.
64 523912 2 7-2-2 Drucksensor nach Brennerdosierventil (DV2); Drucksignal Burner dosing valve (DV2) downstream pressure sensor;
nicht plausibel. plausibility error.
66 523912 0 7-2-2 Brenner-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.
BW 219 D-5 / BW 219 PD-5

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 1250mbar abs (expected: about
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.

701
702
73 523912 4 7-2-2 Für Motoren kleiner 4l: For engines < 4l:
Sammelfehler für Drosselklappe, Wackelkontakt oder Throttle valve error, Open load or short cut to battery, blocked
Kurzschluss nach Masse oder Batterie, blockierte Klappe valve or wrong control signal for valve.
oder falsches Ansteuersignal. For engines with Burner T4i:
Für Brenner Motoren T4i: Pressure Sensor error after valve (DV2), lower limit reached.
Sensorfehler Drucksensor nach Brennerdosierventil (DV2),
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.

Elektrische Wasserpumpe Zwischenkühler: Kabelbruch Water pump control (PWM) only TTCD 6.1/7.8.
(TTCD 6.1/7.8).
77 523914 12 7-2-1 Glühkerzenkontrolle; Leistungsstufe Übertemperatur. Glow plug control; Powerstage over temperature.
78 523914 3 7-2-1 Glühkerzenkontrolle: Kurzschluss gegen Batterie. Glow plug control; Short circuit to battery.
Elektrische Wasserpumpe Zwischenkühler: Kurzschluss Water pump control (PWM).
gegen Batterie (TTCD 6.1/7.8).
79 523914 4 7-2-1 Glühkerzenkontrolle; Massekurzschluss. Glow plug control; Short circuit to ground.
Elektrische Wasserpumpe Zwischenkühler: Kurzschluss Water pump control (PWM).
gegen Masse (TTCD 6.1/7.8).
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 (for engines <8L and
BW 219 D-5 / BW 219 PD-5

handelt es sich um den engine-CAN@250kbaud). 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.
83 16 0 2-7-1 Keine Detailinformationen. No detail information.

84 639 14 2-7-1 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 2-7-1 CAN-Bus 1 "BusOff-Status" CAN-Bus 1: "BusOff-Status"
86 1235 14 2-7-1 Bei CAN-Bus 2 (CAN_C = engine bus) hat "BusOff"-Message CAN-Bus 2 = engine bus "BusOff-Status"
(bei <8L und CV52 : Engine-CAN; 250kbaud).
87 16 0 2-7-1 BusOff Fehler. BusOff error CAN.
88 102 2 2-2-3 Ladedruck Grenzwert überschritten; Warnmeldung wird Charged air pressure above warning threshold.
generiert.

89 102 2 2-2-3 Ladedruck zu hoch (Abschaltschwelle überschritten) - Charged air pressure above shut off threshold.
Wastegate prüfen.
90 110 2 2-2-5 Fehlerbehebung bei absoluter Plausibilitätsprüfung Defect fault check for absolute plausibility test.
92 110 0 2-2-5 Kühlmitteltemperatur zu niedrig, physikalischer unterer Physical range check high for coolant temperature.
Grenzwert überschritten.
93 110 1 2-2-5 Kühlmitteltemperatur zu niedrig, physikalischer unterer Physical range check low for coolant temperature.
Grenzwert unterschritten.
96 110 3 2-2-5 Sensorfehler Kühlmitteltemperatur, oberer Sensor error coolant temperature; Signal range check high.
Spannungsgrenzwert überschritten.
97 110 4 2-2-5 Sensorfehler Kühlmitteltemperatur, unterer Sensor error coolant temperature; Signal range check low.
Spannungsgrenzwert unterschritten.
98 110 0 2-3-2 Kühlmitteltemperatur zu hoch; Warnschwelle erreicht. High coolant temperature; Warning threshold exceeded.
99 110 0 2-3-2 Kühlmitteltemperatur Grenzwert überschritten; Abschaltung Coolant temperature; System reaction initiated.
wird generiert.
101 111 1 2-3-5 Kühlmittelstand zu niedrig. Coolant level too low.
106 598 2 3-2-5 Plausibilitätsprüfung für Kupplung. Plausibility check for clutch.
121 1109 2 3-4-1 Motor Abschaltanforderung wurde vom Fahrer ignoriert. Engine shut off demand ignored.
122 523698 11 5-9-1 Abschaltanforderung durch übergeordnete Überwachung. Shut off request from supervisory monitoring function.
124 523969 11 7-7-4 Fehlereintrag für Override-Steuerungsmodus. Fault entry for override control mode.
125 523717 12 5-9-5 Timeout der CAN-Sendebotschaft AmbCon; Wetter Timeout error of CAN-transmit-frame AmbCon; Weather
Umgebungsbedingungen. environments.
BW 219 D-5 / BW 219 PD-5

126 523603 9 3-3-8 Timeout der CAN-Empfangsbotschaft AMB; Timeout Error of CAN-receive-frame AMB; Ambient
Umgebungstemperatur Sensor. temperature sensor.
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 5-9-6 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 5-9-7 Timeout der CAN-Empfangsbotschaft AT1IG1Vol; NOX Timeout error of CAN-receive-frame AT1IG1Vol; NOX
Sensor vor Katalysator. sensor.

703
704
133 523938 9 7-6-6 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 7-6-6 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 7-6-6 Kalibrierbotschaft 2 von dem Vor-Kat Nox-Sensor ist Timeout error (PCK2PCK) for CAN-Receive-Frame
ausgefallen. AT1IGCVol1.
136 3234 2 1-1-4 DLC Error von dem CAN-Receive-Frame AT1O1. DLC error of CAN-Receive-Frame AT1O1.
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
Katalysator). cat).
138 3234 2 1-1-4 Botschaftslänge des Nach-Kat Nox-Sensors stimmt nicht mit DLC error of CAN-Receive-Frame AT1O1Vol.
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 1-1-7 Timeout der CAN-Empfangsbotschaft AT1OG1Vol. NOX Timeout error of CAN-Receive-Frame AT1OG1Vol.
Katalysator).
140 523941 9 7-6-7 Ausfall der Nach-Kat Nox-Sensor Botschaft. Timeout error (BAM to packet) for CAN-Receive-Frame
Timeout (BAM to packet) der CAN-Empfangsbotschaft AT1OGCVol2.
BW 219 D-5 / BW 219 PD-5

AT1OGCVol2. Faktoren- & Sensorkalibrierung für den NOX
Katalysator).
141 523942 9 7-6-7 Kalibrierbotschaft 1 von dem Nach-Kat Nox-Sensor ist Calibration message 1 of the after catalyst Nox sensor has
ausgefallen. failed.
142 523943 9 7-6-7 Broadcast Announce Nachricht der Kalibrierbotschaft von Timeout error (PCK2PCK) for CAN-Receive-Frame
dem Nach-Kat Nox-Sensor ist ausgefallen. AT1OGCVol2.
Timeout (PCK2PCK) der CAN-Empfangsbotschaft
AT1OGCVol2.
Faktoren- & Sensorkalibrierung für Nox Sensor (SCR-System
nach Katalysator; DPF-System nach Katalysator).
153 523992 9 7-9-3 Wird nicht verwendet. Not used.
155 0 0 - Wird nicht verwendet. Not used.

164 523211 9 3-3-1 Timeout Fehler des CAN-Receive-Frame EBC1. Timeout error of CAN-Receive-Frame EBC1.
167 523704 12 6-1-5 Timeout Error von CAN-Transmit-Frame EEC3. Timeout error of CAN-Transmit-Frame EEC3.
168 523935 12 7-6-3 Timeout der CAN-Sendebotschaft EEC3VOL1. Timeout error of CAN-Transmit-Frame EEC3VOL1.
Motor Sendebotschaften. Engine send messages.
169 523936 12 7-6-4 Timeout der CAN-Sendebotschaft EEC3VOL2. Timeout error of CAN-Transmit-Frame EEC3VOL2.
Motor Sendebotschaften. Engine send messages.
171 523212 9 3-3-3 Timeout der CAN-Empfangsbotschaft ComEngPrt. Timeout error of CAN-Receive-Frame ComEngPrt.
Motorschutzfunktion. Engine Protection.
172 523741 14 6-1-8 Motorabschaltungsaufforderung über den CAN-Bus. Engine shut off request through CAN.
174 523213 12 3-3-4 Timeout Fehler des CAN-Transmit-Frames ERC1. Timeout error of CAN-Transmit-Frame ERC1.
178 523706 12 6-2-3 Timeout Fehler des CAN-Transmit-Frames FlEco. Timeout error of CAN-Transmit-Frame FlEco.
179 523240 9 5-2-7 Timeout der CAN-Empfangsbotschaft FunModCtl. Timeout CAN-message FunModCtl.
Function Mode Control. Function Mode Control.
193 523937 9 7-6-5 Timeout DFC für NOxSensGlbReqTx. Timeout DFC for NOxSensGlbReqTx.
196 3227 2 6-3-8 DFC SAE J1939 Fehler. DFC SAE J1939 error.
198 523216 9 3-3-7 Timeout der CAN-Empfangsbotschaft PrHtEnCmd. Timeout error of CAN-Receive-Frame PrHtEnCmd.
Vorheiz-Anforderung, Motor-Anforderung. Pre-heat command, engine command.
202 523793 9 6-7-8 Timeout der CAN-Empfangsbotschaft UAA10. Timeout error of CAN-Receive-Frame UAA10.
AGS Sensor Service Botschaft. AGS sensor service message.
203 523794 9 6-7-8 Timeout der CAN-Empfangsbotschaft UAA11. Timeout error of CAN-Receive-Frame UAA11.
AGS Sensor Daten. AGS sensor data.
212 523803 9 6-7-8 Timeout der CAN-Empfangsbotschaft RxEngPres. Timeout error of CAN-Receive-Message RxEngPres.
BW 219 D-5 / BW 219 PD-5

Status Brenner Luftpumpe. Status Burner Air Pump.
273 3219 2 6-4-9 DFC SAE J1939 Fehler. DFC SAE J1939 error.
281 523766 9 1-1-8 Timeout der CAN-Empfangsbotschaft Active TSC1AE. Timeout error of CAN-Receive-Frame Active TSC1AE.
282 523767 9 1-1-8 Timeout Fehler der CAN-Empfangsbotschaft Passive Timeout error of CAN-Receive-Frame Passive TSC1AE.
TSC1AE.
283 523768 9 1-1-9 Timeout Fehler der CAN-Empfangsbotschaft Active Timeout error of CAN-Receive-Frame Active TSC1AR.
TSC1AR.
284 523769 9 1-1-9 Timeout der CAN-Empfangsbotschaft Passive TSC1AR. Timeout error of CAN-Receive-Frame Passive TSC1AR.
291 523776 9 1-1-9 Timeout der CAN-Empfangsbotschaft TSC1TE - aktiv. Timeout error of CAN-Receive-Frame TSC1TE - active.
292 523777 9 1-1-9 Passiver Timeout der CAN-Empfangsboschaft TSC1TE. Passive timeout error of CAN-Receive-Frame TSC1TE.
Sollwertvorgabe. Setpoint.
293 523778 9 1-1-8 Aktiver Timeout der CAN-Empfangsbotschaft TSC1TR. Timeout error of CAN-Receive-Frame TSC1TR.

705
706
294 523779 9 1-1-8 Passiver Timeout der CAN-Empfangsbotschaft TSC1TR. Passive timeout error of CAN-Receive-Frame TSC1TR.
299 523788 12 6-5-5 Timeout Fehler der CAN-Sendebotschaft TrbCH. Timeout error of CAN-Transmit-Frame TrbCH.
Status Wastegate. Status Wastegate.
300 523605 9 1-1-8 Timeout Fehler der CAN-Empfangsbotschaft TSC1AE. Timeout error of CAN-Receive-Frame TSC1AE.
Traktionskontrolle. Traction Control.
301 523606 9 1-1-9 Timeout Fehler der CAN-Empfangsbotschaft TSC1AR. Timeout error of CAN-Receive-Frame TSC1AR.
Retarder. Retarder.
305 898 9 1-1-8 Timeout Fehler der CAN-Empfangsboschaft TSC1TE. Aktiv. Timeout error of CAN-Receive-Frame TSC1TE.
Setpoint.
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 error of CAN-Transmit-Frame UAA11.
322 523867 12 6-7-9 Timeout Fehler der CAN-Sendebotschaft UAA1 auf CAN 2. Timeout error of CAN-Transmit-Frame UAA1 on CAN 2.
Ansteuerung Brenner Luftpumpe. Control burner air pump.
360 523982 0 7-3-7 Leistungsstufen Diagnose abgeschaltet. Powerstage diagnosis disabled.
Batteriespannung zu hoch. High battery voltage.
361 523982 1 7-3-7 Leistungsstufen Diagnose abgeschaltet. Powerstage diagnosis disabled.
Batteriespannung zu niedrig. Low battery voltage.
362 523090 2 3-2-9 Motorbremse Vorauswahlschalter. Engine brake Pre-Selection switch.
Plausibilitätsfehler. Plausibility error.
376 630 12 2-8-1 Zugriffsfehler EEPROM-Speicher (Löschen). Access error EEPROM memory (delete).
377 630 12 2-8-1 Zugriffsfehler EEPROM-Speicher (Lesen). Access error EEPROM memory (read).
378 630 12 2-8-1 Zugriffsfehler EEPROM-Speicher (Schreiben). Access error EEPROM memory (write).
BW 219 D-5 / BW 219 PD-5

381 411 4 6-9-3 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 5-5-5 Interner Softwarefehler ECU. Einspritzung unterbrochen. Internal software error ECU.
Injection cut off.
388 190 0 2-1-4 Überdrehzahl Detektion in der Komponente Engine Engine speed above warning threshold.
Protection. Overspeed detection in component engine protection.
389 190 0 2-1-4 Motordrehzahl über Warnschwelle (FOC-Level 1). Engine speed above warning threshold (FOC-Level 1).
390 190 11 2-1-4 Motordrehzahl über Warnschwelle (FOC-Level 2). Engine speed above warning threshold (FOC-Level 2).
391 190 14 2-1-4 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 Ambient air pressure received from a CAN-bus is reported as
defekt gemeldet. defective.

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 maximalen Environment temperature sensor, temperature above upper
physikalischen Grenzwert überschritten. physical threshold.
416 171 1 3-1-2 Umgebungstemperatursensor, Temperatur hat minimalen Environment temperature physical range check low.
Grenzwert unterschritten.
417 171 3 3-1-2 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 3-1-2 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 2-1-2 Sensor Nockenwellendrehzahl, Signal gestört. Sensor camshaft speed, disturbed signal.
420 190 12 2-1-2 Sensor Nockenwellendrehzahl, kein Signal. Sensor camshaft detection.
Out of range, signal disrupted, no signal.
421 190 2 2-1-3 Offsetfehler zwischen Kurbelwelle und Nockenwelle. Offset angle between crank- and camshaft-sensor is too
large.
422 190 8 2-1-2 Fehlerhaftes Kurbelwellensensorsignal Sensor crankshaft detection.
Sensor Kurbelwellendrehzahl, Signal gestört. Out of range, signal disrupted or no signal.
423 190 12 2-1-2 Fehlendes Kurbelwellensensorsignal. Speed detection, out of range, signal disrupted or no signal.
455 975 5 2-3-8 PWM-Signal Lüfter, Leitungsunterbrechung oder Kurzschluss PWM-Signal fan, open load or short-circuit ground.
BW 219 D-5 / BW 219 PD-5

gegen Masse.
457 975 3 2-3-8 Lüfter Aktuator(PWM Ausgang), Batteriekurzschluss. PWM-Signal fan, short-circuit to battery.
458 975 4 2-3-8 Lüfter Aktuator (PWM Ausgang), Massekurzschluss. PWM-Signal fan, open load or short circuit to ground
459 1639 12 2-3-8 Fan speed sensor, electrical error, signal disturbed or very
low fan speed.
460 1639 0 2-3-8 Sensorfehler Lüfterdrehzahl, Signalbereich überschritten. Sensor error fan speed.
Signal range check high or engine speed resp. fan speed too
big.
461 1639 1 2-3-8 Sensorfehler Lüfterdrehzahl, Signalbereich unterschritten. Sensor error fan speed, signal range check low or fan speed
too 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.

707
708
464 97 3 2-2-8 Sensorfehler Wasser in Kraftstoff, Signalbereich Sensor error water in fuel, signal range check high.
überschritten.
465 97 4 2-2-8 Sensorfehler Wasser in Kraftstoff, Signalbereich Sensor error water in fuel, signal range check low.
unterschritten.
472 94 3 2-1-6 Sensorfehler Kraftstoffvordruck, Signalbereich überschritten. Sensor error low fuel pressure, signal range check high.
473 94 4 2-1-6 Sensorfehler Kraftstoffvordruck, Signalbereich unterschritten. Sensor error low fuel pressure, signal range check low.
474 94 1 2-1-6 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.
483 174 11 2-2-7 Kraftstofftemperatur Signal unplausibel. Fuel temperature not plausible.
486 523618 3 1-3-3 Sensorfehler Getriebeöltemperatur, Signalbereich Sensor error gearbox oil temperature, signal range check
überschritten. high.
487 523618 4 1-3-3 Sensorfehler Getriebeöltemperatur, Signalbereich Sensor error gearbox oil temperature, signal range check
unterschritten. low.
488 523619 2 1-3-3 Abgastemperatur vor (SCR-CAT): Maximalwert Physical range check high for exhaust gas temperature
überschritten. upstrem (SCR-CAT).
489 523619 2 1-3-3 Shutoff condition Shutoff condition
Detailinformationen fehlen! No detail informationen!
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 overtemperature.
502 523915 3 1-5-9 Leistungsstufe HCI Dosierventil (DV1): Batteriekurzschluss. HCI dosing valve (DV1): Short circuit to battery.
BW 219 D-5 / BW 219 PD-5

503 523915 3 1-6-4 Batteriekurzschluss Leistungsstufe plusseitig HCI Short circuit to battery high side, HCI dosing valve (DV1).
Dosierventil (DV1).
504 523915 4 1-5-9 HCI Dosierventil (DV1): Kurzschluss gegen Masse. HCI dosing valve (DV1): Short circuit to ground.
505 523915 11 1-6-4 Leistungsstufe Dosierventil (DV1): Kurzschluss gegen HCI dosing valve (DV1): Short circuit high side powerstage.
Batterie plusseitig.
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 HCI dosing valve (DV1) downstream pressure: Physical
überschritten. Abschaltung Regeneration. range check high. Shut off regeneration.
511 523916 1 7-1-9 Druck nach HCI Dosierventil (DV1): Minimalwert HCI dosing valve (DV1) downstream pressure: Physical
unterschritten. Abschaltung Regeneration. range check low. Shut off regeneration.

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.
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.
542 1638 2 3-1-4 Temperatur Hydrauliköl: Physikalischer Wert oberhalb Hydraulic oil temperature check for Shut off condition.
Grenzwert für Abschaltbedingung.
543 676 11 263 Fehler Relais Kaltstarthilfe. Cold start aid relay error.
544 676 11 263 Relais Kaltstarthilfe: Kabelbruch, Kurzschluss gegen Batterie. Cold start aid relay: Open load.
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. -
559 523895 13 1-5-8 Fehlender Injektor Korrekturwert (IMA) Injektor 1. Check of missing injector adjustment value programming
(IMA) injector 1.
BW 219 D-5 / BW 219 PD-5

(IMA) injector 2.
(IMA) injector 3.
(IMA) injector 4.
(IMA) injector 5.
(IMA) injector 6.
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: Ausgang Leistungsstufe defekt. Injector powerstage output defect.

709
710
568 651 5 154 Injektor 1 (nach Zündfolge): Stromunterbrechung. Injector 1 (in firing order): Interruption of electric connection.
575 523756 14 1-5-5 special pattern for special cases special pattern for special cases
580 651 3 154 Injektor 1 (nach Zündfolge): Kurzschluss. Injector 1 (in firing order): Short circuit.
BW 219 D-5 / BW 219 PD-5

590 655 4 1-6-2 Kurzschluss Injektor 5 (nach Zündfolge) zwischen High-side High side to low side short circuit in the injector 5 (in firing
und Low-side order)

591 656 4 1-6-3 Kurzschluss Injektor 6 (nach Zündfolge) zwischen High-side High side to low side short circuit in the injector 6 (in firing
und Low-side order)
592 523615 5 135 Zumesseinheit (Kraftstoffsystem): Kabelbruch. Metering unit (Fuel-System): Open load.
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
plusseitig. side.

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 -
611 1346 0 2-4-1 Misfire detection monitoring Misfire detection monitoring
BW 219 D-5 / BW 219 PD-5

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

711
712
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
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
BW 219 D-5 / BW 219 PD-5

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 5-5-5 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 5-5-5 Überwachung; Versorgungsspannung zu hoch Reported Over Voltage of Supply
646 523612 4 5-5-5 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
654 2634 12 7-5-7 Early opening defect of main relay Early opening defect of main relay
656 2634 12 7-5-7 DFC for stuck main relay error DFC for stuck main relay error
659 3226 2 8-1-3 Nox feed back fault detection Nox feed back fault detection
692 523752 0 7-5-8 Plausibiliti error during Rich to Lean switch over Plausibiliti error during Rich to Lean switch over
693 523752 0 7-5-8 Monitoring of Nox signal readyness Monitoring of Nox signal readyness
714 523612 12 5-5-5 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 5-5-5 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 5-5-5 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 5-5-5 Diagnostic fault check to report WDA/ABE active due to Diagnostic fault check to report WDA/ABE active due to
unknown reason unknown reason
720 98 2 2-1-1 Ölstand Signal unplausibel Plausibility Check
Plausibility Check No detail informationen!
Detailinformationen fehlen!
732 100 3 2-2-4 Sensorfehler Öldruck; Signalbereich überschritten Sensor error oil pressure; signal range check high
BW 219 D-5 / BW 219 PD-5

733 100 4 2-2-4 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 2-3-1 Öldruck zu niedrig; Warnschwelle erreicht Low oil pressure; warning threshold exceeded
737 100 1 2-3-1 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 1-4-5 Override switch; Signal unplausibel. Override switch; plausibility error.

713
714
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 1-3-6 Luftfilter Unterdruckschalter, Luftfilter verschmutzt Air filter differential pressure; air filter cologged.
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
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 2-2-3 Ladeluftdruck nach Ladeluftkühler, Signal unplausibel Pressure downstream charge air cooler, plausibility error
774 102 1 2-2-3 Ladeluftdruck nach Ladeluftkühler, Druck unter unterem Pressure downstream charge air cooler, pressure below
physikalischem Grenzwert lower physical threshold
BW 219 D-5 / BW 219 PD-5

776 102 3 2-2-3 Ladeluftdruck nach Ladeluftkühler, Kurzschluss gegen Pressure downstream charge air cooler, short circuit to
Batterie oder Kabelbruch battery or open load

777 102 4 2-2-3 Ladeluftdruck nach Ladeluftkühler, Kurzschluss gegen Masse Pressure downstream charge air cooler, short circuit to
ground
780 523699 3 1-1-3 Ladedruckkontrolle; negative Reglerabweichung unter Boost pressure control; negative governor deviation below
Grenzwert limit
781 523699 4 1-1-3 learning value too high learning valu too high
785 523889 3 1-1-3 over teperature of device driver of pressure control valve over teperature of device driver of pressure control valve

791 411 0 6-9-3 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
793 411 11 6-9-3 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 6-9-3 Sensor Differenzdruck Venturieinheit (AGR). Sensor error differential pressure Venturiunit (EGR), signal
Sensorfehler Differenzdruck Venturieinheit (AGR), range check low.
Signalbereich überschritten.
796 411 4 6-9-3 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).
806 524058 2 8-4-4 Partikel Filter; Regeneration nicht erfolgreich Particulate filter; regeneration not succesful
807 3253 2 6-9-2 Differenzdrucksensor DPF, Plausibilisierungsfehler Differential pressure DPF, plausibility error
809 3251 0 6-9-2 Differenzdruck DPF Maximalwert überschritten. Differential pressure DPF maximum value is exceeded
Abschaltung Regeneration.
BW 219 D-5 / BW 219 PD-5

810 3251 0 6-9-2 Differenzdrucksensor DPF Differential pressure sensor across DPF exceeds warning
Physikalischer Wert über oberem Grenzwert high limit
812 3251 1 6-9-2 Differenzdruck DPF Minimalwert unterschritten. Differential pressure DPF, pressure below lower shutoff
Abschaltung Regeneration. threshold.
813 3251 1 6-9-2 Differenzdrucksensor DPF. Differential pressure DPF, pressure below lower warning
Physikalischer Wert unter unterem Grenzwert. threshold.
814 3253 3 6-9-2 Sensorfehler Differenzdruck B58 (DPF); Signalbereich Electrical error differential pressure B58 (DPF).
überschritten (signal range check high)
815 3253 4 6-9-2 Sensorfehler Differenzdruck (DPF); Signalbereich Electrical error differential pressure (DPF).
unterschritten. signal range check low.
825 523009 9 2-5-3 Druckbegrenzungsventil (DBV) hat seine maximale Anzahl The pressure relief valve (PRV) has reached the number of
an Schaltvorgängen erreicht. allowed activations.

715
716
826 523470 2 1-4-6 Druckbegrenzungsventil (DBV) ist durch Druckanstieg zum Pressure relief valve is forced to open, perform pressure
Öffnen gezwungen worden. increase.
827 523470 2 1-4-6 Druckbegrenzungsventil (DBV) hat wegen Druckstoß Pressure Relief Valve (PRV) forced to open. Performed by
zwangsgeöffnet. pressure increase.
828 523470 12 1-4-6 Druckbegrenzungsventil (DBV) geöffnet. Pressure Relief Valve (PRV) forced to open.
Abschaltung Shutoff conditions.
829 523470 12 1-4-6 Druckbegrenzungsventil (DBV) geöffnet. Pressure Relief Valve (PRV) forced to open.
Warnung Warning conditions.
830 523470 14 1-4-6 Druckbegrenzungsventil (DBV) geöffnet Open Pressure Relief Valve (PRV)
831 523470 11 1-4-6 Druckbegrenzungsventil (DBV) Fehler. Der Raildruck ist Pressure Relief Valve (PRV) error; Rail pressure out of
außerhalb des Toleranzbereichs tolerance range.
832 523470 11 1-4-6 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 (DBV) 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.
BW 219 D-5 / BW 219 PD-5

Kurzschluss gegen Masse. Short circuit to ground.
847 1176 0 1-3-9 Drucksensor vor Turbine,bei Überprüfung Physikalischer Pressure sensor upstream turbine, Physical Range Check
Messbereich nach oben überschritten . high.

848 1176 1 1-3-9 Drucksensor vor Turbine,bei Überprüfung Physikalischer Pressure sensor upstream turbine, Physical Range Check
Messbereich nach unterschritten. low.
849 1176 3 1-4-1 Drucksensor vor Turbine. Bei Signalcheck (SRC) Pressure sensor upstream turbine, signal range check (SRC)
Spannungssignal über oberer Grenze. high.
850 1176 4 1-4-1 Drucksensor vor Turbine. Bei Signalcheck (SRC) Pressure sensor upstream turbine, signal range check (SRC)
Spannungssignal unter unterer Grenze. low.
856 523613 0 1-3-4 Raildruck unter Sollwert, drehzahlabhängige Schwelle Rail pressure below setpoint, speed-dependent threshold
überschritten. exceeded.
857 523613 0 1-3-4 Raildruck unter Sollwert, Schwelle überschritten. Rail pressure below setpoint, threshold exceeded.

858 523613 0 1-3-4 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 1-3-4 Negative Raildruckabweichung in Zumesseinheit Rail pressure metering unit, Rail pressure below the target
Warngrenze unterschritten (RailMeUn2) range .(RailMeUn2)
Leckage Railsystem (RailMeUn10) Railsystem leakage detected.(RailMeUn10)
861 523613 1 1-3-4 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 1-3-4 Maximaler Raildruck überschritten (RailMeUn4) Rail pressure metering unit, Maximum rail pressure
exceeded.
864 523613 2 1-3-4 Sollwert Zumesseinheit im Schubbetrieb unplausibel. Rail pressure metering unit, Setpoint of metering unit in
overrun mode not plausible.
865 523613 0 1-3-4 Sollwert Zumesseinheit im Schubbetrieb unplausibel Setpoint of metering unit in overrun mode not plausible
874 157 0 1-4-7 rail pressure raw value is above maximum offset Rail pressure raw value is intermittent
Rail pressure raw value is intermittent No detail informationen!
875 157 1 1-4-7 rail pressure raw value is above maximum offset rail pressure raw value is above maximum offset
the rail pressure sensor will be classified as defect. No detail informationen!
876 523470 7 1-4-6 Maximaler Raildruck überschritten (DBV). Maximum rail pressure exceeded (PRV).
877 157 3 1-4-7 Sensorfehler Raildrucksensor, Sensor error rail pressure.
obere Spannungsgrenze überschritten. Sensor voltage above upper limit.
BW 219 D-5 / BW 219 PD-5

878 157 4 1-4-7 Sensorfehler Raildrucksensor, Sensor error rail pressure.
untere Spannungsgrenze unterschritten. Sensor voltage below lower limit.
881 523633 11 1-4-9 Wirkungsgradüberwachung; cat efficiency error Longterm adaption factor below threshold
882 523633 11 1-4-9 Wirkungsgradüberwachung; cat efficiency error within the Nox conversion rate insufficient (SCR-Cat defect, bad DEF
range 1 (Nox-Umsatzrate zu gering, SCR-Kat defect, quality)
mangelhafte DEF qualität)
Nox Konvertierungsrate ungenügend (SCR-Kat defekt,
mangelhafte DEF Qualität)
883 523633 11 1-4-9 Wirkungsgradüberwachung; cat efficiency error within the Nox conversion rate insufficient (SCR-Cat defect, bad DEF
range 2 (Nox-Umsatzrate zu gering, SCR-Kat defect, quality); temperature range 1
mangelhafte DEF qualität)
Nox Konvertierungsrate ungenügend (SCR-Kat defekt,
mangelhafte DEF Qualität); Temperaturbereich 1

717
718
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 DEF 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 DEF Dosiermodul blockiert (SCR) DEF dosing valve blocked (SCR)
914 523720 2 1-4-8 DEF Supplymodul Heizertemperatur; Signal unplausibel DEF supply module heater temperature; plausibility error
(Normalbetrieb). (normal condition).
915 523720 2 1-4-8 Sensor Heizertemperatur DEF Supplymodul; Signal Sensor DEF supply module heater temperature; plausibility
unplausibel (Kaltstart) error (cold start condition)
916 523721 2 6-8-9 Sensor DEF Supplymodul Temperatur; Signal unplausibel Sensor DEF supply module temperature; plausibility error
(Normalbetrieb) (normal condition)
BW 219 D-5 / BW 219 PD-5

917 523721 2 6-8-9 Sensor DEF Supplymodul Temperatur; Signal unplausibel Sensor DEF supply module temperature; plausibility error
(Kaltstart) (cold start condition)

918 523981 11 2-4-3 Heizung DEF-Tank ohne Funktion (Aufheizphase). SCR plausibility, OBD and diagnosis; Stuck in range check of
DEF tank temperature sensor
DEF-tank without heating function (heating phase)
919 523330 14 1-3-1 Wegfahrsperrenschlüssel ungültig. Immobilizer status; fuel blocked
Status Wegfahrsperre; Kraftstoffzufuhr gesperrt.
920 523330 14 1-3-1 DFC to block the fuel by Sia DFC to block the fuel by Sia
921 523330 14 1-3-1 DFC to indicate that TEN-code or UC-code received if ECU is DFC to indicate that TEN-code or UC-code received if ECU is
learned. learned.

922 523330 14 1-3-1 DFC to indicate that no code is received via CAN. DFC to indicate that no code is received via CAN.
923 523330 14 1-3-1 DFC to indicate that wrong code is received. DFC to indicate that wrong code is received.
925 523720 8 1-4-8 SCR: Dutycycle Temperatur Heizer des Supplymoduls ist DEF supply module heater temperature; duty cycle in failure
ausserhalb der Grenzen range.
926 523720 8 1-4-8 SCR: Dutycycle Temperatur des Heizers Supplymodul nicht DEF supply module heater temperature; duty cycle in invalid
gültig range.
DEF Supplymodul Heizertemperatur; Duty Cycle im
ungültigen Bereich
927 523721 11 6-8-9 SCR: Temperaturmessung trotz Anfrage durch ECU nicht Urea supply module temperature measurement not available.
erfolgreich.
DEF Supplymodul Temperaturmessung nicht verfügbar.
928 523722 8 6-9-1 SCR: Periode des PWM Signals vom Supplymodul ist nicht in DEF supply module PWM signal; period outside valid range.
den Zeitgrenzen
929 523722 8 6-9-1 SCR. Kein gültiges PWM Signal vom Supplymodul Detect faulty PWM signal from Supply Modul.
empfangen.
930 523721 8 6-8-9 SCR. Kein gültiges PWM Signal vom Supplymodul DEF supply module temperature; duty cycle in failure range.
empfangen.
931 523721 8 6-8-9 DEF 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 1. Sensor error accelerator pedal.
BW 219 D-5 / BW 219 PD-5

Signalbereich überschritten. signal range check high.
937 29 4 1-2-6 Handgas; Massekurzschluss Handthrottle; 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 DEF Tanklevelsensor; Signalbereich Sensor error DEF tank level; signal range check high
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 DEF Tanklevel; Signalbereich unterschritten. Sensor error DEF tank level; signal range check low
946 1079 13 2-8-2 Ausfall der Sensorversorgungsspannung 1 Failure of sensor supply voltage 1.

719
720
956 677 3 5-1-2 Starterrelais plusseitig; Batteriekurzschluss Starter relay high side.
Short circuit to battery.
957 677 4 5-1-2 Starterrelais plusseitig; Massekurzschluss. Starter relay high side short circuit to ground.
958 677 5 5-1-2 Starterrelais; Kabelbruch. Starter relay low side no load error.
959 677 12 5-1-2 Starter Relais; Leistungsstufe Übertemperatur Starter relay powerstage over temperature.
960 677 3 5-1-2 Starterrelais minusseitig: Batteriekurzschluss Starter relay low side short circuit to battery.
961 677 4 5-1-2 Starterrelais minusseitig: Massekurzschluss. Starter relay low side 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
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 5-5-5 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
BW 219 D-5 / BW 219 PD-5

zwischen Handgas und Leergasschalter. switch.
980 523550 12 5-1-5 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 1-2-8 Temperatur nach Ladeluftkühler; Temperatur unter unterer Charged Air cooler down stream temperature.
physikalischer Grenze Temperature below lower physical threshold.
994 105 3 1-2-8 Sensorfehler Ladelufttemperatur; Signalbereich überschritten Electrical error charged air temperature.
Signal range check high.(SRC)
995 105 4 1-2-8 Sensorfehler Ladelufttemperatur; Signalbereich Electrical error charged air temperature.
unterschritten Signal range check low.
996 105 0 2-3-3 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 2-3-3 Ladelufttemperatur zu hoch; Abschaltschwelle erreicht High 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
1007 412 3 6-8-2 Sensorfehler Temperatur nach AGR Kühler; Signalbereich Electrical error EGR cooler downstream temperature.
überschritten Signal range check high.
1008 412 4 6-8-2 Sensorfehler Temperatur nach AGR Kühler; Signalbereich electrical error EGR cooler downstream temperature.
unterschritten Signal range check low.
1011 523960 0 7-7-1 Abgastemperatur nach AGR Kühler; Maximalwert Physical range check high for EGR cooler downstream
überschritten temperature.
1012 523960 1 7-7-1 Abgastemperatur nach AGR Kühler; Minimalwert Physical range check low for EGR cooler downstream
unterschritten temperature.
BW 219 D-5 / BW 219 PD-5

1014 51 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.
(4.1;6.1;7.8); Signalbereich unterschritten (4.1;6.1;7.8); signal range check low.
1016 51 7 5-9-4 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.
(4.1;6.1;7.8), Signalbereich überschritten (4.1;6.1;7.8); signal range check high
(4.1;6.1;7.8); Signalbereich unterschritten (4.1;6.1;7.8); signal range check low

721
722
1024 51 3 5-9-4 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 51 4 5-9-4 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 6-8-4 Abgastemperatur nach DOC; Signal unplausibel Temperature downstream DOC, plausibility error
1029 4766 0 6-8-4 Abgastemperatur nach DOC; Temperatur über Temperature downstream DOC, temperature above upper
Abschaltgrenze shutoff threshold
1030 4766 0 6-8-4 Abgastemperatur nach DOC; Temperatur über Warngrenze Temperature downstream DOC, temperature above upper
warning threshold
1034 4769 3 6-8-4 Sensorfehler Abgastemperatursensor nach (DOC), oberer Sensor error exhaust gas temperature downstream (DOC);
Grenzwert überschritten signal range check high
1035 4769 4 6-8-4 Sensorfehler Abgastemperatur nach (DOC); Signalbereich Sensor error exhaust gas temperature downstream (DOC);
unterschritten signal range check low
1036 4768 2 6-8-3 Sensor Abgastemperatur vor DOC; Signal unplausibel Temperature upstream DOC, plausibility error
1039 4765 0 6-8-3 Abgastemperatur vor (DOC); Maximalwert überschritten Temperature upstream DOC, temperature above upper
shutoff threshold
1040 4765 0 6-8-3 Abgastemperatursensor vor DOC über oberen Temperature upstream DOC, temperature above upper
Warngrenzwert warning threshold
1044 4768 3 6-8-3 Abgastemperatursensor vor (DOC) Spannung zu hoch Electrical error exhaust gas temperature upstream (DOC);
Sensorfehler Abgastemperatur vor (DOC); Signalbereich signal range check high
überschritten
BW 219 D-5 / BW 219 PD-5

1045 4768 4 6-8-3 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
1069 4360 0 6-6-8 Abgastemperatur vor SCR Katalysator; Physikalischer Wert Exhaust temperature upstream SCR-Cat, temperature above
hat obere Grenze überschritten upper physical threshold
1070 4360 1 6-6-8 Abgastemperatur vor SCR Katalysator; Minimalwert Sensed exhaust temperature before SCR-Cat is < physical
unterschritten low limit

1071 4361 2 6-6-8 SCR: Überwachung der KatTemperatur wenn über CAN Signal error for CAN message
Signal error for CAN message No detail informationen!
1072 4361 3 6-6-8 SCR: Signalrange Check Kattemperatur Ubatt Sensor error DEF catalyst exhaust gas temperature
Sensorfehler Abgastemperatur vor SCR Katalysator; upstream; signal range check high
Signalbereich überschritten
1073 4361 4 6-6-8 SCR: Signalrange Check Kattemperatur Masse Sensor error DEF catalyst exhaust gas temperature
Sensorfehler Abgastemperatur vor SCR Katalysator; upstream; signal range check low
Signalbereich unterschritten
1074 1761 14 1-2-7 Urea Tanklevelsensor; DEF Tanklevel unter Grenzwert DEF tank level; warning threshold exceeded
(Verbleibender Tankfüllstand < 5%)
DEF Tanklevel; Warnschwelle erreicht
1075 3361 6 6-7-7 SCR: Strom des Dosierventils am Ende einer Einspritzung zu DEF dosing valve; power at the end of injection too high
hoch
DEF Dosierventil; Strom am Ende der Einspritzphase zu
hoch
1077 3361 3 6-7-7 SCR: Kurzschluß gegen Ubatt an Lowside Schalter des DEF dosing valve; short circuit to battery on low side
Dosierventils
DEF Dosieventil; Batteriekurzschluss plusseitig
1078 3361 3 6-7-7 DEF Dosierventil; Batteriekurzschluss oder Kabelbruch DEF dosing valve; short circuit to battery or open load on high
plusseitig side
1079 3361 4 6-7-7 SCR: Kurzschluß gegen Masse oder Openload an lowside Urea dosing valve; short circuit to ground or open load on low
des Dosierventils side
DEF Dosierventil; Massekurzschluss oder Kabelbruch
BW 219 D-5 / BW 219 PD-5

minusseitig
1080 3361 4 6-7-7 SCR: Kurzschluß an der Highside des Dosierventils DEF dosing valve; short circuit on high side
DEF Dosierventil; Kurzschluss plusseitig
1081 4345 5 6-7-4 Heizerrelais SCR; Rückleitung; Kabelbruch SCR heater relay DEF returnline sekondary side; open load
SCR Heizer Relais DEF 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; DEF Druckleitung; Kabelbruch SCR heater relay DEF pressureline secondary side; open
SCR Heizer Relais DEF Druckleitung sekundär Seite; load
Kabelbruch
1084 4366 5 7-6-2 SCR Hauptrelais (Sekundärseite); Batteriekurzschluss SCR main relay (secondary side); Shortcut to battery

723
724
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 DEF Versorgungsleitung sekundär Seite; SCR heater relay DEF supplyline secondary side; open load
Kabelbruch
1087 523719 5 6-7-2 Heizer SCR; Supply Modul; Kabelbruch SCR heater relay DEF 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 SCR heater; Pressure line heater error and temperature
SCR-System condition to perform an afterrun (Group error diagnosis
heater)
SCR system heater diagnostic reports error; shut off
SCR-system
1090 4345 5 6-7-4 SCR: Openload Heizerrelais Rücklaufleitung SCR heater relay DEF returnline primary side; open load
SCR Heizer Relais DEF Rücklaufleitung primär Seite;
Kabelbruch
1092 4345 3 6-7-4 SCR DEF Heizer Rücklaufleitung; SCR heater DEF returnline; short circuit to battery
Kurzschluss gegen Batterie
1093 4345 4 6-7-4 SCR DEF Heizer Rücklaufleitung; SCR heater DEF returnline; short circuit to ground
Kurzschluss gegen Masse
1094 4343 5 6-7-3 SCR DEF Heizer Relais Druckleitung Primärseite SCR heater relay DEF pressureline primary side; open load
Open load (Kabelbruch, nicht angeschlossen)
1096 4343 3 6-7-3 SCR Heizer DEF Druckleitung; Batteriekurzschluss SCR heater DEF pressureline; short circuit to battery
1097 4343 4 6-7-3 SCR Heizer DEF Druckleitung; Massekurzschluss SCR heater DEF pressureline; short circuit to ground
BW 219 D-5 / BW 219 PD-5

1098 523718 5 6-7-6 SCR: Openload Tankheizventil tank heating valve; open load
Tankheizventil; Kabelbruch, nicht angeschlossen

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 6-7-6 SCR Hauptrelais (Primärseite); Batteriekurzschluss SCR main relay (primary side); short circuit to battery
1101 523718 4 6-7-6 SCR Hauptrelais (Primärseite); Massekurzschluß SCR main relay (primary side); short circuit to ground
1102 4341 5 6-7-5 SCR: Openload Heizerrelais Saugleitung SCR heater relay DEF supply line primary side; open load
SCR Heizer Relais DEF Versorgungsleitung primär Seite;
Kabelbruch, nicht angeschlossen

1104 4341 3 6-7-5 SCR-Heizer DEF Versorgungsleitung; Kurzschluss gegen SCR-heater DEF supplyline; short circuit to battery
Batterie
1105 4341 4 6-7-5 SCR-Heizer DEF Versorgungsleitung; Massekurzschluss SCR-heater DEF supply line; short circuit to ground
1106 523719 5 6-7-2 SCR: Openload Heizerrelais Supplymodul SCR heater relay DEF supplymodule primary side; open load
SCR Heizer Relais DEF Supply Modul primär Seite;
Kabelbruch
1108 523719 3 6-7-2 SCR: Kurzschluß Heizerrelais Supplymodul gegen Ubatt SCR heater DEF supplymodule; short circuit to battery
SCR Heizer DEF Supply Modul; Batteriekurzschluss
1109 523719 4 6-7-2 SCR: Kurzschluß Heizerrelais Supplymodul gegen Masse SCR heater DEF supplymodule; short circuit to ground
SCR Heizer DEF Supply Modul; Massekurzschluss
1110 4366 5 6-7-1 SCR: Openload Heizerrelais Tankheizung SCR tank heating valve primary side; open load
SCR Tankheizventil primär Seite; Kabelbruch
1112 4366 3 6-7-1 SCR Tankheizventil; Batteriekurzschluss SCR Tank heating valve; short circuit to battery
1113 4366 4 6-7-1 SCR Tankheizventil; Massekurzschluss SCR Tank heating valve; short circuit to ground
1117 523632 11 6-6-6 SCR: Pumpenmotor wird nach Temperaturmessung nicht Pump motor not available for actuation
aktiv
1118 4375 5 6-6-6 DEF Pumpenmotor; Kabelbruch, nicht angeschlossen Urea pump motor; open load
1120 4375 3 6-6-6 SCR: Kurzschluß Motor Supplymodul gegen Ubatt Urea pump motor; short circuit to battery
DEF Pumpenmotor; Batteriekurzschluss
1121 4375 4 6-6-6 SCR:DEF Pumpenmotor Supplymodul, Kurzschluss gegen Urea pump motor; short circuit to ground
Masse
1122 4334 0 6-6-5 SCR: Physikalische Grenze des Pumpendrucks Max Supply module DEF, DEF pressure above upper physical
DEF Supplymodul Drucksensor; Signal über oberen threshold
BW 219 D-5 / BW 219 PD-5

Grenzwert (Defekt am Drucksensor)
1123 4334 1 6-6-5 SCR: Physikalische Grenze des Pumpendrucks Min Urea supply module pressure sensor; physical range check
DEF 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 plausible
vorgegebenen Grenzwert
Sensor DEF 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 DEF Pumpendruck; Signal unplausibel niedrig
1126 523632 2 6-6-5 SCR: Überwachung Signalwert wenn Druck über CAN Signal error for CAN message
Signal error for CAN message No detail informationen!

725
726
1127 523632 3 6-6-5 SCR: Sensorfehler DEF Pumpendruck; Signalbereich Sensor error urea pump pressure; signal range check high
überschritten
1128 523632 4 6-6-5 SCR: Sensorfehler DEF Pumpendruck; Signalbereich Sensor error urea pump pressure; signal range check low
unterschritten
1129 4376 5 6-6-7 SCR Umkehrventil; nicht angeschlossen, Kabelbruch SCR reversal valve; open load
1130 4376 12 6-6-7 SCR: Openload Umkehrventil SCR reversing valve; over temperature
SCR Umkehrventil; Übertemperatur
1131 4376 3 6-6-7 SCR Umkehrventil Kurzschluss gegen Batterie SCR reversal valve; short circuit to battery
1132 4376 4 6-6-7 SCR Umkehrventil; Kurzschluss gegen Masse SCR reversing valve; short circuit to ground
1135 3031 0 6-6-9 DEF Temperatur im Tank zu hoch DEF tank, DEF temperature in DEF tank is to high.
1136 3031 1 6-6-9 DEF-Tank Temperatur, Minimalwert unterschritten DEF tank, DEF temperature below lower physical threshold
1137 4365 2 6-6-9 SCR:Signalfehler CAN Überwachung Signalwert wenn Tank temperature signal error for CAN message
Temperatur über CAN übertragen wird.
1138 4365 3 6-6-9 SCR: Signalrange Check Tanktempsensor Sensor error urea tank temperature: short circuit to battery
Sensorfehler DEF-Tank Temperatur; Batteriekurzschluss
1139 4365 4 6-6-9 SCR: Signalrange Check Tanktempsensor Sensor error urea tank temperature; short circuit to ground.
Sensorfehler DEF-Tank Temperatur; Massekurzschluss
1157 97 12 2-2-8 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
BW 219 D-5 / BW 219 PD-5

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

1170 523612 12 5-5-5 Steuergeräte interner Software Fehler Internal software error ECU
Interner Softwarefehler EMR
1180 168 0 3-1-8 Sensorwert des Batteriespannungssensors über Grenzwert Physical range check high for battery voltage
Batteriespannung; Maximalwert überschritten
1181 168 1 3-1-8 Sensorwert des Batteriespannungssensors unter Grenzwert Physical range check low for battery voltage
Batteriespannung; Minimalwert unterschritten
1183 172 1 2-2-6 Temperatur Luft Menge; Minimalwert unterschritten Air inlet filter sensor out of physical range check
1187 523980 14 7-8-4 SCR Diagnose; Einstellungen der Dosiermenge fehlerhaft, Bad quality of reduction agent detected
nachdem wiederbefüllen mit DEF
Mangelhafte DEF Qualität erkannt
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
BW 219 D-5 / BW 219 PD-5

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 51 5 5-9-4 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

727
728
1224 51 6 5-9-4 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 51 3 5-9-4 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 51 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 51 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 51 4 5-9-4 Aktuator AGR Ventil (2.9;3.6) Drosselklappe (4.1;6.1;7.8); actuator AGR valve (2.9;3.6) throttle valve (4.1;6.1;7.8);
Spannung unter Grenzwert Voltage below threshold.
1239 523984 3 7-8-8 UB7; Batteriekurzschluss Aktuator Relais 7 UB7; Short circuit to battery error of actuator relay 7
1241 523986 4 1-7-6 UB6; Kurzschluss gegen Masse Aktuatorrelais 6 UB6; Short circuit to ground actuator relais 6
1242 523987 4 7-9-1 UB7; Kurzschluss gegen Masse Aktuatorrelais 7 UB7; Short circuit to ground actuator relay 7
1247 524019 11 8-6-2 Luftpumpe; Luftleitung blockiert Burner Control; Air Line - Blocked
Air Pump; air lines blocked
1248 523910 9 6-9-5 Luftpumpe; CAN-Kommunikation unterbrochen Burner Control; Air Pump - CAN Lost
BW 219 D-5 / BW 219 PD-5

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 Burner Control Air Pump; over current
Luftpumpe; elektrisch überlastet Air pump electrically overloaded
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
BW 219 D-5 / BW 219 PD-5

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 plauisibility error off CAN transmit message.
Wastegate
1300 523788 0 6-5-5 Timeout der CAN-Empfangsbotschaft ComTrbChActr; Timeout Error of CAN-Receive-Frame ComTrbChActr;
Wastegate Wastegate

729
730
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)
1325 523996 13 7-9-6 Fehlender Injektor Korrekturwert (IMA) Injektor 8 (nach check of missing injector adjustment value programming
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 5-6-5 Injektor Diagnose; Timeout der Massekurzschluss Timeout of Short-Circuit Ground Diagnosis Cyl. Bank
Überwachung Zyl. Bank 0 0;_IVDiaShCirGndToutBnk_0
1338 2798 4 5-6-6 Injektor Diagnose; Timeout der Massekurzschluss Timeout of Short-Circuit Ground Diagnosis Cyl. Bank
Überwachung Zyl. Bank 1 1;_IVDiaShCirGndToutBnk_1
1339 2797 4 5-6-5 Injektor Diagnose; Test Massekurzschluss Überwachung Zyl. Injector diagnostic; Short circuit to ground cylinder bank 0
Bank 0
1340 2798 4 5-6-6 Injektor Diagnose; Test Massekurzschluss Überwachung Zyl. Injector diagnostic; Short circuit to ground cylinder bank 1
Bank 1
1341 524035 12 5-5-5 Injektor Diagnose; Timeout der SPI Kommunikation Injector diagnostics; time out error in the SPI communication
BW 219 D-5 / BW 219 PD-5

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)
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 8-3-9 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 6-8-1 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
BW 219 D-5 / BW 219 PD-5

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 51 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 51 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 2-2-6 Umgebungstemperatur über Warnschwelle air temperature within air filter box above maximum physical
value
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
1436 524034 5 8-1-6 Tellerseparator; Kabelbruch Disc Separator; open load

731
732
1437 524034 12 8-1-6 Tellerseparator; Leistungsstufe Übertemperatur Disc Separator; powerstage over temperature
1438 524034 3 8-1-6 Tellerseparator; Batteriekurzschluss Disc separator; short circuit to battery
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 Fehler; Der Steller befindet sich aufgrund einer EGR actuator; due to overload in Save Mode
Überlastung im Sicherheitsmodus
1455 3711 12 7-1-1 Temperatur während des Stand-Still zu hoch oder zu niedrig. Temperature during stand-still main phase too low or too high
Stand-Still wird abgebrochen.
1458 523960 0 7-7-1 Fehler AGR Kühler Temperatursensor; Temperatur über High exhaust gas temperature EGR cooler downstream;
Warnschwelle warning threshold exceeded.
Abgastemperatur nach AGR Kühler zu hoch; Warnschwelle
erreicht
1464 0 0 -
1466 0 0 -
1467 0 0 -
1469 0 0 -
1470 0 0 -
1471 0 0 -
1472 0 0 -
1481 524025 5 8-4-5 DPF System; Betriebsspannungsfehler DPF system; operating voltage error
BW 219 D-5 / BW 219 PD-5

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. Nicht plausibel. 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
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
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
BW 219 D-5 / BW 219 PD-5

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 2-4-6 Kabelbruch Nox-Sensor nach SCR Kat NOx sensor downstream SCR-CAT, sensor internally open
load
1534 524075 11 2-4-7 Kurzschluss im Nox-Sensor nach SCR Kat NOx sensor downstream SCR-CAT, sensor internally short
circuit

733
734
1535 524076 9 2-4-8 Kabelbruch im Nox-Sensor vor SCR Kat NOx sensor upstream SCR-CAT, sensor internally open line
1536 524077 11 2-4-9 Kurzschluss Nox-Sensor vor SCR-Kat NOx sensor upstream SCR-CAT, sensor internally short
circuit
1537 524078 9 2-5-5 NOx-Sensor nach SCR-Kat, Lambda Wert über oberen NOx sensor downstream SCR-CAT, lambda value above
Grenzwert upper physical threshold
1538 524079 9 2-5-6 NOx-Sensor nach SCR-Kat, Lambda Wert unter unterem NOx sensor downstream SCR-CAT, lambda value below
Grenzwert lower physical threshold
1539 524080 9 2-5-7 NOx-Sensor vor SCR-Kat, Lambda Wert über oberen NOx sensor upstream SCR-CAT, lambda value above upper
Grenzwert physical threshold
1540 524081 9 2-5-8 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 2-6-1 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 9-1-2 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)
BW 219 D-5 / BW 219 PD-5

1549 1176 2 1-3-9 Drucksensor vor der Turbine; Druck nicht plausibel. Pressure sensor in front of turbine; Pressure not plausible.
1555 524063 5 8-6-9 Heizerrelais nicht angeschlossen (Open load) Relay Urea backflow line heater: broken wiring detected
Reihenmotor: SCR-Rücklaufleitung (K29) (open load)

V-Motor: Master: SCR Ansaug / Rücklaufleitung (K32.1) in-line engine: SCR-backflow line (K29)
Slave: SCR Ansaug / Rücklaufleitung Slave (K32.2) V-engine: Master: SCR-suction / backflow line (K32.1)
Slave: SCR-suction / backflow line (K32.2)
1556 524063 5 8-6-9 Hauptrelais SCR-Heizer, nicht angeschlossen SCR main relay not connected
1557 524063 5 8-6-9 Heizerrelais für die SCR-Druckleitung ist nicht angeschlossen SCR heater pressureline; open load
SCR Heizer Druckleitung; Kabelbruch
1558 524063 3 8-6-9 Kurzschluß nach Battriespannung des SCR-Heizer SCR heater mainrelay; short circuit to battery
Hauptrelais
SCR Heizer Hauptrelais; Kurzschluss gegen Batterie

1559 524063 4 8-6-9 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 8-6-9 Heizerrelais nicht angeschlossen (open load) Relay Urea suction line: Broken wiring detected (open load)
Reihenmotor: SCR-Ansaugleitung (K28) In-line-engine: SCR suction line (K28)
V-Motor: Master: gemeinsame SCR Ansaugleitung (K28) V-engine: Master: Common SCR-suction line (K28)
Slave: gemeinsame SCR Rücklaufleitung (K29) Slave: Commoon SCR backflow line (K29)
1561 524063 5 8-6-9 Heizerrelais für das SCR-Modul ist nicht angeschlossen SCR heater supply module; open load
SCR Heizer Supply Modul; Kabelbruch
1562 524063 5 8-6-9 Heizerrelais für den Urea Tank ist nicht angeschlossen SCR heater tank; open load
SCR Heizer Tank; Kabelbruch
1565 524065 0 8-9-2 Drucksensor vor SCR Kat; Druck über oberen physikalischen Pressure sensor upstream SCR-CAT, pressure above upper
1566 524065 1 8-9-2 Drucksensor vor SCR Kat; Druck unter unteren Pressure sensor upstream SCR-CAT, pressure below lower
physikalischen Grenzwert physical threshold
1569 524065 3 8-9-2 Drucksensor vor SCR Kat; Kurzschluss gegen Batterie oder Pressure sensor upstream SCR-CAT; short circuit battery or
Kabelbruch open load
1570 524065 4 8-9-2 Drucksensor vor SCR Kat; Kurzschluss gegen Masse Pressure sensor upstream SCR-CAT; short circuit ground
1579 524066 3 8-9-3 Heizerendstufe SCR Measurement; Kurzschluss gegen SCR measurement heater output stage; short circuit battery
Batterie oder Kabelbruch or open load
1581 524067 0 8-9-4 Temperatur Heizer SCR Pumpenmodul, oberer DEF supply module, heater temperature above upper
physikalischer Grenzwert überschritten physical threshold
1582 524067 1 8-9-4 Temperatur Heizer SCR Pumpenmodul, unterer DEF supply module, heater temperature below lower physical
physikalischer Grenzwert unterschritten threshold
BW 219 D-5 / BW 219 PD-5

1585 524067 0 8-9-4 Supplymodul Temperatursensor SCR; Temperatur über DEF supply module, temperature above upper physical
oberen Grenzwert threshold
1586 524067 1 8-9-4 Supplymodul Temperatursensor SCR; Temperatur unter DEF supply module, temperature below lower physical
unteren Grenzwert threshold
1593 1761 0 1-2-9 DEF Tank Level; maximaler oberer Grenzwert überschritten DEF tank, DEF level above upper physical threshold
1594 1761 1 1-2-9 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 8-9-2 Drucksensor vor SCR-CAT nicht plausibel. Pressure sensor upstream SCR-CAT, plausibility error
1617 3699 2 8-1-8 Temperatur Sensor vor und nach DOC gleichzeitig defekt Passive regeneration of DPF; DOC error
Temperature sensor us. and ds. DOC simultaneously defect

735
736
1619 524087 5 8-8-4 DEF Fehlerlampe; Kabelbruch Urea Error Lamp; open load
1620 524087 12 8-8-4 DEF Fehlerlampe; Temperatur über Grenzwert Urea Error Lamp; temperatur over limit
1621 524087 3 8-8-4 DEF Fehlerlampe; Kurzschluss gegen Batterie Urea Error Lamp; short circuit battery
1622 524087 4 8-8-4 DEF Fehlerlampe; Kurzschluss gegen Masse Urea Error Lamp; short circuit ground
1630 524132 2 9-5-5 Kraftstoffniederdruck vor Kraftstoffpumpe: Signal unplausibelFuel 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 9-6-6 SCR Koordinator; Timer abgelaufen, Druckaufbau SCR System,pressure build up not possible
Urea-Pumpe nicht erfolgreich. Druckaufbau wurde 5 x für 90
s versucht.
1646 524063 12 8-6-9 DEF Supply Modul, Auftauphase zu lang DEF supply modul, time for defrosting too long
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)
BW 219 D-5 / BW 219 PD-5

1655 1761 14 1-3-8 Urea Tank Level unterhalb Level 2 DEF tank, DEF level below first warning threshold
1656 1761 14 1-3-8 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 9-2-4 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 (AGR Timeout error of CAN-Transmit-Frame ComEGRMsFlw
Steller) (EGR Steller)
1669 524108 9 9-3-2 Timeout der CAN-Sendebotschaft ComEGRTVActr (AGR Timeout error of CAN-Transmit-Frame ComEGRTVActr
Steller) (EGR actuator)
1670 524110 9 9-3-4 Timeout der CAN-Sendebotschaft ComETVActr Timeout error of CAN-Transmit-Frame ComETVActrTO.
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
1675 524103 9 9-2-7 Timeout der CAN-Empfangsbotschaft ComRxDPFBrnAirPmp Timeout error of CAN-Receive-Frame ComRxDPFBrnAirPmp
1676 524104 9 9-2-8 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
(AGR Steller) (EGR actuator)
1678 524107 9 9-3-1 Timeout der CAN-Empfangsbotschaft ComRxEGRMsFlw2 Timeout error of CAN-Receive-Frame ComRxEGRMsFlw2
BW 219 D-5 / BW 219 PD-5

1679 524109 9 9-3-3 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
(elektronischer Wastegatesteller) (wastegate actuator)
1684 524122 9 9-4-6 SCR; Urea Quality; Timeout der CAN-Empfangsbotschaft Timeout error of CAN-Receive-Frame ComRxUQSens (Urea
ComRxUQSens (Empfangsfehler) quality)

737
738
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
(Wastegate Steller) (Wastegate actuator)
1698 524133 2 9-5-6 HMI-System; Wird gesetzt, wenn der digitale HMI system; Set if digital input standstill release switch is
Standstill-Freigabeschalter blockiert ist. blocked.
1699 524134 0 9-5-7 DPF; Aschebeladung Partikelfilter überschreitet den DPF, ash load exceeds the shutoff threshold
Grenzwert.
1700 524134 0 9-5-7 DPF; Aschebeladung Partikelfilter überschreitet die DPF, ash load exceeds the warning threshold
Warnschwelle
1701 524135 0 9-5-8 Die Rußbeladung des DPF hat die Abschaltgrenze DPF, soot load exceeds the shutoff threshold
überschritten
1702 524135 14 9-5-8 Die Rußbeladung des DPF hat die Grenze für DPF, soot load exceeds the service request threshold
Serviceanforderung überschritten
1703 524135 0 9-5-8 Die Rußbeladung des DPF hat die Warnschwelle DPF, soot load exceeds the warning threshold
überschritten
1705 524156 9 9-7-2 Timeout Fehler für die Radgeschwindigkeits Information Timeout error of CAN-Receive-Frame ComRxEBC2.
1706 524157 9 9-7-3 Lüfterkontrolle; Timeout Fehler für die Lüftersteuerung Fancontrol; time out for fan governing
1708 524159 0 9-7-5 Motorlüfter; Kurzschluss gegen Batterie oder Kabelbruch Fan; short circuit battery or open load
1709 524159 1 9-7-5 Motorlüfter; Kurzschluss gegen Masse Fan; short circuit ground
1710 524160 5 9-7-6 Leitungsunterbrechung zur Ansteuerung des Einlasventills für Fan; in/outlet valve 1; open load
BW 219 D-5 / BW 219 PD-5

die Hägleleansteuerung
Motorlüfter; Aus/Einlassventil 1; Kabelbruch

1712 524160 3 9-7-6 Kurzschluss zu Batterie an der Ansteuerung des Fan; in/outlet valve 1; short circuit battery
Einlasventills für die Hägleleansteuerung
Motorlüfter; Aus/Einlassventil 1; Kurschluss gegen Batterie
1713 524160 4 9-7-6 Kurzschluss zu Masse an der Ansteuerung des Einlasventills Fan; in/outlet valve 1; open load ground
für die Hägleleansteuerung
Motorlüfter; Aus/Einlassventil 1; Kurzschluss gegen Masse
1714 524161 5 9-7-7 Leitungsunterbrechung zur Ansteuerung des Auslassventills Fan; in/outlet valve 2; open load
für die Hägleleansteuerung
Motorlüfter; Aus/Einlassventil 2; Kabelbruch
1716 524161 3 9-7-7 Motorlüfter; Aus/Einlassventil 2; Kurschluss gegen Batterie Fan; in/outlet valve 2; short circuit battery
1717 524161 4 9-7-7 Motorlüfter; Aus/Einlassventil 2; Kurzschluss gegen Masse Fan; in/outlet valve 2; open load ground

1718 524162 12 9-7-8 Motorlüfter; Lüftersteuerung; Winkelsensor defekt Fan; fancontrol; angle sensor defect
1719 524163 12 9-7-9 Motorlüfter; Lüftersteuerung; Lüfter oder Ventil defekt Fan; fancontrol; fan or valve defect
1752 2791 7 4-1-5 AGR-Steller, Blockierung erkannt. EGR actuator, actuator blocked
1753 2791 2 4-1-5 AGR Steller, CAN Fehler EGR actuator, CAN error
1754 2791 13 4-1-5 AGR Steller, EOL Lernfehler EGR actuator, EOL calibration error
1755 2791 12 4-1-5 AGR Steller, interner elektrischer Fehler. EGR Actuator, internal electrical fault.
1756 2791 13 4-1-5 AGR Steller, Lernprozess nicht komplett abgeschlossen. EGR actuator, learning process aborted.
1757 2791 6 4-1-5 AGR Steller, Strom über Grenzwert. EGR actuator current is above maximum threshold.
1758 2791 3 4-1-5 AGR Steller, Spannungsversorgung zu hoch EGR actuator supply voltage is above the maximum
threshold
1759 2791 4 4-1-5 AGR Steller, Spannungsversorgung zu niedrig EGR actuator supply voltage is below minimum threshold.
1760 2791 13 4-1-5 AGR Steller, Lernfehler EGR actuator, learning process out of range
1761 2791 7 4-1-5 AGR Steller, Federbruch detektiert. EGR actuator, broken spring detected.
1762 2791 16 4-1-5 AGR Steller, Temperatur über Grenzwert. EGR actuator, temperature high.
1763 2791 0 4-1-5 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 Fehler Turbocharger wastegate, CAN Error
1790 1188 13 8-1-4 Turbolader Wastegate, 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 Einlernprozesses Turbocharger wastegate, learning process aborted.
1793 1188 6 8-1-4 Turbolader Wastegate, Strom über Grenzwert Turbocharger wastegate, current above maximum threshold.
BW 219 D-5 / BW 219 PD-5

1794 1188 3 8-1-4 Turbolader Wastegate, Spannungsversorgung zu hoch Turbocharger wastegate, supply voltage above maximum
threshold.
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 1-9-2 SCR Dosierventil; Blockierung an DEF Dosierventil erkannt DEF dosing valve, dosing valve blocked
1857 523612 12 5-5-5 Motor Starter, Plausibilitätsfehler Freigabe Starter Engine starter, plausibility error of starter release condition
1858 524147 7 9-6-6 SCR Überwachung; Umkehrventil blockiert SCR-System, reverting valve blocked
1859 524175 0 9-9-3 SCR Überwachung; NOx-Wert nach SCR Kat, oberen SCR-CAT, Nox emissions above maximum threshold
Grenzwert erreicht
739
740
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 9-9-5 SCR Systemdrucküberwachung; Saugleitung Blockierung SCR System, DEF suction line blocked
erkannt
1864 524178 7 9-9-6 SCR Systemdrucküberwachung; Systemdruck Fehler SCR System, DEF pressure out of range
1865 4360 2 6-6-8 Temperatur vor SCR Kat nicht plausibel Exhaust temperature sensor upstream SCR, plausibility error
1866 4334 2 6-6-5 DEF Supply Modul Druck, Signal unplausibel DEF supply module pressure, plausibility error
1867 524067 2 8-9-4 Heiztemperatur Supply Module unplausibel Supply module heater temperature, plausibility error
1868 524067 2 8-9-4 Temperatur Supply Module unplausibel Supply module temperature, plausibility error
1869 1761 2 1-2-9 DEF Tankfüllstand; Tanklevelwert nicht plausibel DEF tank level, plausibility error
1870 3031 2 6-6-9 DEF Tank Temperatur unplausibel Urea tank temperature outside of plausible thresholds
1874 524152 2 9-7-1 DEF Qualitätssensor; Timeout CAN-Botschaft Urea Quality Sensor; Timeout CAN message
1875 524153 2 9-9-7 DEF Tanklevel und Tanktemperatur über CAN-Bus, Timeout Urea tank level & urea tank temperature via CAN bus,
CAN-Botschaft timeout of CAN message.
1880 1761 14 1-3-8 DEF Tanklevel unterhalb der dritten Warngrenze DEF tank, DEF level below third warning threshold
1881 4768 2 6-8-3 Plausibilitätsprüfung Temperatursensoren vor und nach DOC exhaust gas temperature sensors up- and downstream DOC
- Temperatursensoren vertauscht 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.
BW 219 D-5 / BW 219 PD-5

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.
1884 524184 9 2-6-7
1889 524189 9 2-6-9 Master / Slave CAN gestört Master / Slave Can disturbed.
1890 524192 12 2-7-4 Motorlüfter; Lüftersteuerung; Endposition beim Ausblasen Fan; Fancontrol; Endposition not reached while blow out.
nicht erreicht.
1891 524190 14 2-7-2 Leistungsreduktion Schritt 1 Inducement level 1 activ

1892 524191 14 2-7-3 Leistungsreduktion Schritt 2 Inducement level 2 activ
1893 524193 8 2-7-5 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. Change oil and reset counter.
Ölwechsel durchführen und Zähler zurücksetzen.
1894 524194 8 2-7-6 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. Change oil and reset counter.
1895 3519 12 2-7-7 DEF Tank Temperatur, Temperatur zu hoch DEF tank temperature, temperature too high
1896 3520 3 2-7-8 DEF Qualitätssensor, Kurzschluss gegen Batterie oder DEF quality sensor, short circuit to battery or open load
Kabelbruch
1897 3520 4 2-7-8 DEF Qualitätssensor, Kurzschluss gegen Masse DEF quality sensor, short circuit to ground
1898 3519 3 2-7-7 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 2-7-7 DEF Qualitätssensor, Kurzschluss gegen Masse des internen DEF quality sensor, internal temperature sensor short circuit
Temperatursensors to ground
1900 524195 14 2-7-9 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
BW 219 D-5 / BW 219 PD-5

1904 3520 2 2-7-8 DEF Qualitätssensor, Stark verdünntes DEF oder eine DEF quality sensor, Significantly diluted DEF or another liquid
andere Flüssigkeit than
als DEF im Tank. DEF in the tank.
1905 3520 8 2-7-8 DEF Qualitätssensor, DEF- Qualitätsmessung konnte nicht DEF quality sensor, DEF quality cannot be measured within a
durchgeführt werden. certain time frame.
1907 3520 13 2-7-8 Urea Quality Überwachung; (Diesel Exhaust Fluid) Urea quality at UQS invalid
ultrasonic/properties sensor; Urea Konzentration/Qualität
ausserhalb der physikalischen Grenzen
1908 3519 13 2-7-7 Urea Quality Überwachung; (Diesel Exhaust Fluid) Temperature at UQS invalid
temperature sensor; Temperatur ausserhalb der
physikalischen Grenzen
1909 4365 12 6-6-9 CAN; Urea (Disel Exhaust Fluid DEF) Tank temperatur Urea Tank Temperature is above the warning threshold
Sensor ; Übertemperatur

741
742
1910 3532 13 1-2-9 DEF Qualitätssensor, Tank Level; DEF qualitysensor, tank level;
Urea Level ausserhalb der physikalischen Grenzen DEF level out of physial range
1911 3532 3 1-2-7 DEF Entnahmeeinheit: Signalwert für DEF Level The DEF Level at UQS out of max. physical range
physiklischer Wert ist größer als max. Grenze.
1912 3532 4 1-2-7 Urea Qualität Sensor; Signalwert kleiner als min. Grenze Quality at UQS out of min. physical range
1913 4365 13 6-6-9 DEF Qualitätssensor, Tank Temperatur; DEF qualitysensor, tank temperatur;
Temperatur ausserhalb der physikalischen Grenzen Temperature out of physial range
1914 4365 3 6-6-9 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)
BW 219 D-5 / BW 219 PD-5

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)
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
1942 524201 11 3-1-3 Abschaltung SCREffMon Überwachung auf Slave ECU. Shutdown SCREff monitoring on Slave ECU.
1943 524202 11 3-1-3 SCR Fehlercode aktiv im Master Steuergerät SCR error code in master ECU active.
1944 524203 11 3-1-3 DEF tank level failure Fehlercode aktiv im Master DEF tank level failure is in master ECU active.
Steuergerät.
1945 524204 11 3-1-3 SCR Nachlauf Fehlercode aktiv im Master Steuergerät. SCR afterrun failure is in master ECU active.
1946 524205 11 3-1-3 SCR Co2Off failure Fehlercode aktiv im Master Steuergerät. SCR Co2Off failure is in master ECU active.
1947 524206 11 3-1-3 SCR disable DEF dosing failure Fehlercode aktiv im Master SCR disable DEF dosing failure is in master ECU active.
Steuergerät.
1971 524230 11 3-1-5 Hardware Fehlercode löst Inducement im Slave Steuergerät Hardware error code triggers inducement in the slave control
aus. unit.
1972 524231 11 3-1-5 SCR-System-Komponente löst Inducement via "Tampering" SCR system component triggers inducement via "Tampering"
im Slave Steuergerät aus. in the slave control unit.
1973 524232 11 3-1-5 SCR-System-Komponente löst Inducement via "Quality" im SCR system component triggers inducement via "Quality" in
Slave Steuergerät aus. the slave control unit.
1974 524233 11 3-1-5 Sammelfehler für EEPROM-Fehler im Slave Steuergerät. Group error concerning EEPROM errors in the slave control
unit.
1975 524234 11 3-1-5 Sammelfehler für Batterie-Fehler im Slave Steuergerät. Group error concerning battery errors in the slave control
unit.
1976 524235 11 3-1-5 Sammelfehler für CAN-Bus-Fehler im Slave Steuergerät. Group error concerning CAN-bus errors in the slave control
unit.
1977 524236 11 3-1-5 Sammelfehler für die Slave ECU Überwachung im Slave Group error concerning slave ECM monitoring errors in the
Steuergerät. slave control unit.
1978 524237 11 3-1-5 Sammelfehler für OCWDA-/SSPMon-Fehler im Slave Group error concerning OCWDA-/SSPMon- errors in the
Steuergerät. slave control unit.
1979 524238 11 3-1-5 Sammelfehler für TECU-Fehler im Slave Steuergerät. Group error concerning TECU errors in the slave control unit.
1980 524239 11 3-1-5 Sammelfehler für einen SCR Regenerationsfehler im Slave Group error concerning SCR regeneration errors in the slave
Steuergerät. control unit.
BW 219 D-5 / BW 219 PD-5

1983 524242 11 3-1-5 Sammelfehler für SW Reset-Fehler im Slave Steuergerät. Group error concerning SW reset errors in the slave control
unit.
1984 524243 11 3-1-5 Sammelfehler für Motordrehzahl-Fehler im Slave Group error concerning engine speed errors in the slave
1989 524248 11 3-1-5 Sammelfehler für einen Nox-Sensor-Fehler (Downstream) im Group error concerning Nox sensor errors (downstream) in
Slave Steuergerät. the slave control unit.
1990 524249 11 3-1-5 Sammelfehler für einen Dosierventil-Fehler im Slave Group error concerning dosing valve errors in the slave
1992 524251 11 3-1-5 Sammelfehler für einen Urea-Druck-Fehler im Slave Group error concerning UREA pressure errors in the slave
1993 524252 11 3-1-5 Sammelfehler für einen Umkehrventil-Fehler im Slave Group error concerning reverting valve errors in the slave

743
744
1994 524253 11 3-1-5 Sammelfehler für einen Heizungsfehler der DEF Group error concerning heating error of the UREA back flow
Rückflussleitung im Slave Steuergerät. line in the slave control unit.
1995 524254 11 3-1-5 Sammelfehler für NOx Abgasemissionen im Abgasrohr im Group error concerning NOx exhaust emission errors in the
Slave Steuergerät. slave control unit.
1996 524255 11 3-1-5 Sammelfehler für Heizungsfehler der DEF Saugleitung im Group error concerning heating error of the UREA suction
Slave Steuergerät. line in the slave control unit.
1997 524256 11 3-1-5 Sammelfehler für einen Heizungsfehler der DEF Group error concerning heating error of the UREA supply
Versorgungseinheit im Slave Steuergerät. module in the slave control unit.
1998 524257 11 3-1-5 Sammelfehler für einen SCR Abgasdruck-Fehler (Upstream) Group error concerning SCR exhaust pressure errors
im Slave Steuergerät. (upstream) in the slave control unit.
1999 524258 11 3-1-5 Sammelfehler für einen SCR Abgastemperatur-Fehler Group error concerning SCR exhaust temperature errors
(Upstream) im Slave Steuergerät. (upstream) in the slave control unit.
2000 524259 11 3-1-5 Sammelfehler für einen Heizungsfehler der DEF Druckleitung Group error concerning heating error of the UREA pressure
im Slave Steuergerät. line in the slave control unit.
2001 524260 11 3-1-5 Sammelfehler für einen DEF Pumpentemperatur-Fehler im Group error concerning UREA pump temperature errors in
Slave Steuergerät. the slave control unit.
2002 524261 11 3-1-5 Sammelfehler für einen DEF Heizungsrelay-Fehler im Slave Group error concerning UREA heater realy errors in the slave
2003 524262 8 3-1-6 CAN; Timeout error detection of CAN message
Frm_ComMS_SCR2_MRcv
2007 524267 14 2-8-7 Ankündigung, dass Inducement Level 2 ausgelöst wird. Announcement triggers the Inducement Level 2.
2008 524025 8 8-4-5 Maximale Launchzeit für Stand Still überschritten (60min). Max. launch time for stand still exceeded (60min).
2011 4171 2 6-6-8 Dynamischer Temperaturcheck der Temperatur vor SCR. Dynamic temperature check of temperature before SCR.
BW 219 D-5 / BW 219 PD-5

2013 524147 13 9-9-6 Wird zusammen mit dem Fehler KWP 1639 Set together with DFC_SCRCoBldUpLoPres.
(DFC_SCRCoBldUpLoPres) gesetzt. DFC_SCRCoBldUpLoPresRst is only used for inducement

Wird für Inducement-Zwecke verwendet. purposes.
Stellt sicher, dass das Inducement korrekt funktioniert. It ensures that legal inducement is working correctly.
2014 3520 1 2-7-8 Verdünntes DEF im Tank. Diluted DEF in the tank.
2032 411 2 6-9-3 Dp Venturi-Signal ändert sich nicht (ausreichend). Dp venturi signal does not change (sufficient).
2033 1176 2 1-3-9 P3-Signal ändert sich nicht (ausreichend). P3-signal does not change (sufficient).

Troubleshooting – Trouble shooting, hydraulics
7.5 Trouble shooting, hydraulics

7.5.2 Insufficient hydraulic power................................... 746
7.5.3 Troubleshooting axial piston pumps...................... 749
7.5.4 Troubleshooting axial piston motors...................... 751
7.5.5 Troubleshooting table for hydraulic components... 753
7.5.1 Preliminary remarks

service department.
There are many reasons for faults and malfunctions occurring in

hydraulic systems. After years of trouble-free operation, even a
perfectly designed and carefully operated system will eventually
suffer line losses or undesirable side effects that can be described
as natural: They are caused by wear, clogging and material fatigue.
In such cases, it is particularly important to quickly detect sources
of fault or defective parts and replace them as cost-effectively as
possible. The cause of a component failure needs to be deter-
mined.
Preventive maintenance and servicing, especially regular checks of
oil cleanliness, is of course the best method to pre-emptively mini-
mise any faults and malfunctions. Nevertheless, malfunctions and
faults may occur during operation of a hydraulic system or machine
which impair the general functional sequence but also the safety of
the hydraulic system or machine. In addition to impairing product
quality, this may result in hazards that can no longer guarantee
working safely with the machine.
If the control system is not a purely hydraulic system and, in fact,
the hydraulic system is operated as part of an electro-hydraulic
control system, it may be necessary to involve a qualified electri-
cian in troubleshooting. In the case of complex systems operated
with electronic controls, it may also be necessary to call in a spe-
cialist for electronic hardware or software.
At the beginning of troubleshooting, the necessary technical docu-
ments and information should be available, e.g. operating instruc-
tions, and circuit diagrams including measuring points.
Common symptoms and causes Unusual or excessive noise during operation may indicate clogged
filters or foreign matter in the line. However, even a suction line
bent one time too many or too far, stiff valves, incorrectly adjusted
engines/motors, tired pumps and incorrect operating temperatures
can often cause “unhealthy” noises.
BW 219 D-5 / BW 219 PD-5 745

Too little or no pressure – this is how a hydraulic system may stop

working. There is often incorrect air in the system because there
are one or more leaks. The correct viscosity of the liquid used and
sufficient cooling are also important for the pressure to be correct.
And, of course, the coupling, pump and engine must not be
allowed to grind, overheat or foam.
Fluctuations in pressure and flow make operation difficult and the
system unpredictable. This is usually caused by contamination,
blockages or tension. Many hydraulic systems can already be rem-
edied by cleaning the corresponding components, bleeding the
system and replacing the old liquids.
7.5.2 Insufficient hydraulic power

Trouble shooting charge pressure,
example travel circuit If the charge pressure is not inside the nominal
range, no high pressure can be built up in the
system.
746 BW 219 D-5 / BW 219 PD-5

Diesel engine running, travel lever

position "0"
Fig. 783: Charge pressure (6S) present

1 Charge pump
2 Variable displacement pump
3 Hydraulic motor
4 Charge pressure relief valve (example 30 bar)
5 Pressure limiting valves (example 300 bar)
6 Pressure gauge, (6S) charge pressure, (6H) high pressure
7 Cooler (optional)
8 Filter
9 Connection for pump control
n If the charge pressure in the system drops, there is an internal

leak in the hydraulic circuit.
n But there may also be an internal leak in an external compo-
nent, which is also controlled by charge pressure. For example:
Brake valve, brake piston, etc.
n However, the steering pump could also be defective, because
the steering pump delivers the the oil that is fed into the closed
hydraulic circuit.
BW 219 D-5 / BW 219 PD-5 747

Troubleshooting closed circuit

using the example of a travel circuit
Fig. 784
10 Pressure resistance plugs
1. Connect pressure gauges (6) for high pressure and charge
pressure.
2. Disconnect hydraulic motor/s (3) and close the ports with
pressure resistant plugs (10).
ð The variable displacement pump can now be pressure

tested.
NOTICE!
Do not run the test over a longer period of time
(danger of overheating).
3. Start the engine and accelerate to full speed.

4. Shift the travel lever to forward and reverse.
5. Read the pressure gauges (6).Read the pressure gauge.
ð If the pressure gauges show the correct values, the vari-
able displacement pump is OK. The fault is in the
hydraulic motor/s (3).
748 BW 219 D-5 / BW 219 PD-5

7.5.3 Troubleshooting axial piston pumps

The following table should be of help when performing trouble-
shooting. This table is by no means complete. In practice, other
problems may occur that have not been listed here.
Procedure: 1. Always proceed systematically, even under time pressure.
Indiscriminate, ill-considered disassembly and changing of
settings can lead to a situation in which the original cause of
a fault can no longer be detected.
2. Get an overview of the function of the product in connection
with the overall system.
3. Try to clarify whether the product was able to deliver the
required function within the overall system before the fault
occurred.
4. Develop a clear understanding of the troubleshooting
process. If necessary ask the direct operator or machine
driver.
5. Have conditions or area of application of the product been
changed?
6. Were changes (e.g. changeovers) or repairs made to the
overall system (machine/plant, electrics, control) or to the
product? If yes: What kind?
7. Has the product or the machine been operated as intended?
8. How does the fault manifest itself?
Fault description Cause Remedy

Unusual noises Insufficient suction conditions, e.g. air in the Machine or system manufacturer
suction line, inadequate diameter of the suc- (e.g. optimize feed conditions, use
tion line, excessive viscosity of the pressure suitable pressure fluid).
fluid, extreme suction height, too low suction
Completely purge the axial piston
pressure, foreign bodies in the suction line.
unit, fill the suction line with pres-
sure fluid.
Remove foreign bodies from
inside the suction line.
Inappropriate fastening of the axial piston unit. Check the fastening of the axial
piston unit as specified by the
machine or plant manufacturer.
Observe the tightening torques.
Inappropriate fastening of attachment parts, Fasten attachment parts as speci-
e.g. coupling and hydraulic lines. fied by the coupling or fittings
manufacturer.
Pressure limiting valves of the axial piston unit Purge the axial piston unit, check
(charge pressure, high pressure, pressure the viscosity of the pressure fluid,
override valve). consult the service department.
Consult the service department.
Mechanical damage to the axial piston unit. Replace the axial piston unit, con-
sult the service department.
BW 219 D-5 / BW 219 PD-5 749


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.
750 BW 219 D-5 / BW 219 PD-5


Fluctuations in pres- Insufficient suction conditions, e.g. air in the Remove foreign bodies from
sure/volumetric flow suction line, inadequate diameter of the suc- inside the suction line.
tion line, excessive viscosity of the pressure
Pressure fluid too hot Excessive input temperature on axial piston Check the system, e.g. malfunc-
unit. tion of the cooler, pressure fluid
level in tank too low.
Malfunction of the pressure control valves (e.g. Consult the service department.
high pressure limiting valve, pressure override
valve, pressure controller).
Malfunction of the flushing valve (not for nom- Consult the service department.
inal size 18).
Wear of the axial piston unit. Replace the axial piston unit.
7.5.4 Troubleshooting axial piston motors

The following table should be of help when performing trouble-
shooting. This table is by no means complete. In practice, other
Procedure: 1. Always proceed systematically, even under time pressure.
Indiscriminate, ill-considered disassembly and changing of
settings can lead to a situation in which the original cause of
a fault can no longer be detected.
2. Get an overview of the function of the product in connection
with the overall system.
3. Try to clarify whether the product was able to deliver the
required function within the overall system before the fault
occurred.
4. Develop a clear understanding of the troubleshooting
process. If necessary ask the direct operator or machine
driver.
5. Have conditions or area of application of the product been
changed?
6. Were changes (e.g. changeovers) or repairs made to the
overall system (machine/plant, electrics, control) or to the
product? If yes: What kind?
7. Has the product or the machine been operated as intended?
8. How does the fault manifest itself?

Unusual noises Inappropriate fastening of the axial Check the fastening of the axial
piston unit piston unit as specified by the
machine or plant manufacturer.
Observe the tightening torques
BW 219 D-5 / BW 219 PD-5 751


Unusual noises Inappropriate fastening of attachment Fasten attachment parts as specified
parts, e.g. coupling and hydraulic lines by the coupling or fittings manufac-
turer
Mechanical damage to the axial piston Replace the axial piston unit
unit
Fluctuations in pressure/ Axial piston unit not or insufficiently Completely purge the axial piston
volumetric flow purged unit
Operation data are not Insufficient flow from hydraulic pump Check the function of the hydraulic
reached pump
Minimum displacement incorrectly set Consult the service department
External control and setting facilities Check the external control
defective
Control pressure too low Check control pressure, consult the
service department
Functional disturbance in the control Consult the service department
facility or the regulator on the axial
piston unit
Pressure fluid not within the optimal vis- Use appropriate pressure fluid
cosity range
Wear of the axial piston unit Replace the axial piston unit
Mechanical damage to the axial piston Replace the axial piston unit
unit
Pressure fluid too hot Excessive input temperature on axial Check the system, e.g. malfunction
piston unit of the cooler, pressure fluid level in
tank too low
Malfunction of the pressure control Consult the service department
valves (e.g. high pressure limiting valve,
pressure override valve, pressure con-
troller)
Failure of the flushing valve Consult the service department
Wear of the axial piston unit Replace the axial piston unit
752 BW 219 D-5 / BW 219 PD-5

7.5.5 Troubleshooting table for hydraulic components

The following table shows possible malfunctions of hydraulic com-
ponents. This table is by no means complete. In practice, other
Drive elements
Fault Possible cause
n Mechanical parts on the drive side are defective (clutch seat, align-
Abnormal noises
ment faults, etc.)
No or insufficient volumetric n Speed transfer or distance transfer defective
flow
No or insufficient pressure n Torque transfer defective
Fluctuation of pressure/volu- n Drive elements defective
metric flow
Hydraulic cylinder/hydraulic motor

n Insufficient rotary speed or velocity
n Overtaking processes (hydraulic motor is driven by machine to the
pump)
Abnormal noises
n Braking noises
n Faulty inner seal
n Drive damage
n Internal losses
No or insufficient volumetric
n Leaking sleeves
flow
n Wear caused by dirt
n Inner or outer leaks
No or insufficient pressure n Wear caused by dirt
n Drive damage
n Not or insufficiently vented
n Defective sleeves
Fluctuation of pressure/volu-
n StickSlip effect
metric flow
n Changing load direction
n Displacement of hydraulic motor incorrect (to low or too high)
n Internal leakage
n Gap losses
Hydraulic fluid too hot
n Wear damage
n Hydro motor and cylinder too small
BW 219 D-5 / BW 219 PD-5 753

Flow valves
n Trapped air
Abnormal noises n Differential pressure too small
n Vibrations
No or insufficient volumetric n Control orifice blocked
flow n Throttle check valve adjusted
n Trapped air
Fluctuation of pressure/volu- n Differential pressure too small
metric flow n Flow valve contaminated
n Check valve defective
n Wear
n Gap losses
Pressure valves/anti-cavitation valves (secondary)

n Vibrations or noises indicate trapped air or missing damping
n Wrong pressure setting
Abnormal noises n Anti-cavitation defective
n Opening pressure of anti-cavitation valves too high
n Cavitation on oil motor
n Setting too low
n Valve seat damaged
flow
n Clogged with dirt
n Setting too low
No or insufficient pressure
n Broken spring
n Foreign body in valve seat
n Changing counter pressure
n Pressure valve set too low
metric flow
Setting too high:
n Increase of gap losses in all components
n Increased leakage
n Excessive load frequency caused by machine
Setting too low:
n Power loss
n Generation of heat
n Valve cone jams in open position
754 BW 219 D-5 / BW 219 PD-5

Way-valves
n Control defective
Abnormal noises n Design fault (nominal width)
n Restrictions
n Incorrect or inaccurate spool position
n Negative overlap
flow
n Control pressure too low - does not switch
n Incorrect position
n Mechanically jammed
No or insufficient pressure n Return spring broken
n Leaking
n Dummy plug loose
n Flow forces influence the spool action and the opening distances
Fluctuation of pressure/volu- n Positioning fault
metric flow n Unstable position
n Control pressure fluctuations
n Incorrect position
n Throttle losses
Hydraulic fluid too hot n Dimensioning too small
n Cross-section too small
n Wear
Pressure valves (primary)

n Vibrations or noises indicate trapped air or missing damping
Abnormal noises
n Wrong pressure setting
n Setting too low
flow
n Clogged with dirt
n Setting too low
n Broken spring
n Foreign body in valve seat
BW 219 D-5 / BW 219 PD-5 755

Pressure valves (primary)

n Changing counter pressure
n Pressure valves set too low
metric flow
Setting too high:
n Increase of gap losses in all components
n Increased leakage
n Excessive load frequency caused by machine
Setting too low:
n Power loss
n Generation of heat
n Valve cone jams in open position
Pressure accumulator
n Accumulator bladder defective
n Nitrogen filling enters hydraulic circuit
n Defective seals
Abnormal noises
n Inflow and outflow velocity too high
Note: Accumulators in connection with throttle losses can form resonant
systems
No or insufficient volumetric n Nitrogen filling pressure too low
flow
n Nitrogen filling pressure too low or too high _ Stored power is not
enough
Fluctuation of pressure/volu- n Resonant system between hydraulic accumulator, pressure and flow
metric flow valves and pump
Return flow lines

n Line not connected below the pressure fluid level
n Turbulence towards the suction side
Abnormal noises n Lack of partitioning
n Mechanical vibrations
n Insufficient fastening
Hydraulic fluid too hot n Cross-section too small
756 BW 219 D-5 / BW 219 PD-5

Filter
n Insufficient fastening
Abnormal noises
No or insufficient volumetric n In the case of high pressure filters: Insert contaminated
flow n Bypass vale jammed
n In the case of high pressure filters: Insert contaminated
n Bypass vale jammed
Hydraulic fluid too hot n Opening pressure of bypass valve too high
Radiator
n Air/oil radiator fan noises
Abnormal noises
n Dimensioning too small
n Insufficient cooling effect
n Room or ambient temperature too high
n External ventilation or water supply interrupted
n Surface contaminated
n Bypass valve open
Pressure lines
n Inappropriate fastening
Abnormal noises n Structure-borne noise
n Pipe cross-section too small
n Screw fittings leaking
flow
n Throttle actuator pressure increase
n Line breakage
No or insufficient pressure n Screw fittings leaking
n Display or measuring equipment defective
n Not correctly vented
n Display or measuring equipment defective
metric flow
n Incorrect display
n Necking caused by insufficiently large bending radii
BW 219 D-5 / BW 219 PD-5 757

Drive motor
n Incorrect rotary direction
n Speed too high
Abnormal noises
n Bearing clearance
n Bearing damage
No or insufficient volumetric n Speed too low
flow
n Incorrect rotary direction
n Output power too low
Fluctuation of pressure/volu- n Inhomogeneity of engine too high
metric flow n Engine idle speed too low
Hydraulic fluid too hot n Speed too high
Clutch
n Clutch seat defective
Abnormal noises n Alignment fault
n Flexible elements defective
No or insufficient volumetric n Rotary speed transfer defective
flow
No or insufficient pressure n Torque transfer defective
Pump
n Speed too high
n Air intake
Abnormal noises
n Cavitation
n Mechanical damage
No or insufficient volumetric n Internal leakage
flow n Wear caused by dirt
n Internal leakage
No or insufficient pressure n Wear caused by dirt
n Drive damage
758 BW 219 D-5 / BW 219 PD-5

Pump
n Air intake
n Internal leakage
n Wear caused by dirt
Fluctuation of pressure/volu- n Drive damage
metric flow n With engine under load or temporary overloading disturbed control
behaviour caused by contamination
n Engine overload caused by power input on auxiliary drive
n Governor oscillates
n Internal leakage
n Wear damage
Leakage oil line

Abnormal noises n Insufficient fastening
n High temperatures caused by high leakage indicate an expected
failure of a component
Suction conditions
n Insufficient suction cross-section
n Suction head too high
n Redirections
n Cross-section narrowing
Abnormal noises
n Leaking suction line
n Air bubbles
n Tank shut-off valve not opened
n Resistance on filter
n Suction behaviour disturbed
No or insufficient volumetric n Suction head too high
flow n Redirections
BW 219 D-5 / BW 219 PD-5 759

Suction conditions
No or insufficient pressure n Redirections
n Trapped air
n Redirections
metric flow
n Trapped air
Hydraulic oil tank

n Oil level too low
n Frothing of oil
n Water in oil
Abnormal noises
n Cold hydraulic fluid
n Excessive viscosity
n Tank ventilation ineffective
No or insufficient volumetric n Oil level too low
flow n Tank ventilation ineffective
n Oil level too low
n Insufficient viscosity of hydraulic fluid _ caused by high leakage
losses
n Gap losses
n Air bubbles
n Turbulence from return flow to suction side
metric flow
n No partitioning between return flow and suction space
n Incorrect viscosity
n Oil filling too low
n In the case of extreme local heating up, the lubricity, pressure loading
Hydraulic fluid too hot and ageing resistance of the hydraulic fluid is impaired
n Wear of components
n Gap losses
n Heating up
760 BW 219 D-5 / BW 219 PD-5

Troubleshooting – Troubleshooting the air conditioning system
7.6 Troubleshooting the air conditioning system

7.6.1 Basic principles...................................................... 761
7.6.3 Leak test................................................................ 781
7.6.4 Checking the magnetic clutch ............................... 782
7.6.1 Basic principles

Requirements For trouble shooting two requirements must be fulfilled:
n Expert knowledge
n technical equipment
BW 219 D-5 / BW 219 PD-5 761

Overview
Fig. 785: Refrigerant circuit diagram

1 Cold air
2 Evaporator
3 Thermostat
4 Warm air
5 Fan
6 Inspection glass
7 Expansion valve
8 Pressure gauge, high pressure
9 Pressure switch with high and low pressure contacts
10 Dryer
11 Fluid container
12 Hot air
13 Compressor
14 Condenser
15 Cooling air
16 Pressure gauge, low pressure
762 BW 219 D-5 / BW 219 PD-5

Fig. 786: Refrigerant circuit with t, h- diagram

1 Hot gas line (superheated steam)
2 Desuperheating (superheated steam)
3 Condenser
4 Condensation (wet steam)
5 Fluid line (subcooled fluid)
6 Expansion valve
7 Injection line (wet steam)
8 Evaporation (wet steam)
9 Evaporator
10 Superheating (superheated steam)
11 Suction steam line (superheated steam)
12 Compressor
13 Subcooling (liquid)
14 Compaction
15 Expansion
General procedures n Visual inspection of the complete system for damage.

n Check the compressor mounting bracket on the vehicle engine
for tight fit and damage.
n Check the condition, alignment and tightness of the V-belt.
BW 219 D-5 / BW 219 PD-5 763

n Check the routing of refrigerant hoses and cables in the area of

the vehicle engine and transmission, as well as on the chassis
for chafing and rectify any detected faults. Ensure sufficient
clearance to hot parts, such as the exhaust; install a protective
shield, if necessary.
n Check the routing of refrigerant hoses and cables in the area of
the vehicle engine and transmission, as well as on the chassis
for chafing and rectify any detected faults. Ensure sufficient
clearance to hot parts, such as the exhaust; install a protective
shield, if necessary.
n Check the routing of hoses and hoses on the attachment box
or in the cabin.
n Check all hose and screw fittings for leaks.
n Check the fastening of the condenser unit.
n Clean the condenser fins, replace the condenser block if dam-
aged fins are found.
n Check the fastening of the evaporator unit.
n Check the function of evaporator and condenser fans.
n Check the electric control panel. If discolourations are found on
conductors, these are to be replaced and possibly also the cor-
responding relays.
n Switch on the cooling system and check the refrigerant level.
n Filter/dryer and filter/dryer/fluid container combinations must
always be replaced after opening the refrigerant circuit. If these
are in service for more than 1 year, there is a risk that they may
be clogged by excessive absorption of moisture! The filter/
dryer should be replaced at regular intervals.
n Measure the temperature on the evaporator: Measure the
intake air temperature - measure the blow out air temperature.
- The temperature difference should be at least 8-10 K.
n Measure the pressure in the refrigerant circuit.
Technical equipment Pressure gauge and thermometer are the most important auxiliary
tools for troubleshooting. The refrigerant states, such as super-
heating and subcooling, provide important information when per-
forming troubleshooting. Never underestimate your own senses
when troubleshooting. Bubbles in the inspection glass, contamina-
tion and white frost are visible indicators. If the compressor draws
in wet steam, this is visible in the suction line and may also be
audibly perceptible. An overloaded compressor can even be
smelled.
The following tools and auxiliary means nedd to be available for
troubleshooting:
n Service station
n Pressure gauge
n Thermometer
n Dry nitrogen
n Refrigerant bottle for new refrigerant
n Container for old oil
n Vacuum pump
n Hoses
n Scales
764 BW 219 D-5 / BW 219 PD-5

n Suction station
n Leak detector
The measuring equipment must be checked at regular intervals.
Calibration can only be made by an approved testing authority.
Pressure gauge: Most pressure gauges used in practice are (for
cost reasons) overpressure gauges. These pressure gauges
measure the excess pressure in relation to the ambient pressure
(air pressure). In order to achieve the absolute (actual) pressure
the ambient pressure must be added to the pressure gauge
reading. The absolute pressure is needed for the calculation and
determination of material data.
Pabs = Pamb + Pe
Pabs = absolute pressure
Pamb = atmospheric air pressure (ambient pressure)
Pe = excess pressure (pressure gauge reading)
Example:
A totally empty air conditioning system holds an atmospheric pres-
sure of approx. Pamb = 1 bar.
Fig. 787: Pressure gauge
Filling the system with refrigerant causes an overpressure of Pe = 3
bar.
Pabs = Pamb + Pe = 1 bar + 3 bar = 4 bar
Evacuating the system down to Pe = -0.6 bar, creates a "vacuum"
(negative overpressure).
Pabs = Pamb + Pe = 1 bar +(- 0.6) bar = 0.4 bar
Pressure gauge with saturation temperature scale: Tempera-

ture scales on the pressure gauges always refer to the absolute
pressures Pabs. Please note that it is not possible to measure a
temperature directly with a pressure gauge. The indicated temper-
atures are just reference values. Only the saturation temperature is
assigned to the measured pressure.
If the refrigerant is fluid, the temperature is below the saturation
temperature.
If the refrigerant is gaseous, the temperature is above the satura-
tion temperature.
Pressure gauges must indicate 0 bar when not connected to the
system.
Low pressure gauges have a blue border; high pressure gauges a
red one.
Fig. 788: Absolute pressure gauge
Thermometer: The thermometers used are normally digital ther-

mometers with surface or attachment sensors. Good heat insula-
tion of the measuring location must be assured, especially in case
of big temperature differences. An economical use of heat-conduc-
tion paste is recommended. If the measuring location is exces-
BW 219 D-5 / BW 219 PD-5 765

sively contaminated, it needs to be cleaned and possibly treated

with a fine emery cloth. Only the temperature of the sensor is
measured. Temperature differences between the measured and
the actual values of a few degree Kelvin may be caused by missing
heat insulation and by insulating oxide layers on the cable.
Subcooling It is the task of the thermostatic expansion valve Ä Fig. 789 to

reduce the refrigerant to a lower pressure level (evaporation pres-
sure) after it has been liquefied. For the valve to function perfectly,
pure fluid must be applied to its inlet port.
The refrigerant must "squeeze" (literally speaking) through a
throttle gap inside the expansion valve. When comparing a certain
mass of refrigerant in liquid and vaporous condition (under con-
stant pressure), the vaporous refrigerant requires a much higher
volume. That is why the vaporous refrigerant needs a much longer
time to "squeeze" through the throttle gap.
Vaporous refrigerant upstream of the expansion valve reduces the
flow rate and results in an undersupply of the evaporator with
refrigerant. Evaporation pressure and evaporator power will drop.
If the refrigeration system is operated with the "expansion valve
inlet" state directly on the boiling curve, bubbles may form
upstream of the expansion element if the operating conditions fluc-
tuate slightly.
For this reason, the "expansion valve inlet" state is moved away
from the boiling curve into the liquid area and is referred to as sub-
cooling. This subcooling ensures a fluid supply upstream of the
expansion valve.
Common subcooling values: In systems with fluid container, the
subcooling at the fluid container outlet is approx. zero "0" Kelvin
(assuming that the system is filled with the correct refrigerant quan-
tity). In this case, the fluid container provides the required fluid
supply.
Reasons for very low or no subcooling:

n Insufficient refrigerant (check the refrigeration circuit for leaks)
n Insufficient heat dissipation from the heater at high pressure
downstream of the compressor
n Expansion valve is not properly adjusted or defective.
Reasons for excessive subcooling:
n Too much refrigerant
n Dry cartridge is defective (e.g. clogged)
n Expansion valve is not properly adjusted or defective
n Low flow rate in the heating circuit (check the pump).
Subcooling is calculated as follows:

Delta tc2u = tc - tc2u
Delta tc2u, subcooling at condenser outlet in K
tc2u, temperature at evaporator outlet in °C
766 BW 219 D-5 / BW 219 PD-5

tc, condensation temperature in °C

“u” stands for “subcooled”
1 2 3
8 7 6
5 4
S-KLI-0004
Fig. 789: Thermostatic expansion valve

1 Diaphragm
2 Capillary tube
3 Pressure compensation line
4 Refrigerant to compressor
6 Regulator spring
7 Valve pin
8 Refrigerant from compressor
Superheating Due to its design a refrigerant compressor can only deliver gas-
eous or vaporous substances. Fluids are not compressible and
must therefore not enter into the compression chamber of the com-
pressor.
If the suction condition of the compressor is directly on the dew
line, an e.g. incorrect evaporator load can cause "wet suction".
This can lead to two processes, which are destructive for the com-
pressor. The liquid refrigerant washes off the lubricating film
between piston and cylinder wall, and insufficient lubrication will
cause extreme wear. Liquid refrigerant remaining in the cylinder
causes a direct energy transfer from piston to cylinder cover during
compression. The valve plate may then be damaged by so-called
fluid strokes.
Apart from protecting the compressor against fluid, superheating
has further advantages. Since the flow rate of the compressor is
reduced by liquid components in the suction steam, it may be
increased by a certain superheating. Superheating also improves
the oil recirculation.
BW 219 D-5 / BW 219 PD-5 767

Common superheating values: The optimal superheating value

is approx. 5-8 Kelvin. With this superheating the maximum system
power is reached. However, the thermostatic expansion valve
Ä Fig. 789 is unable to regulate this value precisely. Depending
on design and operating conditions, superheating fluctuates within
a range of 4 to 12 Kelvin. The influence of the ambient air on the
suction line causes an additional superheating effect.
Reasons for low or no superheating:

n Expansion valve is not properly adjusted
n Capillary tube is not properly fitted
n Expansion valve is defective, stays open, and ices up.
Reasons for excessive superheating:
n Expansion valve is defective, won’t open, and ices up
n Expansion valve is not properly adjusted
n Capillary tube is not properly fitted
n Insufficient refrigerant (check the refrigeration circuit for leaks).
Superheating is calculated as follows:

Delta to2h = to2h - to
Delta to2h, superheating at evaporator outlet in K
to2h, temperature at evaporator outlet in °C
to, evaporation temperature in °C
“H”h” stands for “superheated”
7.6.2 Troubleshooting
Troubleshooting air conditioning The most frequent sources of mechanical faults in mobile air condi-
systems tioning systems are leaks and blockages in the refrigerant circuit
and the resulting compressor damage. Especially when replacing a
compressor, it is important to determine the causes of the com-
pressor failure in order to avert another failure. In the process, the
specialist must ask whether the fault is in the automatic air condi-
tioning system or in the refrigerant circuit. The specialist should
also know when and why an air conditioning system is flushed and
how to do this professionally.
Visual inspection With the appropriate experience some faults can be visually
detected or felt. Frequently occurring condenser contamination or
formation of steam bubbles in the inspection glass can be quickly
detected.
In the case of unusual evaporator frost, the frost pattern provides
valuable information. An evaporator that is only frosted on the inlet
side is a clear indication that the refrigerant supply is too low, which
indicates an improperly operating expansion element or lack of
refrigerant. Complete frost covering indicates load problems, i.e. no
or insufficient air flow.
768 BW 219 D-5 / BW 219 PD-5

Even superheating can sometimes be detected with the naked eye.

At the end of the evaporator there should be an area which is dry
or at least drier at evaporator temperatures above -2 °C.
The fluid line in the refrigeration system is warm. If a local cooling
can be felt or if condensation develops, this is a clear indication of
an extreme pressure drop in the line. Similar phenomena can be
noticed in the case of blocked filters.
Unusually cold pressure lines indicate "wet" intake of the com-
pressor.
The oil level in the compressor sight glass provides information
about the oil quantity and the oil recirculation in the system. How-
ever, the oil level may also be considerably influenced by con-
densing refrigerant. Discolouration can provide an indication of the
state of the oil.
Water in the system can simply be detected through the inspection
glass with moisture indicator.
The dangerous part of common rules is that they

apply in most, but not in all cases. The refrigerant
states in the individual piping sections or compo-
nents must therefore be exactly determined by
means of pressure and temperature measure-
ments.
Test prerequisites n Cooler and condenser are clean, clean if necessary.

n The ribbed belt for compressor and generator is correctly tight-
ened.
n All air ducts, covers and seals are OK and correctly fitted.
Flaps reach their end positions.
n The engine has operating temperature.
n Evaporator and heating (with highest fresh air fan speed) do
not draw leak air.
n The fresh air fan runs when the engine is running and the air
conditioning system is set to max. cooling power.
n Ambient temperature above 15 °C.
n The thermostat is correctly installed and the switching tempera-
tures are correct.
BW 219 D-5 / BW 219 PD-5 769

Function tests n Rule out operating errors: In order to check the function of an
air conditioning system and also to rule out any possible oper-
ating errors by the vehicle driver, the cooling system needs to
be set to maximum and the engine speed increased. If cold air
then comes out of the air outlet openings, however, it cannot
be assumed one hundred percent that the air conditioning
system is working properly; in fact, the following points are also
to be observed.
n Initial diagnosis: It is quick and easy to determine whether
refrigerant is being pumped by touching the high and low pres-
sure lines by hand. The high-pressure line must be warm (cau-
tion: there is a risk of burns in systems with high pres-
sures). The low pressure line, on the other hand, must be cold.
If this is the case, refrigerant is still present and the compressor
is running.
n Check for leaks: Despite the use of forming gas, it is generally
not possible to detect all leaks in the air conditioning system. If
there is no hissing noise or if the inspection with an electronic
gas analyser does not reveal any leaks in the system, practical
expertise will be required: In this case, the belt wheel of the
compressor is to be shaken back and forth by hand (when the
motor is at a standstill); in this way, a slight hissing noise may
be heard. Refrigerant losses are primarily caused by leaking
compressor shaft seals. The compressor shaft is centred
during operation of the air conditioning system, which means
that the seal ring fits tightly against the compressor shaft. At
standstill, however, the shaft rests against the seal ring on one
side and can be damaged as a result. Leaks are aggravated if
the compressor is not switched on in winter and no oil is sup-
plied to the shaft seal.
n Target pressure diagnostics: To detect further damage, the
system pressures must be checked with an A/C service unit. If
the target pressures (high pressure: 8 to 14 bar; low pressure:
1 to 3 bar) are reached at an ambient temperature of approx.
20 °C, the problem of insufficient cooling is not in the refrig-
erant circuit.
n Temperature discharge diagnostics: In addition, the air
outlet temperature at the air outlet openings should also be
determined with a suitable temperature measuring device. The
appropriate test conditions such as outside temperature,
ambient air pressure or air humidity are to be observed. A
rough indication in this case is an outlet temperature of no
more than approx. 8 °C at an ambient temperature of 20 to 25
°C.
n Check for subcooling: Furthermore, the three temperature
zones of the condenser are to be checked. Subcooling is the
difference between the condensing temperature and the tem-
perature of the refrigerant at the outlet of the air conditioning
condenser. For example, if refrigerant flows into the condenser
at 50 °C, it will have a temperature of approximately 33 °C at
the end of the pre-cooling zone at an assumed cooling air tem-
perature of 25 °C; it will also have the same temperature at the
end of the condensation zone. Only in the subcooling zone
must the temperature have fallen significantly. If the tempera-
ture already drops in the upper third of the condenser, this indi-
cates insufficient subcooling and a lack of refrigerant.
n Check superheating
770 BW 219 D-5 / BW 219 PD-5

Measuring points and measure-

ments
Fig. 790: Flow diagram with measuring points

n C, condenser measuring points
n E, expansion valve measuring points
n O, evaporator measuring points
n V, compressor measuring points
The flow diagram contains "Minimum Requirements" which must
be fulfilled to be able to check the system or perform trouble
shooting.Temperature and pressure at the evaporator outlet can be
used to derive the overheating of the evaporator. Overheating is a
clear indicator for the evaporator filling level. In case of excessive
overheating the refrigerant quantity fed into the evaporator is too
low, in case of insufficient overheating it is too high. In individual
cases one must then check if this situation is caused by the expan-
sion element or by insufficient filling. A differentiation is only pos-
sible if there is a clear indicator for the refrigerant filling quantity.
Pressure and temperature at the condenser outlet can be used to
derive the supercooling. This can be used to assess the filling
quantity. In systems with fluid container the inspection glass is
most suitable to check the minimum filling quantity. Supercooling is
in this case the between indicator for overfilling.The hot gas tem-
perature can be used to check whether the compressor runs in the
permissible operating range.
Example: Measurement of over- n a) Which measuring equipment is required?

heating n b) Where to measure with which size?
BW 219 D-5 / BW 219 PD-5 771

n c) A pressure gauge connected to the evaporator indicates

"Peo2 = 1.7 bar". How high is the evaporator pressure "Po" ?
n d) How high is the evaporator temperature "to" ?
n e) A thermal sensor attached to the evaporator outlet meas-
ures the temperature "to2h = +3 °C". How high is the over-
heating „Δto2h“ ?
n f) Evaluation of the measured overheating.
Example: Measuring supercooling n a) Which measuring equipment is required?

n b) Where to measure with which size?
n c) A pressure gauge connected to the condenser indicates
"Pec2 = 15 bar". How high is the condensing pressure "Pc" ?
n d) How high is the condensing temperature "tc" ?
n e) A thermal sensor attached to the condenser outlet measures
the temperature "tc2u = 58 °C". How high is the supercooling
"Δtc2u" ?
n f) Evaluation of the measured supercooling.
Solution: n a) Pressure gauge, thermometer, steam table

n b) Condensing pressure "Pec2" and temperature "tc2u" are
measured at the same point on the condenser.
n c) Pc = Pec2 + Pamb, "Evaporation pressure = pressure on evap-
orator + atmospheric pressure" = 15 bar + 1 bar = 16 bar.
n d) "Pcc = 16 bar can then be used to derive an condensing
temperature "tc" of 57.9 °C from the steam table for R134a.
n e) Δtc2u = tc - tc2u, "Supercooling at condenser outlet = con-
densing temperature - condenser outlet temperature" = 57.9°C
- 58 °C) = -0.1 Kelvin.
n f) The determined overheating is within the usual range of
approx. "0" Zero Kelvin.
Typical faults and possible causes Most of the faults in the refrigerant side can be assigned with the
help of the checklist. In many cases faults have a quite similar
appearance, but totally different causes. White frost on an evapo-
rator, for instance, may be quite normal. However, in this case the
expansion valve may be defective or there may be oil return prob-
lems.
The following list contains pressure values in a system, that can be
expected at various ambient temperatures (measured at medium
speeds).
Suction pressure (low pressure gauge)

Ambient temperature in °C Excess pressure in bar
25 approx. 2.0
30 approx. 2.5
35 approx. 3
772 BW 219 D-5 / BW 219 PD-5

High pressure (high pressure gauge)

Ambient temperature in °C Excess pressure in bar
25 approx. 8.0
35 approx. 13
40 approx. 16
45 approx. 18
Values effecting the operating pres- Since the pressures occurring in a refrigeration system are highly
sures dependent on environmental conditions, it is mandatory to know
these dependencies. The following table contains some of these
dependencies.
Measured variable Suction pressure High pressure

increase drops increase drops
s s
Com- increase X X
pressor s
speed
drops X X
Vehicle increase X X
interior s
temper-
ature
drops X X
Ambient increase X X
temper- s
ature
drops X X
Humidit increase X X
y s
drops X X
BW 219 D-5 / BW 219 PD-5 773

Suction pressure too low (1), high

pressure too low to normal (2)
Fig. 791
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
774 BW 219 D-5 / BW 219 PD-5

Suction pressure normal (1), high

pressure too high (2)
Fig. 792

Condenser dirty high hot gas temperature, low cooling power clean
Condenser fan failed high hot gas temperature, high pressure shut down repair
overfilled high hot gas temperature, low supercooling, low cooling Correct the filling
power capacity
Leak gas (air) high hot gas temperature, low measured supercooling, renew filling
low cooling power
Restriction between com- high hot gas temperature, low cooling power Check lines and
pressor and condenser valves
BW 219 D-5 / BW 219 PD-5 775

Suction pressure too high (1), high

pressure too low to normal (2)
Fig. 793

Compressor defective Cooling power too low Replace the compressor
Suction pressure too high (1), high

pressure too high (2)
Fig. 794
776 BW 219 D-5 / BW 219 PD-5


Expansion valve defective overheating too low, wet operation of compressor Replace the valve
Condenser The following symptoms may indicate a defective condenser:

n Poor cooling power
n Air conditioning failure
n Condenser fan is constantly on.
Causes of the faults may be:
n Leaky connections or damage
n A lack of heat exchange due to contamination.
Test steps for troubleshooting:
n Check the condenser for contamination
n Leak test
n Pressure test on the high and low pressure side.
Filter/dryer The following symptoms may indicate a filter/dryer failure:

n Air conditioning failure.
Causes of the filter/dryer failure may be:
n Obsolescence
n Defective filter pad inside
n Leaky connections or damage.
The following steps are to be observed during troubleshooting:
n Check the maintenance intervals (every 2 years)
n Leak test/proper fit of connections and check for damage
n Pressure test on the high and low pressure side.
Expansion/throttle valve A defective expansion valve may be indicated as follows:

n Air conditioning failure.
Reasons for failure may have multiple causes:
n Temperature problems due to superheating or icing up
n Contamination in the system
n Leaks in the component or connecting lines.
In the event of a malfunction, the following test steps are to be per-
formed:
n Visual inspection
n Acoustic inspection
n Check the connecting lines are tight and secure
n Check the component and connections for leaks
n Temperature measurement of the pipeline system
n Pressure measurement with the compressor on and the motor
running.
BW 219 D-5 / BW 219 PD-5 777

Evaporator A defective evaporator shows the following symptoms:

n Air conditioning failure
n Poor fan output.
Causes of the evaporator failure may be:
n Pipelines in the evaporator are clogged
n Evaporator is leaking (at connections; due to damage)
n Evaporator is contaminated (air flow is disrupted).
The following test steps are to be observed during troubleshooting:
n Check the evaporator for contamination
n Check the evaporator for damage
n Check the connecting lines are secure
n Leak test
running
n Temperature measurement of the input and output line.
Pressure switch A defective or failed pressure switch may be indicated as follows:

n Air conditioning not functioning
n Compressor coupling is frequently switched on and off.
Reasons for failure may have multiple causes:
n Contact failure at electrical connections
n Contamination in the system
n Damage to housing caused by vibration or accidents.
Test steps for troubleshooting:
n Visual inspection
n Check the connector plugs are properly fitted
n Check the component for damage
running
n Component check when dismantled with nitrogen bottle, pres-
sure-reducer and multimeter.
778 BW 219 D-5 / BW 219 PD-5

Other faults
Symptom Cause Possible effect Remedy

Hot gas temperature Lack of refrigeration oil increased com- Refill refrigeration oil
too high, the hot gas pressor wear
line becomes so hot
that it cannot be
touched long with a
hand
Compressor does not Pressure switch or any other System stopped Check the control units,
start safety feature has triggered, check cause for switching
electrical fault, cylinder filled and rectify
with liquid refrigerant
Compressor switches Switching difference too small, Cycling of com- Check the control units,
continuously triggering of a switching ele- pressor, increased check cause for switching
ment (overpressure switch, low wear, too low and rectify
pressure switch), lack of refrig- cooling power
erant, fan defective, overfilled
Excessive overheating Expansion valve deadjusted or low cooling power, Replace the expansion
screen blocked, lack of refrig- hot gas tempera- valve, clean the screen,
erant tures too high fill in refrigerant, leak test
Hoarfrost on inlet side incorrectly working expansion too low infeed of Check the expansion
of evaporator valve, lack of refrigerant refrigerant into the valve, check the refrig-
evaporator erant filling
Evaporator fully cov- Load problem, too low air flow low cooling power of Clean the evaporator,
ered with hoarfrost volume system check the evaporator fan
Fluid line is warm and Pressure drop in fluid line, filter low cooling power Eliminate the pressure
shows condensation dryer clogged drop, replace the filter
dryer
Exceptionally cold pres- "Wet intake" of the compressor low cooling power, Clean the compressor,
sure lines due to insufficient overheating excessive wear of replace if necessary,
of evaporator compressor replace the expansion
valve if necessary
Noise in system
Faults Possible cause Remedy

V-belt loose or excessively worn V-belt slips and generates Retention or renew the V-belt
noise
Magnetic clutch loud Magnetic clutch runs until high Repair or replace the mag-
pressure builds up, then the netic clutch
clutch starts to slip
Refrigerant compressor is loud Mounting bracket is loose, Repair the mounting bracket,
internal parts worn, low oil replace the compressor,
level in compressor renew the refrigeration oil
Fan is loud, fan motor excessively worn Replace the fan motor
BW 219 D-5 / BW 219 PD-5 779


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
780 BW 219 D-5 / BW 219 PD-5

7.6.3 Leak test
NOTICE!
The use of leak detection colouring matter is not
permitted, because its chemical composition is
unknown and its effect on compressor oil and
rubber elements is not predictable. The use of leak
detection colouring matter makes any warranty
claims null and void.
Before starting the evacuation process, the refrigerant circuit is

filled with nitrogen through a pressure reducer valve (approx. 22
bar). After this all connections in the air conditioning system are
checked with the help of a suitable leak detection spray. A leak is
thereby indicated by means of foam bubbles.
A leak test is required if a pressure drop is noticed.
The leak test must be repeated after filling the air conditioning
system with refrigerant.
Leak test with electronic leak tester
Small leaks with only very low amounts of refrigerant escaping can
be detected, e.g. with an electronic leak tester. Such equipment is
able to detect leaks of less than 5 gr. per year.
The leak tester used must be specially designed for the refrigerant
composition in the air conditioning system. For example, leak
detectors for refrigerant R12 are not suitable for R134a, because
the refrigerant R134a is free of chlorine atoms, meaning that this
leak detector will not respond.
Fig. 795
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. 796: Soap bubble test
BW 219 D-5 / BW 219 PD-5 781

7.6.4 Checking the magnetic clutch

Cross-section of non-operated
magnetic clutch
If the coil (7) is not supplied with operating voltage, there is no con-
tact between the front plate of the clutch (1) and the V-belt pulley
(2). A spring presses the front plate away from the belt pulley. The
V-belt pulley rotates with the bearing (3) in idle speed, the com-
pressor does not work. When the coil is supplied with operating
voltage (12 or 24 V), a magnetic field is generated and pulls the
front plate of the clutch. Both front plate and compressor shaft (8)
are then driven by the V-belt pulley, the compressor works.
In case of excessive flatness faults or deviations

the magnetic clutch needs to be replaced.
Fig. 797
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. 798: Measuring the air gap
at 24 Volt vehicle voltage approx. 1.75 Amp.
Overcurrent indicates a short circuit inside the
magnetic coil.
No current indicates an interrupted electric circuit.
782 BW 219 D-5 / BW 219 PD-5

Troubleshooting – Troubleshooting the auxiliary heating
7.7 Troubleshooting the auxiliary heating

7.7.1 Fuse assignment................................................... 783
7.7.2 Components.......................................................... 784
7.7.3 Control and safety elements.................................. 785
7.7.5 Diagnostics of control panel, old version............... 786
7.7.6 Diagnostics of control panel, new version............. 794
7.7.7 Check the fuel supply............................................ 797
7.7.8 Circuit diagram, AIRTRONIC D2/D4...................... 799
B-586-0424
Fig. 799

BW 219 D-5 / BW 219 PD-5 783

7.7.2 Components
9
11
8
7
10
6 5
4
12
2
13
S-586-0262
Fig. 800
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)
784 BW 219 D-5 / BW 219 PD-5

10 Lining – plug socket, with assembly tool

11 Cover
12 Outer shell (bottom part)
13 Flange gasket
7.7.3 Control and safety elements

n If the AIRTRONIC does not ignite within approx. 90 seconds
after the start of fuel delivery, the start will be repeated.
Should the AIRTRONIC still not ignite after another approx. 90
seconds, a fault related shut-down will occur, i.e. fuel delivery
off and fan overrun for another 4 minutes.
n If the flame goes out by itself during operation, the system will
first be started again. If the AIRTRONIC does not ignite within
approx. 90 seconds after the fuel supply has been reopened,
or it ignites, but goes out again within 15 minutes, a fault
related shut-down will occur, i.e. fuel supply off and fan overrun
of approx. 4 minutes.
This fault related shut-down can be eliminated by switching the
system off and on again. This switching off and on should not
be repeated more than 2 times!
n In case of overheating, the combined sensor will respond, the
fuel supply will be shut off and a fault related shut-down will
occur.
Once this overheating has been eliminated, the AIRTRONIC
can be restarted by switching it off and on again.
n When the lower or upper voltage limit is reached, a fault related
shut-down will occur after 20 seconds.
n With a defective glow pin, fan motor or an interrupted electric
line to the dosing pump the AIRTRONIC will not start.
n With a defective combined sensor or an interrupted electric line
the AIRTRONIC will not start and a fault related shut-down will
occur.
n The rotary speed of the fan motor is continuously monitored.
If the fan motor does not run or if its rotary speed deviated by
more than 10 %, a fault related shut-down will take place after
30 seconds.
n When switching the AIRTRONIC off, the glow pin is switched
on again during the overrun of the fan (post glowing) to clean it
from combustion residues.
7.7.4 Troubleshooting
WARNING!
BW 219 D-5 / BW 219 PD-5 785

NOTICE!
During the maintenance process the AIRTRONIC
should be de-energized. Disconnect the plug-in
connection to the AIRTRONIC.
If the AIRTRONIC does not start after being switched on:

n Switch the AIRTRONIC off and on again, but not more than 2
times in succession.
If the AIRTRONIC still does not start, please check if:
n Fuel in tank?
n Fuses ok?
n Electric cables, connections, terminals ok?
n Hot air duct, combustion air duct or exhaust duct congested?
n If the AIRTRONIC remains in “Ventilation” condition after
switching on, check the control element for short circuits.
In this case no fault code will be submitted.
7.7.5 Diagnostics of control panel, old version
Fig. 801: Old version

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 for auxiliary heating on/off
6 Push button to reduce the heating period
7 Push button to extend the heating period
786 BW 219 D-5 / BW 219 PD-5

Optional equipment
Calling up the fault log

1. Press push button (5) Ä Fig. 802.
ð The heater unit is switched on.
2. Press push button (3), hold it down and press push button (4)
within 2 seconds.
ð The current fault is displayed, e.g. F:64
Calling up all other faults

Fig. 802
The remaining stored faults (max. 5
faults ) can be called up with button (6)
and button (7).
Deleting the fault 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” Ä Fig. 803.
Fig. 803: Switching the ignition on
2. Press push button (5) Ä Fig. 804.

ð The current fault is displayed.
3. Press push button (3), hold it down and press push button (4)
within 2 seconds.
ð The module clock is now in the program “Call up fault
log”.
Fig. 804
BW 219 D-5 / BW 219 PD-5 787

4. Turn the ignition key to position “0” Ä Fig. 805.
Fig. 805: Switch the ignition off
5. Press button (3) Ä Fig. 806 and button (4) simultaneously,

switch the ignition on at the same time and wait until the dis-
play shows the following reading .
Fig. 806
ð Display flashing, heating symbol not flashing Ä Fig. 807.

After 3 seconds the control unit is unlocked, the heater
unit will then start and the display will show the following
reading.
Fig. 807: Display reading after igni-

tion “On”
ð No current fault, heating symbol Ä Fig. 808.
Fig. 808: Display reading after the

heater unit has been started
788 BW 219 D-5 / BW 219 PD-5

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. ®
BW 219 D-5 / BW 219 PD-5 789


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.
790 BW 219 D-5 / BW 219 PD-5


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).
BW 219 D-5 / BW 219 PD-5 791


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.
792 BW 219 D-5 / BW 219 PD-5


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.
BW 219 D-5 / BW 219 PD-5 793

7.7.6 Diagnostics of control panel, new version
1 4
2
3 17:30 21°C
6 5
B-DIS-0523
Fig. 809

1 [◀] button Navigating in the menu levels
2 Menu bar Display of available menus
3 Status section Time
Cabin temperature
Information on active functions
Fault indicator
4 [▶] button Navigating in the menu levels
5 [ ] button Selecting menu levels and functions
Switching functions on
6 [ ] button Switching functions on and off
Returning to the main menu
Optional equipment
794 BW 219 D-5 / BW 219 PD-5

If a fault occurs, the following dis-

plays are possible:
Display Description Remedy

Automatic detection is active. Wait until the automatic recogni-
tion has been completed, then set
EasyStart Timer was discon- up the time and weekday.
nected from the power supply and
then reconnected.
INIT
S-586-0470
No communication. Check the fuse for heater unit,

replace if necessary.
Visit workshop.
NO SIGNAL
S-586-0471
Fault 1. Heater unit Visit workshop.
Error
S-586-0472
Fault 2. Heater unit Visit workshop.
Error
S-586-0473
Undervoltage is applied. Load battery; if necessary, visit

workshop.
S-586-0474
BW 219 D-5 / BW 219 PD-5 795

Display Description Remedy

Temperature sensor defective. Visit workshop.
18:30 °C
S-586-0475
796 BW 219 D-5 / BW 219 PD-5

7.7.7 Check the fuel supply

Before measuring the fuel quantity, check the following points in
the fuel supply:
n Check the screen in the dosing pump.
n Check the routing of the fuel lines.
n Check the fuel lines for leaks.
n Check and retighten the hose connections.
Preparation
Fuel measurement
For an accurate fuel measurement, at least 11/22
Volt or maximum 13/26 Volt should be applied to
the control unit.
Hold the measuring glass at height of the glow pin
during the measurement.
1. Pull the fuel line off the AIRTRONIC and hold it into the
4 measuring glass (size 25 ml) Ä Fig. 810.
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. 810
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.
BW 219 D-5 / BW 219 PD-5 797

If the measured fuel quantity is outside the values listed

above, the dosing pump needs to be replaced.
798 BW 219 D-5 / BW 219 PD-5

7.7.8 Circuit diagram, AIRTRONIC D2/D4
Fig. 811
1 Overheating and flame sensor
2 Fan motor
3 Glow pin
BW 219 D-5 / BW 219 PD-5 799

4 Control unit
5 Control element, module clock
6 Fuel dosing pump
7 Fuses
8 Ignition switch
bk Black
wt White
rd red
ye yellow
gn green
vi violet
br brown
gr grey
bl blue
li lilac
Resistance values
Component AIRTRONOC D2 AIRTRONOC D2 AIRTRONOC D4 AIRTRONOC D4
12 Volt 24 Volt 12 Volt 12 Volt
Fan motor 0.6 W ± 0.1 W 2 W ± 0.4 W 0.4 W ± 0.1 W 1.5 W ± 0.3 W
When applying a When applying a When applying a When applying a
voltage of 8 V ± 0.1 voltage of 18 V ± voltage of 8 V ± 0.1 voltage of 18 V ±
V, a current of £ 6.5 0.1 V, a current of £ V, a current of £ 6.5 0.1 V, a current of £
A will be present 6.5 A will be A will be present 6.5 A will be
after 40 seconds. present after 40 after 40 seconds. present after 40
seconds. seconds.
Glow pins 0.5 W ± 0.05 W 2 W ± 0.2 W 0.5 W ± 0.05 W 2 W ± 0.2 W
Applying a voltage Applying a voltage Applying a voltage Applying a voltage
of 8 V results in a of 18 V results in a of 8 V results in a of 18 V results in a
current flow of 9 A current flow of 4 A current flow of 9 A current flow of 4 A
+ 1.5 A / - 1.2 A. ± 0.5 A + 1.5 A / - 1.2 A. ± 0.5 A
Dosing pump 10 W ± 0.5 W 36 W ± 1.8 W 10 W ± 0.5 W 36 W ± 1.8 W
Control facility nom- 1740 - 2180 W ± 80 W
inal value potenti-
ometer Resistance value at short circuit < 486 W
Resistance value in case of interruption > 7175 W
Flame sensor
Temperature °C Resistance min. Resistance max.
- 40 825.90 W 859.60 W
0 980.00 W 1020.00 W
40 1132.30 W 1278.50 W
80 1282.80 W 1335.10 W
120 1431.50 W 1489.90 W
160 1578.30 W 1642.80 W
800 BW 219 D-5 / BW 219 PD-5


200 1723.40 W 1793.70 W
240 1866.60 W 1942.80 W
280 2008.10 W 2090.00 W
320 2147.70 W 2235.40 W
360 2285.50 W 2378.80 W
400 2421.50 W 2520.30 W
Resistance value in case of interruption > 7175 W
Resistance value at short circuit < 486 W
Check the flame sensor with a digital multimeter, if the resistance value is outside the value table replace
the combined sensor.
Overheating sensor
- 40 1597.00 W 1913.00 W
- 20 458.80 W 533.40 W
0 154.70 W 175.50 W
20 59.30 W 65.84 W
40 25.02 W 28.04 W
60 11.56 W 13.16 W
80 5.782 W 6.678 W
100 3.095 W 3.623 W
120 1.757 W 2.081 W
140 1.050 W 1.256 W
160 0.6554 W 0.792 W
180 0.4253 W 0.5187 W
200 0.2857 W 0.3513 W
Resistance value in case of interruption > 223W
Resistance value at short circuit < 183 W
Check the overheating sensor with a digital multimeter, if the resistance value is outside the value table,
replace the combined sensor.
Engine speeds
Control stage AIRTRONOC D2 AIRTRONOC D4
Power 4800 U/min ± 140 U/min 4400 U/min ± 130 U/min
High 4000 U/min ± 120 U/min 3600 U/min ± 100 U/min
BW 219 D-5 / BW 219 PD-5 801

Control stage AIRTRONOC D2 AIRTRONOC D4

Medium 2800 U/min ± 80 U/min 2800 U/min ± 80 U/min
Low 2000 U/min ± 60 U/min 1600 U/min ± 50 U/min
Ventilation 4800 U/min ± 140 U/min 3600 U/min ± 100 U/min
802 BW 219 D-5 / BW 219 PD-5

Special tools
8 Special tools
BW 219 D-5 / BW 219 PD-5 803

Special tools – Special tools, electrics
8.1 Special tools, electrics........................................... 804

8.2 Special tools for hydraulic system....................... 805
8.2.1 Special tools, tests and adjustments..................... 805
8.2.2 Special tools for flushing........................................ 807
8.3 Special tools for oscillating articulated joint....... 808
8.4 Special tools, drum................................................. 810
8.5 List of special tools................................................ 812
8.1 Special tools, electrics
Special pliers tool kit

The contacts are not included in the kit. Depending
on the contact to be crimped, the matching tool
head must be attached to the handle.

n Comprising:
– Different tool heads
– Unlocking tools
Fig. 812: Special pliers – Manual
– Operating manual and plastic boxes for storing different
contacts
Equipment kit for special pliers tool kit
Fig. 813: Equipment kit (1)
Measuring set

n Comprising:
– Clamp multimeter
– Measuring adapter
– Measurement lines
– Screwdriver
Fig. 814: Measuring set
– Other accessories
804 BW 219 D-5 / BW 219 PD-5

Special tools – Special tools for hydraulic system
8.2 Special tools for hydraulic system

8.2.1 Special tools, tests and adjustments
n Hydraulic test case, large
n BOMAG part no.: 007 610 03
– 4 x 60 bar pressure gauges

– 8 pressure test hoses
Fig. 815
n Hydraulic test case, small


– 4 pressure test hoses
Fig. 816
n Measurement lines
n 1000 mm BOMAG part no.: 079 930 02
n 2500 mm BOMAG part no.: 079 930 03
Fig. 817
BW 219 D-5 / BW 219 PD-5 805

n Pressure gauge
n 60 bar BOMAG part no.: 059 721 07
n 600 bar BOMAG part no.: 059 721 04
Fig. 818
n Adapter for pressure test hose

Fig. 819
n Gear pump testing device

Fig. 820
806 BW 219 D-5 / BW 219 PD-5

n Vacuum pump for hydraulic oil tank

n BOMAG part no.: 007 610 04 (12 Volt)
n BOMAG part no.: 007 610 24 (24 Volt)
Fig. 821
8.2.2 Special tools for flushing
The following list informs about special tools for

flushing. You should choose the corresponding tool
for the work to be carried out.
n Filling and filtering unit

Fig. 822
n Flushing filter (S connection)

n Filter element 1μ
n Flushing hose 20S - 25S (2 pieces)
n Screw socket R1“ - 25S (2 pieces)
Fig. 823
n Flushing filter (L connection)

n Filter element
n Flushing hose 15L (2 pieces)
n Screw socket R3/4“ -- 15L (2 pieces)
Fig. 824
BW 219 D-5 / BW 219 PD-5 807

Special tools – Special tools for oscillating articulated joint
8.3 Special tools for oscillating articulated joint

n Pressing in the rocker bearing
Fig. 825
n Pressing bushing for outer rocker bearing race
Fig. 826
n Pressing bushing for inner rocker bearing race
Fig. 827
n Guide pin
Fig. 828
808 BW 219 D-5 / BW 219 PD-5

Special tools – Special tools for oscillating articulated joint
n Clamping device
Fig. 829
n Disassembly device
Fig. 830
BW 219 D-5 / BW 219 PD-5 809

Special tools – Special tools, drum
8.4 Special tools, drum

n Disassembly device for side plate
n BOMAG part-no.: 007 211 55
Fig. 831
n Assembly device for side plate

Fig. 832
n Assembly device for coupling hub and flanged hub
Fig. 833
n Pressing plate for cylinder roller bearing
Fig. 834
810 BW 219 D-5 / BW 219 PD-5

Special tools – Special tools, drum
n Pressing plate for travel bearing
Fig. 835
n Pressing bushing for radial seal
Fig. 836
n Lifting device for exciter unit

Fig. 837
BW 219 D-5 / BW 219 PD-5 811

Special tools – List of special tools
8.5 List of special tools

Belt tension tester
BOMAG No. 079 947 09
Fig.
Rotation angle disc

BOMAG 057 250 72
Fig.
812 BW 219 D-5 / BW 219 PD-5

Index
9 Index
BW 219 D-5 / BW 219 PD-5 813

Index
D
Description
Electric components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Hydraulic units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
Deutz operating means
B6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
B40.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
B40.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
B43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
B48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
B49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
B51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
B54 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
B56 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
B58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
B61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
B63 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
B64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
B65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
B66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
B78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
B88 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
B90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
D2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
F80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
K2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
K27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
K28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
K29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
K30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
K31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Y15.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Y15.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Y15.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Y15.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Y19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Y20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Y24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Y30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
814 BW 219 D-5 / BW 219 PD-5

Index
Y31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Y35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Deutz plug
D2.1 (A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
D2.2 (K) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
X17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
X23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
X39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
X47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
E
Electrics
Circuit diagram for auxiliary heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 799
Electrics training
Machine control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
L
List of equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
List of error codes
Deutz DTC error code list, EMR3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 699
List of fault codes
Machine control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Optional heating, AIRTRONIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 789
M
Maintenance intervals
Additional heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 637
Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 623
Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463
Drive axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 588
Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 556
Electric systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
O
Operating equipment
A01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
A02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
A12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108, 141, 157, 169
A15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108, 141, 145, 146, 166, 169, 446
A16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108, 141, 157
A34 . . . . . . . . . . . . . . . . . . . . . . . . 108, 141, 143, 144, 166, 169, 185, 186, 195, 409, 410, 443, 444, 446
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Index
A48
108, 111, 141, 143, 144, 151, 152, 153, 166, 169, 185, 186, 196, 408, 409, 410, 429, 442, 443, 444, 446
A67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108, 141, 166, 169, 446
A83 . . . . . . . . . . . . . . . . . . . . . 108, 141, 143, 144, 162, 166, 169, 185, 186, 195, 409, 410, 443, 444, 446
A87 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166, 169, 446
A93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101, 169
A103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163, 166, 169, 446
A108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
A124 . . . . . . . . . . . . . . . . . . . . . . . . . . . 108, 141, 143, 144, 166, 169, 185, 186, 409, 410, 443, 444, 446
A161 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144, 166, 169, 186, 197, 410, 444, 446
A162 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144, 164, 166, 169, 186, 197, 410, 444, 446
A175 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166, 169, 446
A177 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166, 169, 446
A178 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166, 446
B03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108, 141, 147, 169, 203
B11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108, 141, 146
B11.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148, 169
B11.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148, 169
B21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108, 141, 148, 169, 203, 361
B30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
B51.L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
B51.R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
B51L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
B51R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
B55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108, 141, 147, 169
B57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108, 141, 143, 144, 169, 185, 186, 409, 410, 443, 444
B59 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155, 169
B60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
B62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162, 169
B84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163, 169
B88 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
B93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
B97 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
B104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170, 612
B105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113, 597
B113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
B114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
B124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111, 147, 170, 204, 408, 429, 442
B130 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
B133 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
B171 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162, 170
816 BW 219 D-5 / BW 219 PD-5

Index
B208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
B209 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
B214 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153, 154, 170
B215 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153, 154, 170
B216 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153, 154, 170
B218 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108, 141, 147, 170
B221 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
B222 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153, 170
B223 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153, 154, 170
B224 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153, 154, 170
B225 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153, 154, 170
B234 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108, 141, 170
B235 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108, 141, 170
B236 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108, 141, 170
B237 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108, 141, 170
B238 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
B305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153, 154, 170
B312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
B313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
D2.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170, 200
D2.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170, 200
D2.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171, 200
D2.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171, 200
D05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171, 190
D6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
D09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171, 190
D11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171, 190
D13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171, 190
D16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171, 190
D22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171, 190
D38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171, 190
D41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171, 190
D43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171, 190
D48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171, 190
D61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171, 190
D118 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
D145 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171, 190
D209 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171, 190
DX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171, 190, 193
E08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
E09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
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E10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
E11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
E12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
E13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
E14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
E15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
E16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
E17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
E23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108, 141, 156, 171
E25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108, 141, 156, 171
E27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108, 141, 156, 171
E28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108, 141, 156, 171
E29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
E30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114, 171, 631
E32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156, 172
E72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
E104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153, 172
E105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153, 172
E106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153, 172
E107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
E243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
F00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149, 172, 182, 678
F05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172, 181, 192, 676
F07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172, 181, 192, 676
F08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172, 181, 192, 676
F09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172, 181, 192, 677
F10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172, 181, 192, 677
F11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172, 181, 192, 677
F13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172, 181, 192, 677
F17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
F19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172, 181, 192, 677
F22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172, 181, 192, 677
F23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172, 181, 192, 677
F24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172, 181, 192, 677
F25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
F27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
F28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
F29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172, 181, 192, 677
F39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172, 181, 192, 677
F40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172, 181, 192, 677
F41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
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F48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149, 172, 182, 678

F67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172, 181, 192, 677
F68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172, 181, 192, 677
F84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172, 181, 192, 677
F91 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172, 181, 192, 677
F95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149, 172, 182, 678
F103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172, 181, 192, 677
F122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172, 181, 192, 677
F124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172, 181, 192, 677
F129 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
F143 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
F146 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173, 181, 192, 677
F148 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173, 181, 192, 677
F150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
F157 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173, 181, 192, 677
F164 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149, 173, 182, 678
F169 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173, 181, 192, 677
F238 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173, 183, 679
F243 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182, 192, 677
F244 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173, 182, 192, 677
F250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173, 183, 679
F251 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173, 183, 679
F264 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
F266 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
F268 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173, 182, 192, 677
F271 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
F272 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
F279 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
F310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173, 183, 679
F312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173, 183, 679
F313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173, 183, 679
F320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114, 160, 173, 184, 631, 632, 635, 680, 783
F321 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114, 160, 173, 184, 631, 632, 635, 680, 783
FM1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173, 182, 192, 677
FM2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173, 182, 192, 677
FX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
G01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108, 141, 150, 153, 173
G02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147, 149, 173
G03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150, 173
H06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
H07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146, 173
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H14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108, 141, 148, 173

K05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174, 191
K06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174, 191
K09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174, 191
K11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174, 191
K13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174, 191
K14.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
K16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174, 191
K20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174, 200
K21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174, 200
K22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174, 191
K32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174, 200
K38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174, 191
K39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
K41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174, 191
K43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174, 191
K48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174, 191
K61 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174, 191
K78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
K141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174, 200
K145 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174, 191
K189 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
K192 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
K193 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
K194 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
K195 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
K196 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
K209 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
K227 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
M01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149, 174
M04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108, 141, 174
M05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108, 141, 174
M06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108, 141, 146, 174
M07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108, 141, 146, 174
M10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
M41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
M57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114, 175, 631
P09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108, 141, 157, 175
P11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108, 141, 175
P15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166, 175, 446
P32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108, 141, 175
820 BW 219 D-5 / BW 219 PD-5

Index
P42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108, 141, 175

P43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
R03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108, 141, 175
R06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
R10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175, 190
R19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
R20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
R21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
R22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
R23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
R24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
R25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
R26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
R27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
R28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
R29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
R30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
R31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
R32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
R33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
R34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
R40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
R79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165, 175
R80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
R80.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
R80.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
S00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145, 146, 175
S01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145, 146, 175
S06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
S09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145, 146, 176
S14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
S15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145, 176
S25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
S26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145, 176
S28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114, 176, 631, 632
S29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
S30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108, 141, 149, 150, 176
S35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146, 176
S36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146, 176
S37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145, 176
S42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145, 146, 176
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S55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108, 141, 145, 146, 166, 176, 446

S64 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
S107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146, 176
S109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
S127 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145, 146, 176
S139 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
S154 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
S299 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145, 146, 176
T14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
T21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
V01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
V02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
V03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
V04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
V05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
V06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
V07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
V08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
V09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
V10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Y04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108, 141, 148, 176, 361, 363
Y07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148, 176, 369
Y08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148, 176, 369
Y14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114, 160, 631, 632
Y15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113, 147, 176, 597
Y16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148, 177, 364
Y17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148, 177, 364
Y30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148, 155, 177
Y31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148, 177, 363
Y60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Y72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Y73 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Y98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Y102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Y122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Y123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Y137 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Y140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Y141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Y142 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Y143 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
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Y144 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Y145 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Y147 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Y148 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Y149 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Y166 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Y169 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Y170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Y174 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Y261 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Y291 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Y292 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153, 177
Y293 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153, 177
Y378 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Y379 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Y380 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Operating means
A67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
A87 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
A124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
A138 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
B55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
B62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
B88 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
B93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
B104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
B105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 599, 607
B113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
B114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
B124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411, 462
B130 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
B133 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
B145 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
B171 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
B214 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413, 430
B215 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413, 430
B216 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413, 430
B218 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
B221 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
B222 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
B223 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
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B224 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413, 430, 434

B225 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413, 430, 434
B305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413, 430
E104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
E105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
E106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
E107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
F17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183, 679
F27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183, 679
F28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183, 679
F143 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183, 679
F150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183, 679
F238 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199, 445
F250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199, 445
F251 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199, 445
F264 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183, 679
F266 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183, 679
F271 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183, 679
F272 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184, 680
F279 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184, 680
F310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199, 445
F312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199, 445
F312/2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199, 445
F313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199, 445
F313/2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199, 445
K192 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199, 445
K193 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199, 445
K194 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199, 445
K195 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199, 445
K196 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199, 445
K227 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199, 445
M09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
M41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
R03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
R19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462
R79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411, 462
S44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Y04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110, 347
Y07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348, 349
Y08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348, 349
Y15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198, 599
824 BW 219 D-5 / BW 219 PD-5

Index
Y16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348, 349

Y17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348, 349
Y291 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
Y292 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
Y293 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
Overview
Additional heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114, 631
Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113, 597, 599
Auxiliary heating, AIRTRONIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 632
Central electrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143, 185, 409, 443
Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111, 408, 429, 442
Diesel engine, coolant circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
Diesel engine, exhaust gas aftertreatment system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413, 430
Diesel engine, exhaust gas recirculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
Diesel engine, fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411
Diesel engine, injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420, 453
Diesel engine, lubrication oil circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
Diesel engine, SCR system components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
Drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112, 365, 373, 500
Electric system, power board for SCR heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199, 445
Electrics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108, 141
Electrics, cabin control console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Electrics, CAN bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166, 446
Electrics, diesel engine with sensors and actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
Electrics, fuse assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Electrics, fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199, 445
Electrics, power board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Electrics, wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110, 347
Hydraulic system, charge circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
Hydraulic system, flushing diagram for vibration circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
Hydraulic system, steering circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
Hydraulic system, travel circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363
Hydraulic system, travel circuit flushing diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381, 383
Hydraulic system, vibration circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
Hydraulics, closed circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
Hydraulics, open circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339
P
Plug
X4E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
BW 219 D-5 / BW 219 PD-5 825

Index
X5.E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
X5E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
X5E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
X7.C2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
X7C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
X8A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
X8B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
X20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
X21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
X32 . . . . . . . . . . . . . . . . . . . . . . . . 108, 141, 143, 144, 166, 185, 186, 187, 409, 410, 429, 443, 444, 446
X34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108, 141, 143, 144, 166, 185, 186, 187, 409, 410, 443, 444, 446
X39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
X41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143, 144, 185, 186, 409, 410, 443, 444
X45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143, 144, 185, 186, 409, 410, 443, 444
X67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
X76 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
X88 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
X100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
X100 - X109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108, 141, 143, 144, 185, 186, 409, 410, 443, 444
X101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
X102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
X103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
X104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
X105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
X106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
X107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162, 187
X108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
X109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
X109f . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
X109m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
X110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
X200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
X201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
X202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
X203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
X204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
X205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157, 200
X206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
X207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
X400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164, 166, 446
XA103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
826 BW 219 D-5 / BW 219 PD-5

Index
XA161 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
XR79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
XS28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Plugs
X0A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149, 189
X0B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147, 189
X0C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149, 189
X1A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147, 189
X1B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151, 152, 189
X2A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148, 189
X2B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148, 189
X4A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146, 189
X4B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146, 189
X4D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146, 189
X4E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
X5A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
X5B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
X5E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
X6B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146, 189
X6C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146, 189
X6D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158, 189
X7A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146, 189
X7B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159, 189
X7C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
X7D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
X8A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
X8B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
X10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
X11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
X12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
X14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146, 156
X15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
X16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
X23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
X24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
X25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
X26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
X30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
X31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153, 156
X32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151, 152, 452
X33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
BW 219 D-5 / BW 219 PD-5 827

Index
X36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
X41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151, 152
X45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151, 152
X48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151, 152
X50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
X65 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
X66 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
X67 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
X68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
X69 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
X72 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
X73 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
X78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147, 153
X79 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
X80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
X81 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
X82 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
X83 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
X85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156, 161
X87 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
X90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
X91 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
X93 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
X94 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
X95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
X96 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
X99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
X101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
X102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
X103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
X104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
X108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147, 151, 152
X200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
X201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
X202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
X203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
X204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
X205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
X210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
X211 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
X300/30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153, 199, 445
828 BW 219 D-5 / BW 219 PD-5

Index
X300/31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153, 199, 445

X301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153, 199, 445
X302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153, 199, 445
XS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
T
Trouble shooting
Additional heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 783
Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 761
Diesel engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 692
Electric systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 671
Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745
Troubleshooting
Hydraulics - axial piston motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 751
Hydraulics - axial piston pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 749
Hydraulics - insufficient hydraulic power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 746
Hydraulics - troubleshooting table for hydraulic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 753
BW 219 D-5 / BW 219 PD-5 829

Index
830 BW 219 D-5 / BW 219 PD-5

Appendix
Appendix
BW 219 D-5 / BW 219 PD-5 831

Appendix
A Circuit diagrams.......................................................... 833
832 BW 219 D-5 / BW 219 PD-5

Circuit diagrams
A Circuit diagrams
A.1 Circuit diagram 518................................................ 833
A.2 Circuit diagram 642................................................ 932
A.3 Hydraulic diagram 477......................................... 1040
A.4 Hydraulic diagram 614......................................... 1050
A.1 Circuit diagram 518

Validity of circuit diagrams
Circuit diagram 518:
– BW 219 D-5
101 587 32 1001 ⇒ 101 587 32 9999

– BW 219 D-5
101 586 95 1001 ⇒ 101 586 95 9999
– BW 219 PD-5
101 586 96 1001 ⇒ 101 586 96 9999
– BW 213 DH-5
101 587 50 1001 ⇒ 101 587 50 9999
– BW 213 PDH-5
101 587 51 1001 ⇒ 101 587 51 9999
– BW 213 DH+P-5
101 587 53 1001 ⇒ 101 587 53 9999
– BW 216 DH-5
101 587 57 1001 ⇒ 101 587 57 9999
BW 219 D-5 / BW 219 PD-5 833

Circuit diagrams
834 BW 219 D-5 / BW 219 PD-5

Table of contents
Inhaltsverzeichnis
Page Higher-level function Function
Blatt Anlage Funktion Description Beschreibung
1 Cover sheet Deckblatt
2 Table of contents Inhaltsverzeichnis
5 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
BW 219 D-5 / BW 219 PD-5

24 =ENGI ==SDR Deutz TCD 4.1/6.1 - Exhaust aftertreatment Deutz TCD 4.1/6.1 - Abgasnachbehandlung
27 =MON ==SDR Monitoring, Failure indicators Überwachung, Störmeldungen
28 =DRIV ==SDR Slope sensor, Speed sensors Neigungssensor, Geschwindigkeitsaufnehmer
29 =DRIV ==SDR Travel lever Fahrhebel
30 =DRIV ==SDR Pressure sensors Drucksensoren
31 =DRIV ==SDR Brake, Travel pumps, Speed ranges Bremse, Fahrpumpen, Fahrstufen
32 =DRIV ==SDR Warning horns, Back up alarm, Warnhörner, Rückfahralarm,
33 =VIB ==SDR Vibration Vibration
34 =EXC ==SDR Variocontrol Variocontrol
35 =DBL ==SDR Dozer blade Planierschild
36 =VPL ==SDR Vibratory plate compactor Anbauplatten
37 =VPL ==SDR Vibratory plate compactor Anbauplatten
38 =MEAS ==SDR Measurement equipment Messtechnik
39 =MEAS ==SDR Economizer Economizer
0 1 2 3 4 5 6 7 8 9
EFS M. Vogt Function Page from
Created MFS Funktion == Blatt 2 von 98
Erstellt
14.12.2017
BW 219-226 D, DH, BVC-5 Table of contents Higher-level function
=
Anlage 518
Circuit diagrams
Checked K. Brand Mounting location

Deutz TCD 4.1_6.1 Tier 4f Inhaltsverzeichnis Einbauort + TOC
Geprüft 14.12.2017
835
EPE / 000 / 00
836
Table of contents
Inhaltsverzeichnis
40 =MEAS ==SDR Economizer Economizer
Circuit diagrams
41 =OPT ==SDR Rops - Lighting, Socket Rops - Beleuchtung, Steckdose

42 =OPT ==SDR StVZO illumination StVZO Beleuchtung
43 =OPT ==SDR Electronical Burglary protection Elektronische Diebstahlsicherung
44 =OPT ==SDR Interface measurement Schnittstelle Messtechnik
45 =OPT ==SDR BOMAG Telematics BOMAG Telematik
46 =OPT ==SDR Morey Telematics, ZTR Telematics Morey Telematic, ZTR Telematic
47 =OPT ==SDR Cabin - Additional heater Kabine - Zusatzheizung
48 =OPT ==SDR Cabin - Heating, Air conditioning, Washer pumps Kabine - Heizung, Klimaanlage, Wascherpumpen
49 =OPT ==SDR Cabin - Supply Kabine - Versorgung
50 =OPT ==SDR Cabin - Fuse protection Kabine - Absicherung
51 =OPT ==SDR Cabin - Lighting Kabine - Beleuchtung
52 =OPT ==SDR Cabin - Cabin equipment Kabine - Kabinenausrüstung
53 =OPT ==SDR Cabin - Cabin equipment Kabine - Kabinenausrüstung
54 =OPT ==SDR Cabin - Radio, Tachograph, Printer measurement Kabine - Radio, Tachograph, Drucker Messtechnik
55 =OPT ==SDR BOMAG Compaction Management BCM, GPS BOMAG Verdichtungsmanagement BCM, GPS
56 =OPT ==SDR Back up monitoring Rückraumüberwachung
57 Device tag list Betriebsmittelliste
BW 219 D-5 / BW 219 PD-5

66 Pin overview A15 Pin Übersicht A15
74 Pin overview S55 Pin Übersicht S55
75 Plug overview Steckerübersicht
0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
=
Anlage 518
Geprüft 14.12.2017 EPE / 000 / 00
Table of contents
Inhaltsverzeichnis
94 Overview CAN Communication Übersicht CAN Kommunkikation
95 Overview Central Electric Übersicht Zentralelektrik
96 Overview plugs X100 - X110 Übersicht Stecker X100 - X110
97 Overview Powerboard Übersicht Powerboard
BW 219 D-5 / BW 219 PD-5

0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
=
Anlage 518
Circuit diagrams

Geprüft 14.12.2017
837
EPE / 000 / 00
838
Structure identifier overview
Strukturkennzeichenübersicht
Functional assignment
Funktionale Zuordnung Description Beschreibung
==SDR Basic machine Single drum roller Basismaschine Walzenzug
Circuit diagrams
Anlage Description Beschreibung
=COM Communication Kommunikation
=DBL Dozer blade Planierschild
=DRIV Drive functions Antriebsfunktionen
=ENGI Engine Antriebsmaschine
=EXC Exciter displacement Erregerverstellung
=MEAS Measurement equipment Messtechnik
=MON Monitoring, Failure indicators Überwachung, Störmeldungen
=OPT Optional functions Optionale Funktionen
=SUPL Supply Versorgung
=VIB Vibration and compaction Vibration und Verdichtung
=VPL Vibratory plate Vibrationsplatte
Mounting location
Einbauort Description Beschreibung
+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
BW 219 D-5 / BW 219 PD-5

+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
0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
BW 219-226 D, DH, BVC-5 Structure identifier overview Higher-level function
=
Anlage 518
Deutz TCD 4.1_6.1 Tier 4f Strukturkennzeichenübersicht Einbauort + SIO
Geprüft 14.12.2017 EPE / 000 / 00
Strukturkennzeichenübersicht
Kind of Document
Dokumentenart Description Beschreibung
&DOC1 Leading documentation Einleitende Dokumentation
&DOC2 Reports and drawings Auswertungen und Zeichnungen
&EFS Circuit diagram Schaltpläne
BW 219 D-5 / BW 219 PD-5

0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
BW 219-226 D, DH, BVC-5 Structure identifier overview Higher-level function
=
Anlage 518
Circuit diagrams

Deutz TCD 4.1_6.1 Tier 4f Strukturkennzeichenübersicht Einbauort + SIO
Geprüft 14.12.2017
839
EPE / 000 / 00
840
Circuit diagrams
+FRFR
+DRUM +REFR
+PLA
+CAB
+ROPS
+DPL
+SEAT
+MOT
+ARC +PUMP
+BAT
BW 219 D-5 / BW 219 PD-5

+EBOX
0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
BW 219-226 D, DH, BVC-5 Layout mounting locations Higher-level function
=
Anlage 518
Deutz TCD 4.1_6.1 Tier 4f Übersicht Einbauorte Einbauort + VIEW
Geprüft 14.12.2017 EPE / 000 / 00
F13:2 / 9.0
+REFR X4.A 9
RD
4 mm² F95:2 / 10.0
X0.A
RD 1 +ARC RD
25 mm² 30_PB / 9.0 1,5 mm²
RADSOK® 8mm RD
1,5 mm² S15:11 / =OPT/42.0
30
P 0 IIIIII
RD
50 mm² S00 P,0,I
1 switch ignition 83 15/54 19 17 50a

Schalter Motorstart
WH
F39 1,5 mm²
80A
MAXI Fuse
2
Fuse, main cabin WH
MAXI Sicherung
1,5 mm² S15:23 / =OPT/42.0
Hauptsicherung WH WH WH
1,5 mm² 1,5 mm² 1,5 mm²
RD Kabine
70 mm²
X8.A
Fuse, engine controller

Sicherung Motorsteuerung
Fuse, main battery
Hauptsicherung Batterie
Fuse, B+ charge
Sicherung B+ Ladeleitung
=OPT+CAB/49.1
G02:B+ X4.A 13 3 20
=ENGI/18.1
S00:50a / 10.0
2 2 2
F95 4 F00 3 F164 1 S00:19 / =ENGI/20.1

30A 125A 150A 1
1 1 1
V01 15_CAB
=OPT+CAB/49.1
S5G-E3 2
+MOT 30
86 1 1
K61
RD
70 mm² K61 R10 /8.6 87 87a
D61
green
/8.7 2 ‎82Ω / 22W Relay, charge control
85 2 Relais Ladekontrolle
12V/20A
!!! Auch bei ausgeschaltetem Batterietrennschalter unter Spannung

K39:2 / =ENGI/22.8
K39:1 / =ENGI/22.8
D+ / =MON/27.0
(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 K15 =OPT/44.0
3 88 1
Disconnect switch, battery X7.C-2 5 A162:31
(85)
RD Batterietrennschalter
4 mm²
=OPT+DPL/47.1
X7.C-2
5 31_AH
BW 219 D-5 / BW 219 PD-5

XM01.50
1
+BAT RD B+ D+
70 mm² 30 50
86 1 86 1
X7.C 4
RD G
70 mm²
M01 G02 K09 K11
D09
D11
green
green
M1 14V / 150A X7.C-2 4 12V/20A 2 12V 2

85 85
Starter - Generator B- BN
X300:30 / =ENGI/26.0 W 1,5 mm²
Starter Relay, starter Generator
G03 + G01 + -U300
Ground engine Relais Anlasser
12V / 88Ah Battery
1Masse Motor 2 3 X7.C-2 4
Battery - Batterie -
Batterie at BW 219-226
bei BW 219-226
12V / 88Ah 4
X300:31 / =ENGI/26.0 X7.C
at BW 211-216
Only at BW 219-226
Nur bei BW 219-226
12V / 110Ah
X0.B
bei BW 211-216 BN 1
16 mm² Gnd_PB / 9.0
BK XU600.3 RADSOK® 6mm
70 mm² 31_Eng / =ENGI/18.0
BK
3 XU600.4
70 mm²
XU600.2
4 31_EMR / =ENGI/21.0 X8.B / =OPT+CAB/49.1
BK
70 mm² -U600 31_DCtrl / 11.0
Ground Central Electric 2 5
1Masse Zentralelektrik 87 30 87 /10.0
6 31_MCtrl / 12.0 87a 30 =OPT+CAB/48.1
1Ground rear frame 2 3

Masse Hinterrahmen 7 31_RFr / =DRIV+REFR/31.0
-U500 Relay, air conditioning Relay, potential 30 on 15
Relais Klimaanlage Relais Potential 30 auf 15
8 31_Ar / 14.6
9 31_Db / 14.1
XU600.10
10 31_Econ / =MEAS/39.1
0 1 2 3 4 5 6 7 8 9
Function Page from
Created VogtM Funktion == SDR Blatt 8 von 98
Erstellt 14.12.2017 BW 219-226 D, DH, BVC-5 Supply, Starting unit Higher-level function
=
Anlage SUPL 518
Checked
Circuit diagrams
K. Brand Mounting location

Geprüft Deutz TCD 4.1_6.1 Tier 4f Versorgung, Starten Einbauort + EBOX
14.12.2017
841
EPE / 000 / 00
842
8.6 / 30_PB 30_PB / 10.0
30
K06
=OPT/41.5 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
Circuit diagrams
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 30 F07:2

=OPT/42.0
K145
WH
=ENGI/20.8 87a 87 X7.C 1 1,5 mm²
Relay, solenoid starter F11:2
Relais Hubmagnet Starter X7.C-2 1 =OPT/42.0
11 21 A1
+ARC-S01
Switch, emergency off 12 22 A2 F146:2
Schalter NOT AUS 12.0
30
RD
/10.2
K38 1,5 mm²
WH F67:2
=ENGI/20.6 87a 87 1,5 mm²
Relay, starter control 11.0
X7.C-2 1
Relais Anlassteuerung
X7.C 1 10 F23:2
=DRIV+REFR/31.7
X4.A
=DRIV+REFR/32.2
1 2 F84:2
BW 219 D-5 / BW 219 PD-5

X1.A
1 =COM/15.0
Fx
Fuseholder, fuse test S01:12
2 11.0
Sicherungshalter Sicherungstest
F19:2
=OPT/41.0
1 F22:2
=OPT/41.0
Dx
green 2
Indicator light, fuse test X400:A
Meldeleuchte Sicherungstest =OPT/44.0
F68:2
=OPT+DPL/47.1
8.9 / Gnd_PB Gnd_PB / =COM/15.0
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 14.12.2017 BW 219-226 D, DH, BVC-5 Fuse protection potential 30 Higher-level function
=
Anlage SUPL 518
Geprüft Deutz TCD 4.1_6.1 Tier 4f Absicherung Potential 30 Einbauort + EBOX
14.12.2017 EPE / 000 / 00
8.6 / F95:2
8.9 / S00:50a 30
9.9 / 30_PB X0.C 30

RADSOK® 3,6mm
X0.C / =ENGI/20.1
1 1 1 1 1 1 1 1 1 1 1 1 1
BW11RH - F41 BW11RH - F25
30 F103 F122 F148 F24 F91 F05 F08 F124 F244 F40 F29 F169 F243
K11 15A 2 10A 2 10A 2 10A 2 5A 2 20A 2 10A 2 25A 2 5A 2 30A 2 15A 2 5A 2 7,5A 2
/8.8 87
Relay, potential 30 on 15
Relais Potential 30 auf 15
Fuse, socket
Fuse, sensors
Fuse, indicators
Sicherung Blinker
Fuse, potential 15
Sicherung Sensoren
Sicherung Steckdose
Sicherung Startstrom
Fuse, starting current
Fuse, fuel-pre-heating
Fuse, heating unit cabin
Fuse, monitoring module

Sicherung Kabinenheizung
Sicherung Kraftstoffvorheizung
Sicherung Überwachungsmodul
Fuse, compressor suspension seat

Sicherung Kompressor Luftfedersitz
Fuse, Bomag telematics (potential 15)

Sicherung Bomag Telematik (Potential 15)

F243:2
=OPT/45.1
F169:2
=ENGI/20.1
X4.A 12
F29:2
=OPT+CAB/48.1
F40:2
WH =OPT+CAB/48.1
1,5 mm²
21 F244:2
=OPT/45.1
BW 219 D-5 / BW 219 PD-5

+ARC-S01
/9.4 22
F124:2
WH =ENGI/18.0
1,5 mm²
F08:2
1 =OPT/42.0
X4.A
F05:2
=OPT/41.0
F91:2
=DRIV/28.0
X7.C 2 3
X7.C-2 2 3 F24:2
14.0
WH F148:2
1,5 mm²
11.0
X7.C-2 2 3 S01:22
14.0
X7.C 2 A162:30
=OPT/44.0
F103:2
=OPT+DPL/47.1
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 14.12.2017 BW 219-226 D, DH, BVC-5 Fuse protection potential 15 Higher-level function
=
Anlage SUPL 518
Checked
Circuit diagrams

Geprüft Deutz TCD 4.1_6.1 Tier 4f Absicherung Potential 15 Einbauort + EBOX
14.12.2017
843
EPE / 000 / 00
844
9.9 / S01:12 S01:12 / 12.0
10.9 / F148:2 F148:2 / 12.0
9.9 / F67:2
Ground Electronic Ground Electronic Ground Electronic Ground Electronic Ground Electronic
Masse Elektronik Masse Elektronik Masse Elektronik Masse Elektronik Masse Elektronik
GND GND GND GND GND
Circuit diagrams
Driving Controller
Fahrsteuerung A34 A34 A34 A34 A34
GND GND GND GND GND
X35 55 X35 65 X35 66 X35 67 X35 68
X35 55 X35 65 X35 66 X35 67 X35 68
A34
X5.A 19 18 3
X35
Plug, ECU propulsion
Stecker ECU Fahrantrieb
WH
2,5 mm²
Splice
Spleiss 38
B57:2 / =DRIV/28.0
Splice
Spleiss 39
BW 219 D-5 / BW 219 PD-5

X35 28 X35 54 X35 56 X35 57 X35 58 X35 59 X35 60
X35 28 X35 54 X35 56 X35 57 X35 58 X35 59 X35 60

+Ignition / 0..32V +UE / 0..32V +UB / 0..32V +UB / 0..32V +UB / 0..32V +UB / 0..32V +UB / 0..32V
A34 A34 A34 A34 A34 A34 A34
+ Ignition +UE +UB +UB +UB +UB +UB

Ignition Power Supply (Electronic) Power Supply (Outputs) Power Supply (Outputs) Power Supply (Outputs) Power Supply (Outputs) Power Supply (Outputs)
Zündung Spannungsvers. (Elektronik) Spannungsvers. (Ausgänge) Spannungsvers. (Ausgänge) Spannungsvers. (Ausgänge) Spannungsvers. (Ausgänge) Spannungsvers. (Ausgänge)
8.5 / 31_DCtrl 31_DCtrl / =DRIV/28.0
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 14.12.2017 BW 219-226 D, DH, BVC-5 Supply Driving Controller Higher-level function
=
Anlage SUPL 518
Geprüft Deutz TCD 4.1_6.1 Tier 4f Versorgung Fahrsteuerung Einbauort + EBOX
14.12.2017 EPE / 000 / 00
11.9 / F148:2 F148:2 / =COM/15.0
9.9 / F146:2
11.9 / S01:12
Measurement controller GND GND GND GND GND

Messtechnik Steuerung A83 A83 A83 A83 A83
GND GND GND GND GND
X5.E 4 13 6
X88 55 X88 65 X88 66 X88 67 X88 68
X5.E2 4 13 6
X88 55 X88 65 X88 66 X88 67 X88 68
A83
X5.E2 4 13 6
X5.E 13 6 X88
Plug, measurement controller
Stecker Messtechniksteuerung
X5.E 4 X5.E3 4 WH
2,5 mm²
Splice
Spleiss 43
=MEAS/39.1 / X5.E:4
BW 219 D-5 / BW 219 PD-5

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

A83 A83 A83 A83 A83 A83 A83
8.5 / 31_MCtrl 31_MCtrl / =EXC/34.1
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 14.12.2017 BW 219-226 D, DH, BVC-5 Supply Measurement controller Higher-level function
=
Anlage SUPL 518
Checked
Circuit diagrams

Geprüft Deutz TCD 4.1_6.1 Tier 4f Versorgung Messtechniksteuerung Einbauort + EBOX
14.12.2017
845
EPE / 000 / 00
846
FM1 / =DRIV/28.0
AGND_DC / =COM/15.0
FM2 / =EXC/34.1
Circuit diagrams
2 2
FM1 FM2
ATO Fuse
ATO Fuse
1A 1A
ATO Sicherung
ATO Sicherung
1 1
Fuse, sensors Fuse, sensors
Sicherung Sensoren Sicherung Sensoren
X5.A 4 13 X5.E 9
X5.E2 9
X5.E2 9
X5.E 9
AGND / =DRIV/28.0 AGND_MC / =MEAS/38.1

Splice
Spleiss 42
BW 219 D-5 / BW 219 PD-5

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 14.12.2017 BW 219-226 D, DH, BVC-5 Supply 8,5V sensors Higher-level function
=
Anlage SUPL 518
Geprüft Deutz TCD 4.1_6.1 Tier 4f Versorgung 8,5V Sensoren Einbauort + EBOX
14.12.2017 EPE / 000 / 00
10.9 / S01:22 S01:22 / =ENGI/20.1
10.9 / F24:2
X4.A 18 X4.B 7
+ARC +SEAT
Splice Splice
Spleiss 48 Spleiss 51
15_Db / =ENGI/19.1 15_Ar / =DRIV+SEAT/29.0
A15 S55
Monitoring module Travel lever
Überwachungsmodul Fahrhebel
X33 26 1
X23
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
X33 25 X23 2 X23 9 X23 10
X33 Splice
BW 219 D-5 / BW 219 PD-5

Plug, monitoring module
Spleiss 83
Stecker Überwachungsmodul
31_Db_2 / =MON/27.0
Splice
Spleiss 67
BN
2,5 mm²
8.5 / 31_Db 31_Db / =DRIV+REFR/32.1 8.5 / 31_Ar 31_Ar / =DRIV/28.0
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 14.12.2017 BW 219-226 D, DH, BVC-5 Supply Monitoring module, Travel lever Higher-level function
=
Anlage SUPL 518
Checked
Circuit diagrams

Geprüft Deutz TCD 4.1_6.1 Tier 4f Versorgung Überwachungsmodul, Fahrhebel Einbauort + EBOX
14.12.2017
847
EPE / 000 / 00
848
=SUPL/9.9 / F84:2 F84:2 / =OPT/43.1
=SUPL/12.9 / F148:2 F148:2 / 17.0
=SUPL/13.9 / AGND_DC AGND_DC / =DRIV/28.0
CAN1+ / 16.0
CAN1- / 16.0
Circuit diagrams
CAN2+ / 16.0
X7.D 15 13 5
CAN2- / 16.0
M_CAN1+ / 17.0
M_CAN1- / 17.0
X34 Diagnosis interface BOMAG
Pot. 30 - 12V
Pot. 15 - 12V
AGND 1
N A B C D E F X34 = Diagnosesteckdose BOMAG
P R J
Gnd
CAN 1 low
CAN 2 low
CAN 3 low
CAN 1 high
CAN 2 high
CAN 3 high
bestückt
Widerstände nicht
Resistors not equiped
X7.D 2 10 R20 7 6 R22 3 11 R24 8

1 2 1 2 1 2
‎120 Ω ‎120 Ω ‎120 Ω

=SUPL/9.1 / Gnd_PB Gnd_PB / 17.0
R21
1 2 R25
1 2
‎120 Ω
X7.C 13 X7.C 14 ‎120 Ω
X7.C-2 13 X7.C-2 14
X5.A 12 15 6 9 X5.E 15 12
BW 219 D-5 / BW 219 PD-5

X5.E2 15 12
X7.C-2 13 X7.C-2 14 X5.E2 15 12
X5.E 15 X5.E3 15 X5.E 12 X5.E3 12
X5.E:12 / =MEAS/39.1
X5.E:15 / =MEAS/39.1
X35 27 X35 26 X35 53 X35 33 X88 27 X88 26
X35 27 X35 26 X35 53 X35 33 X88 27 X88 26

CAN1_H CAN1_L CAN2_H CAN2_L CAN1_H CAN1_L
A34 A34 A34 A34 A83 A83
CAN 1 high CAN 1 low CAN 2 high CAN 2 low CAN 1 high CAN 1 low
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 14.12.2017 BW 219-226 D, DH, BVC-5 Communication, Diagnosis Higher-level function
=
Anlage COM 518
Geprüft Deutz TCD 4.1_6.1 Tier 4f Kommunikation, Diagnose Einbauort + EBOX
14.12.2017 EPE / 000 / 00
15.9 / CAN1+ CAN1+ / 17.0
15.9 / CAN1- CAN1- / 17.0
15.9 / CAN2+ CAN2+ / 17.0
15.9 / CAN2- CAN2- / 17.0
CAN3+ / =OPT+CAB/49.1
CAN3- / =OPT+CAB/49.1
R26
1 2
‎120 Ω
R27
1 2
‎120 Ω
X5.E 1 2
X5.E2 1 2
A162:L1 / =OPT/44.0
X4.A 14 17 X4.B 1 4
A162:H1 / =OPT/44.0
X5.E2 1 2
X5.E 1 X5.E3 1 X5.E 2 X5.E3 2
X5.E:2 / =MEAS/40.1
X5.E:1 / =MEAS/40.1
+ARC +SEAT
BW 219 D-5 / BW 219 PD-5

X33 21 X33 22 6 7 X88 53 X88 33
X23 X23
X33 21 X33 22 X23 6 X23 7 X88 53 X88 33
CAN high CAN low CAN bus high CAN bus low CAN2_H CAN2_L
A15 A15 S55 A83 A83
CANH CANL CAN + CAN - CAN2_H CAN2_L
CAN high CAN low CAN low CAN 3 high CAN 3 low
CAN high CAN low CAN low CAN 3 high CAN 3 low
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 14.12.2017 BW 219-226 D, DH, BVC-5 Communication Higher-level function
=
Anlage COM 518
Checked
Circuit diagrams

Geprüft Deutz TCD 4.1_6.1 Tier 4f Kommunikation Einbauort + EBOX
14.12.2017
849
EPE / 000 / 00
850
16.9 / CAN2+ CAN2+ / =ENGI/20.1
16.9 / CAN2- CAN2- / =ENGI/20.1
16.9 / CAN1+ CAN1+ / =OPT/43.1
16.9 / CAN1- CAN1- / =OPT/43.1
15.1 / Gnd_PB Gnd_PB / =ENGI/20.1

Circuit diagrams
15.9 / F148:2 F148:2 / =OPT/43.1
15.9 / M_CAN1+ CAN2+_TM / =OPT/45.1
15.9 / M_CAN1- CAN2-_TM / =OPT/45.1
R28
1 2
‎120 Ω

Widerstände nicht bestückt
R29
1 2
‎120 Ω
BW 219 D-5 / BW 219 PD-5

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 14.12.2017 BW 219-226 D, DH, BVC-5 Communication Higher-level function
=
Anlage COM 518
Geprüft Deutz TCD 4.1_6.1 Tier 4f Kommunikation Einbauort + EBOX
14.12.2017 EPE / 000 / 00
=SUPL/10.9 / F124:2
=SUPL/9.9 / F268:2
+MOT
=SUPL/8.6 / G02:B+
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
K14:2_4.1_6.1
22.9
K14:1_4.1_6.1
22.8
(85) (88a)
1 WH WH
4 1,5 mm² 1,5 mm²
K 14
K2 /18.1 2 3
Fitted on the engine

Am Motor angebaut
(88) Splice X78
(86) 84
Spleiss 1 1
WH
Relay, glow plug system 2,5 mm² X78:1 / 26.0
Relais Vorglühen K14:3_4.1_6.1
22.9 WH
2,5 mm²
X67 1
1 WH
R19 2,5 mm²
167A 1
R4 XR79
Heating flange 2
1
BW 219 D-5 / BW 219 PD-5

Heizflansch 31 1
Ground Engine
Masse Motor
R79
200W 2
Fuel-pre-heater
Kraftstoffvorheizung
2
XR79 2
BN
2,5 mm²
X67 2
BN
2,5 mm²
BN Splice
=SUPL/8.5 / 31_Eng 6 mm² Spleiss 31_Eng / =MON/27.0
74
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 14.12.2017 BW 219-226 D, DH, BVC-5 Pre-heating, Fuel lift pump, Fuel-pre-heating Higher-level function
=
Anlage ENGI 518
Checked
Circuit diagrams

Geprüft Deutz TCD 4.1_6.1 Tier 4f Vorglühen, Kraftstoffförderpumpe, Kraftstoffvorwärmung Einbauort + EBOX
14.12.2017
851
EPE / 000 / 00
852
+ARC
=SUPL/14.2 / 15_Db VIB_TM / =OPT/45.1

Circuit diagrams
13 23 13 23
low
eco
high
1 Stop
0
2 Request
S127 S299 X4.A 16
Switch, engine speed 14 24 Switch, regeneration mode 14 24
Schalter Motordrehzahl Schalter Regenerationsmodus
BW 219 D-5 / BW 219 PD-5

X33 9 X33 10 X33 11 X33 12 X33 4
X33 9 X33 10 X33 11 X33 12 X33 4

active high active high active high active high +UB, max 1,5A
A15 A15 A15 A15 A15
DIN3 DIN4 DIN5 DIN6 DOUT2

Switch, engine speed Sx. 1 Switch, engine speed Sx. 2 Switch, regeneration Sy. 1 Switch, regeneration Sy. 2 Vibration Telematics
Schalter Motordrehzahl Sx. 1 Schalter Motordrehzahl Sx. 2 Schalter Regeneration Sy. 1 Schalter Regeneration Sy. 2 Vibration Telematik
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 14.12.2017 BW 219-226 D, DH, BVC-5 Engine speed, Regeneration mode Higher-level function
=
Anlage ENGI 518
Geprüft Deutz TCD 4.1_6.1 Tier 4f Motordrehzahl, Regenerationsmodus Einbauort + EBOX
14.12.2017 EPE / 000 / 00
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 16 X1.B 12 10 13 15 18
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 86 1 12V/40A 86 87 87a 86 1

2 2
CN403
D41
green
green
green
87a 87
D209
D145
K41 K05
12V/25A 30 86 1 2 Relay, starter control =DRIV+SEAT/29.8 30 2
K209 85 K145 85
BW 219 D-5 / BW 219 PD-5

CN413 12V/30A 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+REFR/32.9 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/45.1
=COM/17.8 / Gnd_PB Gnd_PB / =DRIV/28.0
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 14.12.2017 BW 219-226 D, DH, BVC-5 Engine - Machine-part Higher-level function
=
Anlage ENGI 518
Checked
Circuit diagrams

Geprüft Deutz TCD 4.1_6.1 Tier 4f Motor - Fahrzeugseite Einbauort + EBOX
14.12.2017
853
EPE / 000 / 00
854
A48
Circuit diagrams
EDC 17 CV-52
ECU engine controller
ECU Motorsteuergerät
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
-A48 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 WH WH WH BN BN BN
2,5 mm² 2,5 mm² 2,5 mm² X45:13 / 25.0 2,5 mm² 2,5 mm² 2,5 mm²
X45:31 / 25.0
Splice
Spleiss 68
X45:18 / 25.0
WH WH
2,5 mm² 2,5 mm²
K22:87a / 24.0
X108 1 2 X108 3 4 5
Splice
Spleiss 33
+MOT X73 1 2
+MOT
1
1
1 X48 1 R30
2 2
B124 2‎120 Ω
2 Plug, engine stop
Stecker Motor Stop
B218 R23
BW 219 D-5 / BW 219 PD-5

‎120 Ω 1
Sensor, water trap fuel 2

Sensor Wasserabscheider Kraftstoff
Temperature sensor, ambient temperature

Temperatursensor Umgebungstemperatur
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
20.8 / X1.B:18
20.4 / X1.B:14
20.5 / X1.B:16
20.6 / X1.B:12
20.7 / X1.B:10
20.7 / X1.B:13
CAN 1 = Diagnosis CAN

CAN 2 = Customer CAN
Diagnosis interface EMR

Diagnoseschnittstelle EMR
BN Splice
=SUPL/8.5 / 31_EMR 6 mm² Spleiss 31_AGR / 24.0
69
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 14.12.2017 BW 219-226 D, DH, BVC-5 Deutz TCD 3.6, 4.1 u. 6.1 Machine part Higher-level function
=
Anlage ENGI 518
Geprüft Deutz TCD 4.1_6.1 Tier 4f Deutz TCD 3.6, 4.1 a. 6.1 Fahrzeugseite Einbauort + EBOX
14.12.2017 EPE / 000 / 00
A48
EDC 17 CV-52
Harness EMR - Engine interface

Kabelbaum EMR - Motorschnittstelle

Harness Engine interface - Engine internal Stecker Motorsteuergerät Motorseite = X44 D2.1 (A) D2.2 (K) -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
-A48 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
BW 219 D-5 / BW 219 PD-5

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
/22.0
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 /22.0
1
X17.1
B130 n
B40.2
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
Injector A4 Injector A5 Injector A6 Injector A4 Injector A2 EMR Motordrehzahlsensor 1
=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 / K14:1_4.1_6.1
18.1 / K14:2_4.1_6.1
18.1 / K14:3_4.1_6.1
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 14.12.2017 BW 219-226 D, DH, BVC-5 Deutz TCD 4.1/6.1 Higher-level function
=
Anlage ENGI 518
Checked
Circuit diagrams

Geprüft Deutz TCD 4.1_6.1 Tier 4f Deutz TCD 4.1/6.1 Einbauort + EBOX
14.12.2017
855
EPE / 000 / 00
856
A48
EDC 17 CV-52
Circuit diagrams


D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1
-A48 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 2 55 18 76 51 8
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
BW 219 D-5 / BW 219 PD-5

1
2 1 1
2 4 2
Y137 B93 B133 3
B145 3 1
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 3
B238 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 14.12.2017 BW 219-226 D, DH, BVC-5 Deutz TCD 4.1/6.1 Higher-level function
=
Anlage ENGI 518
Geprüft Deutz TCD 4.1_6.1 Tier 4f Deutz TCD 4.1/6.1 Einbauort + EBOX
14.12.2017 EPE / 000 / 00
A48
EDC 17 CV-52

1 Plug, Plug, Kabelbaum EMR - Motorschnittstelle
engine-controller engine-controller 1
R32 motor-part machine-part
‎120Ω 2 Stecker Stecker R31
Motorsteuergerät Motorsteuergerät ‎120Ω 2
Motorseite = X44 D2.1 (A) D2.2 (K) -X45 = Maschinenseite
Harness Engine interface - Engine internal
D2.1 D2.1
X41 38 39 -A48 98 77 X41 36 35
X23 X23
X44 98 77
D2.1
21.9 / 31_AGR
X36 39
38 37 13
21.6 / K22:87a X39
31_EAT / 26.0
F310:2 / 26.0
F251:2 / 26.0
X41 28 29 WH
1,5 mm²
X23
+MOT
Splice
Spleiss 14
BW 219 D-5 / BW 219 PD-5

Splice Splice
X46.2 57 59 28 29 23 22 Spleiss 15 Spleiss 16
X17.2
Splice
Spleiss 19
Splice
Spleiss 20
+
Stichleitungslänge max. 300mm
Branch line length max. 300mm

Ub Gnd CAN L CAN H CAN L CAN H 1 Can L

Y174 1 2 6 3 4 5 2
Ub
Ub
Y20
Gnd
Gnd
OUT IN B224 4 3 2 1 B225 4 3 2 1

Can L
Can L
Can H
Can H
Can H
EMR Exhaust gas recirculation B54 B56

3
EMR Abgasrückführung 4 grey black
ECU B222 grau schwarz
-
B90 ECU ECU
M
Sensor, urea temperature and level Sensor, NOx before SCR-Kat Sensor, NOx behind SCR-Kat
Sensor Ureatemperatur und Füllstand Sensor NOx vor SCR-Kat Sensor NOx nach SCR-Kat
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 14.12.2017 BW 219-226 D, DH, BVC-5 Deutz TCD 4.1/6.1 - Exhaust aftertreatment Higher-level function
=
Anlage ENGI 518
Checked
Circuit diagrams

Geprüft Deutz TCD 4.1_6.1 Tier 4f Deutz TCD 4.1/6.1 - Abgasnachbehandlung Einbauort + EBOX
14.12.2017
857
EPE / 000 / 00
858
A48
EDC 17 CV-52
Circuit diagrams


Stecker Motorsteuergerät Motorseite = X44 D2.1 (A) D2.2 (K) -X45 = Stecker Motorsteuergerät Maschinenseite
D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1
-A48 15 48 09 32 29 20 27 47 26 70 57 19 82 05 89 59 92
X44 15 48 9 32 29 20 27 47 26 70 57 19 82 5 89 59 92
21.6 / X45:18
D2.1
21.6 / X45:31
21.6 / X45:13
X36 18 19 3 4 15 14 5 28 22 33 29 24 30 16 36 35 25
X39
X41 32 33 34
X23 WH WH
1,5 mm² 1,5 mm²
M41:9 / 26.0
+MOT E107:+ / 26.0
X36 10 9 8 +REFR
X39
E107:- / 26.0
BW 219 D-5 / BW 219 PD-5

Y292:4 / 26.0
WH WH WH
1,5 mm² 1,5 mm² 1,5 mm²
Splice
Spleiss 13
X31 4 3 2 12 11 8 10 9 5 6
3 2 2 2 3
2 2
3 3 4 -E107
P P 1 2 + 4
1 1 1 1 1 2
B305 B223 B214 B215 B216
B88 B78 B65 B66 B58 P R
2 1 M41 - 1
black grey 1
schwarz grau
Y293 B221 Y291 5 M10 ???W
Y292
Y24 B63 Y30 Y31
Boost module
Fördermodul
EMR Pressure sensor, pressure after DPF EMR Sensor, temperature exhaust gas before oxy cat
EMR Drucksensor, Druck nach DPF EMR Temperatursensor Abgas vor Oxy Kat Solenoid valve, urea dosing Solenoid valve, urea extraction Heating, supply modul
Magnetventil Ureadosierung Magnetventil Urea Absaugung Heizung Versorgungsmodul
EMR Sensor, temperature exhaust gas after oxy cat
EMR Temperatursensor Abgas nach Oxy Kat Sensor, urea pressure behind pump Urea pump Solenoid valve, urea tank heating
Sensor, Ureadruck nach Pumpe Urea Pumpe Magnetventil Ureatank Heizung
Temperature sensor, exhaust gas before SCR kat EMR Sensor, differential pressure DPF
Temperatursensor Abgas vor SCR Kat EMR Sensor Differenzdruck DPF
0 1 2 3 4 5 6 7 8 9
Function Page from
=
Anlage ENGI 518
14.12.2017 EPE / 000 / 00
+MOT
25.9 / M41:9
A48
18.9 / X78:1 EDC 17 CV-52
25.9 / E107:- ECU Motorsteuergerät
Plug,
engine-controller
25.9 / E107:+ Plug, engine-controller machine-part
motor-part Stecker
25.9 / Y292:4 Stecker Motorsteuergerät Motorsteuergerät
Motorseite = X44 D2.2 (K) X45 = Maschinenseite
D2.1 (A)
24.7 / F310:2
D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1

24.7 / F251:2 -E105 -E106 -E104 62 80 37 61
+ + + -A48 03 41 04
X300:30
=SUPL/8.2 R R R X44 3 41 4 62 80 37 61
- - -
X300:31 D2.1
=SUPL/8.2 BN
10 mm²
24.7 / 31_EAT X36 34

RD 11 23 31 32 21 20
10 mm² X39
Heating, suction line

Heizung Saugleitung
Heizung Druckleitung
Heating, pressure line
Heizung Rücklaufleitung
Heating, return flow line
+BAT WH WH WH WH WH WH WH
2,5 mm² 2,5 mm² 2,5 mm² 2,5 mm² 2,5 mm² 2,5 mm² 2,5 mm²
X300 31 X300 F312 2 F313 2 X301 12 15 14 4 5 1 7 8 6 3 2 9 10 13 X302 1 2 3 4 5 6 7

30
M6
M5
M5
Stud bolt
Stud bolt
Stud bolt
Gewindebolzen
Gewindebolzen
Gewindebolzen
BW 219 D-5 / BW 219 PD-5

Fuse, reserve
Sicherung Reserve
Fuse, SCR control
Sicherung SCR Ansteuerung
Fuse, reserve
Sicherung Reserve
Fuse, NOx sensors
Sicherung NOx Sensoren
Fuse, sensor urea quality
Sicherung Sensor Ureaqualität
Fuse, exhaust gas recirculation
Sicherung Abgasrückführung
Relay, SCR control
Relais, SCR Ansteuerung
Relay, heating urea feed-in modul
Relais Heizung Urea-Einspeisemodul
Relay, heating urea suction hose
Relais Heizung Urea-Saugleitung
Relay, heating urea restriction hose
Relais Heizung Urea-Drosselleitung
Relay, heating urea pressure hose
Relais Heizung Urea-Druckleitung
2 2 2 2 2 2
Relay, SCR control

5A
K227 K192 K193 K194 K195 K196
30A
10A
15A
F312
F250
F313
F251
F310
F238
87 87 87a 87 87a 87 87a 87 87a 12V 86 12V 86 12V 12V 12V 12V
max. 20A
max. 20A
1 1 1 1 1 1 85 85 85 85
K192 K194 K195 K196 K193
K31 30 K28 30 K29 30 K30 30 K27 30 K31 K27 86 K28 86 K29 86 K30 86
85 85
/26.7 /26.8 /26.9 /26.9 /26.8
87
K227
87
87a
87
87a
87
87a
87
87a
87
30 87
30
Relay, potential 30 on 15 /26.1

30
30
30
30
30
/26.6
/26.4 /26.6 /26.5 /26.5 /26.6
0 1 2 3 4 5 6 7 8 9
Function Page from
=
Anlage ENGI 518
Checked
Circuit diagrams

14.12.2017
859
EPE / 000 / 00
860
+ARC
D+ Alternator Coolant level Water in Fuel Maintenance switch, air cleaner Hydraulic oil filter Warning buzzer, breakdown Fuel level
Circuit diagrams
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/45.1
+REFR
X11 1
1
+MOT +REFR
X72 1
X69 2
XB03 1
3 3 (1) + 1
3
BW 219 D-5 / BW 219 PD-5

B55 B03 P B21 P H07 R03
4
4 4 (2) 70mA - ‎BW 211-216 = 66 Ω 2
2 ‎BW 219-226 = 64,2 Ω
XB03
X69 3
X72 2
X11 2
=ENGI/18.8 / 31_Eng 31_Eng / =OPT+CAB/48.1
=SUPL/14.2 / 31_Db_2 31_Db_2 / =DRIV+SEAT/29.0
=DRIV+REFR/31.0 / 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 14.12.2017 BW 219-226 D, DH, BVC-5 Monitoring, Failure indicators Higher-level function
=
Anlage MON 518
Geprüft Deutz TCD 4.1_6.1 Tier 4f Überwachung, Störmeldungen Einbauort + EBOX
14.12.2017 EPE / 000 / 00
=SUPL/13.9 / FM1
=SUPL/10.9 / F91:2 F91:2 / +REFR/30.1
=ENGI/20.8 / Gnd_PB Gnd_PB / +SEAT/29.8
=SUPL/14.7 / 31_Ar 31_Ar / =EXC/34.1
=SUPL/11.9 / 31_DCtrl 31_DCtrl / +REFR/31.0
=SUPL/13.3 / AGND AGND / =VIB/33.1

1 1
=COM/15.9 / AGND_DC V07 V09
Only at DH-Version S1M 2 S1M 2
=SUPL/11.1 / B57:2 Nur bei DH-Version
1 1
V08 V10
S1M 2 S1M 2
X2.A 12 14 9 13 X5.A 2 16 1
B57
0,5-4,5V
sensor slope speed range selection 1 2 3
X106:1 / =VIB/33.1
Splice
Neigungssensor Stufenumschaltung Spleiss 41
- + S
X106:5 / =VIB/33.1
B
+REFR X104 1 2 3 4 X105:11 / =VPL/36.1
X14
-
+SEAT BU 5
4+
S06 B60 3 speed
Switch, seat contact SW Speed sensor, axle +DRUM
Sitzkontaktschalter Drehzahlsensor 2
A Achsgeschwindigkeit dir Only at DH-Version
X14
Nur bei DH-Version
W3 3 4
7x1,0
-
5
+4
B59
speed 3
X2.A 1 X2.A 4 Speed sensor, drum
2 Drehzahlsensor
dir Bandagengeschwindigkeit
11 10
BW 219 D-5 / BW 219 PD-5

X7.C X7.C
5 6 W3
X7.C-2 11 X7.C-2 10 7x1,0
X4.B 2
X7.C-2 11 X7.C-2 10
X5.B 10 X5.B 6 X5.B 5
X100 1 X104 5 6
X35 32 X35 15 X35 16 X35 13 X35 12 X35 35 X35 17
X35 32 X35 15 X35 16 X35 13 X35 12 X35 35 X35 17

AIN8 / 10V 25mA DIN8 / 0..32V DIN10 / 0..32V, DRZ DIN4 / 0..32V DIN2 / 0..32V, DRZ DIN3 / 0..32V, DRZ DIN12 / 0..32V
A34 A34 A34 A34 A34 A34 A34
AIN_8 DIN_8 DIN_10 DIN_4 DIN_2 DIN_3 DIN_12
Slope sensor Seat contact Proximity switch, arm rest right Direction axle Speed axle Speed drum Direction drum
Neigungssensor Sitzkontakt Näherungsinitiator Armlehne rechts Drehrichtung Achse Geschwindigkeit Achse Geschwindigkeit Bandage Drehrichtung Bandage
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 14.12.2017 BW 219-226 D, DH, BVC-5 Slope sensor, Speed sensors Higher-level function
=
Anlage DRIV 518
Checked
Circuit diagrams

Geprüft Deutz TCD 4.1_6.1 Tier 4f Neigungssensor, Geschwindigkeitsaufnehmer Einbauort + EBOX
14.12.2017
861
EPE / 000 / 00
862
+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
Only at BVC Not at BVC A34
12 Stufen bei DH, 5 Stufen bei D
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
31_Db_2 31_Db_2 Relais Startstrom 87
3 87a 30 +REFR/31.7
=MON+EBOX/27.8 =OPT+EBOX/42.0 87
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
Switch, vibration plates 13 Pushbutton, float 13 1 1
Frequenzverstellung - S
Schalter Vibration position plates
K05 K48
D05
D48
green
green
Anbauplatten Anbauplatten Taster Schwimmstellung

15_Ar 15_Ar 1 2 12V/20A 85 2 12V/20A 85 2
=SUPL+EBOX/14.7 =EXC+EBOX/34.1 Splice
Anbauplatten
Spleiss 49
X26 1 2 Splice
Spleiss 50
Splice
Spleiss 47
Gnd_PB Gnd_PB
+EBOX/28.9 +REFR/32.7
X23 11 X23 8 X23 5 X23 12 X24 4 X24 3 X24 1 X24 2 X23 3
BW 219 D-5 / BW 219 PD-5

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 14.12.2017 BW 219-226 D, DH, BVC-5 Travel lever Higher-level function
=
Anlage DRIV 518
Geprüft Deutz TCD 4.1_6.1 Tier 4f Fahrhebel Einbauort + SEAT
14.12.2017 EPE / 000 / 00
+EBOX
+EBOX/28.9 / F91:2 F91:2 / =MEAS+EBOX/38.1
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 P B235 P B236 P B237 P

Pressure sensor, travel Pressure sensor, travel Pressure sensor, travel Pressure sensor, travel
pump axle MA 2 pump axle MB 2 pump drum MA 2 pump drum MB 2
Drucksensor Fahrpumpe Drucksensor Fahrpumpe Drucksensor Fahrpumpe Drucksensor Fahrpumpe
Achse MA Achse MB Bandage MA Bandage MB
right - front left - front right - back left - back
Y17
rechts - vorne links - vorne rechts - hinten links - hinten
Y08
X55 2 X56 2 X57 2 X58 2
at DH Version
-X25 1 2 3 4 bei DH Version
B234
B236 (X55)
+EBOX (X57)
BW 219 D-5 / BW 219 PD-5

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 14.12.2017 BW 219-226 D, DH, BVC-5 Pressure sensors Higher-level function
=
Anlage DRIV 518
Checked
Circuit diagrams

Geprüft Deutz TCD 4.1_6.1 Tier 4f Drucksensoren Einbauort + REFR
14.12.2017
863
EPE / 000 / 00
864
+EBOX
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/29.9
Relais, Fahrhebel 0-Stellung 87 87a
X4.A 21
WH
1,5 mm²
A1
Splice
+ARC-S01 Spleiss 61
=SUPL+EBOX/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
X7.C-2 12
Splice Splice +DRUM

7 8 Spleiss 71 Spleiss 70
-X25 1 W3
7 8 X7.C-2 12
7x1,0
X11 3 4
+PUMP at DH Version a.
BW 216-219 D
BW 219 D-5 / BW 219 PD-5

bei DH Version u.
BW 216-219 D
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
bei D Version
Splice 2 W3
Spleiss 75
Only at DH-Version 7x1,0
Nur bei DH-Version
6
31_RFr.2
=MON+EBOX/27.0 -X25 6 5 8
X11 +EBOX-X104
BN
1,5 mm²
31_RFr BN Splice 31_RFr
10 mm² Spleiss
=SUPL+EBOX/8.5 72 32.1
31_DCtrl 31_DCtrl
+EBOX/28.9 =VIB+EBOX/33.1
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 14.12.2017 BW 219-226 D, DH, BVC-5 Brake, Travel pumps, Speed ranges Higher-level function
=
Anlage DRIV 518
Geprüft Deutz TCD 4.1_6.1 Tier 4f Bremse, Fahrpumpen, Fahrstufen Einbauort + REFR
14.12.2017 EPE / 000 / 00
+EBOX
=SUPL+EBOX/9.9 / F23:2
Back-up alarm buzzer Warning horn Relay, shut off solenoid engine
Warnsummer Rückwärtsfahrt Signalhorn Relais Hubmagnet Abschaltung Motor
30
DO_5 DO_3 DO_1
K13 A34 A34 A34
/32.8 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/49.1
X2.A 2
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 D-5 / BW 219 PD-5

BW 219-226 -5 BW 219-226 -5
1 1 2 2 1 1 + 86 1 86 1
B11.3 B11.1 V02 V03 B11.2 B11.4 H14 K13 K22
D13
D22
green
green
max. 3,5A 2 max. 3,5A 2 SF 64 1 1 SF 64 2 max. 3,5A 2 max. 3,5A 300mA - 12V/20A 85 2 12V/20A 85 2
BN BN
1,5 mm² 1,5 mm²
X30 2
BN BN
1,5 mm² 1,5 mm²
=SUPL+EBOX/14.2 / 31_Db 31_Db / =OPT+EBOX/41.0
31.9 / 31_RFr 31_RFr

=VIB+EBOX/33.1
Gnd_PB Gnd_PB
+SEAT/29.9 =VIB+EBOX/33.1
87 87
87a 30 /32.3 87a 30 =ENGI+EBOX/20.6
Warning horn Warning horn Warning horn Warning horn Back-up alarm buzzer Relay, warning horn Relay, shut off solenoid engine
Signalhorn Signalhorn Signalhorn Signalhorn Warnsummer Rückwärtsfahrt Relais Signalhorn Relais Hubmagnet Abschaltung Motor
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 14.12.2017 BW 219-226 D, DH, BVC-5 Warning horns, Back up alarm, Higher-level function
=
Anlage DRIV 518
Checked
Circuit diagrams

Geprüft Deutz TCD 4.1_6.1 Tier 4f Warnhörner, Rückfahralarm, Einbauort + REFR
14.12.2017
865
EPE / 000 / 00
866
=DRIV/28.9 / X106:5
=DRIV/28.9 / X106:1
=DRIV/28.9 / AGND
Speed vibration drum Vibration pump low/high Vibration pump PWM

Circuit diagrams
Drehzahl Vibration Bandage Vibrationspumpe klein/groß Vibrationspumpe PWM
DIN_1 PWM_3 PWM_4

A34 A34 A34
DIN1 / 0..32V, DRZ OUT3 / 4A curr.-measur. OUT4 / 4A curr.-measur.
X35 34 X35 48 X35 49
X35 34 X35 48 X35 49
X106 2 1 5 3
X5.B 8 X5.B 1
BW11RH - K78 30
K43
/33.4 87 87a
Relay, vibration
Relais Vibration
X5.B 9 3
not used today
wird zur Zeit nicht genutzt
X103 12 13
BW 219 D-5 / BW 219 PD-5

86 1 +PUMP 1 1
BW11RH - K78
K43 Y07 Y08
D43
green
12V/20A 2 640...1580mA 2 640...1580mA 2
85
C1 C2
X106 6
=DRIV+REFR/31.9 / 31_DCtrl 31_DCtrl / =DBL/35.1
=DRIV+REFR/32.6 / 31_RFr 31_RFr / =OPT/42.0
=DRIV+REFR/32.9 / Gnd_PB Gnd_PB / =OPT/41.0
87
87a 30 /33.5
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 14.12.2017 BW 219-226 D, DH, BVC-5 Vibration Higher-level function
=
Anlage VIB 518
Geprüft Deutz TCD 4.1_6.1 Tier 4f Vibration Einbauort + EBOX
14.12.2017 EPE / 000 / 00
=SUPL/13.9 / FM2
X5.E 11
+SEAT X5.E2 11
=DRIV/28.9 / 31_Ar 31_Ar X5.E2 11

=OPT+CAB/48.1
=DRIV+SEAT/29.2 / 15_Ar X5.E 11
X107 7
+DRUM Exciter up Exciter down Exciter priority

X86:2 Erreger auf Erreger ab Erreger Priorität
W1 =MEAS/38.1
12x0,75 9 10
PWM_2 PWM_1 DO_5
A83 A83 A83
2 (+) OUT2 / 4A curr.-measur. OUT1 / 4A curr.-measur. OUT6 / 4A
1 (-) X86 1 X88 47 X88 46 X88 61
S107
switch amplitude adjustment RD 47 46 61
3 (S) + X86 X88 X88
Schalter Amplitudenverstellung
12 steps - BK
2
12 Stufen B97
4...20mA Sensor, adjustable motor
S
Sensor Verstellmotor
WH
X86 3
X107 9 10 11
X4.B 8
W1
12x0,75 11
X5.E 14 +DRUM
X5.E2 14 W2
X107 8
7x1,0 1 3
X5.E2 14
X5.E 14 1 1
BW 219 D-5 / BW 219 PD-5

Y140 Y141
400-1200mA 2 400-1200mA 2
X88 32 X88 9 b1 (v.r.) a1 (v.l.)
X88 32 X88 9 -W2 2 4

AIN8 / 10V 25mA AIN7 / 10V 25mA 7x1,0
A83 A83
AIN_8 AIN_7 Splice
Y140
Spleiss 8 Y141
+SEAT-S107:3 (S) +DRUM-B97:S BN
1,5 mm²
switch amplitude adjustment Sensor, adjustable motor
Schalter Amplitudenverstellung Sensor Verstellmotor
X107 12
BN
=SUPL/12.9 / 31_MCtrl 1,5 mm²
Solenoid valve, exciter up Solenoid valve, exciter down

Magnetventil Erreger auf Magnetventil Erreger ab
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 14.12.2017 BW 219-226 D, DH, BVC-5 Variocontrol Higher-level function
=
Anlage EXC 518
Checked
Circuit diagrams

Geprüft Deutz TCD 4.1_6.1 Tier 4f Variocontrol Einbauort + EBOX
14.12.2017
867
EPE / 000 / 00
868
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
Circuit diagrams
DO_6 DO_9 PWM_6 PWM_8 DO_10 DO_11

A34 A34 A34 A34 A34 A34
OUT7 / 2,5A curr.-feedb. OUT20 / 2,5A curr.-feedb. OUT13 / 4A curr.-measur. OUT15 / 4A curr.-measur. OUT21 / 5A curr.-feedb. OUT22 / 5A curr.-feedb.
X35 62 X35 11 X35 42 X35 43 X35 50 X35 51
X35 62 X35 11 X35 42 X35 43 X35 50 X35 51
X5.E 10
X105 1 2 3 4 5 6
X105:1 / =VPL+REFR/37.0
X5.A 7 X105:2 / =VPL+REFR/37.0
X105:3 / =VPL+REFR/37.0
Y379
X105:4 / =VPL+REFR/37.0
Y378 +DRUM X105:5 / =VPL+REFR/37.0
W4
X105:6 / =VPL+REFR/37.0
12x0,75 1 3 5 7
Y380
1 1 1 1
Y102 Y378 Y102 Y379 Y380
2 2 2 2
BW 219 D-5 / BW 219 PD-5

W4
12x0,75 2 4 6 8
Splice
Spleiss 2
BN
1,5 mm²
X105:7 / =VPL+REFR/37.0
X105:10 / =VPL/36.1
X105:12 / =VPL/36.1
X105 7 10 12
BN BN BN
1,5 mm² 1,5 mm² 1,5 mm²
=VIB/33.8 / 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 14.12.2017 BW 219-226 D, DH, BVC-5 Dozer blade Higher-level function
=
Anlage DBL 518
Geprüft Deutz TCD 4.1_6.1 Tier 4f Planierschild Einbauort + EBOX
14.12.2017 EPE / 000 / 00
X105 11 Splice
=DRIV/28.9 / X105:11 Spleiss
22
Splice
=DBL/35.8 / X105:12 Spleiss
23
+REFR
W8 X28 2 1 W7 X29 2 1
BINDER Sensorcable M12 90° BINDER Sensorcable M12 90°
2 1 2 1
4x0,5 BU BN 4x0,5 BU BN
- (bu) - (bu)
3 3
1 1
B312 + (bn) B313 + (bn)
Sensor, height adjustment plates Sensor, lateral adjustment plates
Sensor Höhenverstellung Platten 4 Sensor Seitenverstellung Platten 4
4...20mA S (bk) 4...20mA S (bk)
W8 BK W7 BK
4x0,5 3
4x0,5 3
X28 3 X29 3
13 14
X105 13 X105 14
Hour meter plates Plate pump enable Vibration pump plates

Stundenzähler Platten Freigabe Plattenpumpe Vibrationspumpe Platten
8 X35 31
+PLA DO_7 X35 DIN_18 PWM_11
X35 8 X35 31
View from plate side AIN5 / 10V 25mA AIN6 / 10V 25mA
Ansicht von Plattenseite A34 A34 A34 A34 A34
OUT8 / 2,5A curr.-feedb. AIN_5 DIN18 / 0..32V AIN_6 OUT18 / 4A curr.-measur.
X35 63 X35 10 X35 22
X35 63 X35 10 X35 22

Sensor Höhenverstellung Platten Sensor Seitenverstellung Platten
X105 9 X105 15 X105 8
+REFR
BW 219 D-5 / BW 219 PD-5

X29 4 X29 5
X27 4 5
W6
1 3x0,75 BK GY
3
2
-X27 3 X27 +MOT
2
1
1
Plug, quick connect coupling plates W9
X27 = Stecker Schnellverschlußkupplung Platten Y98
2X0,75 2 1
400-1200mA 2
Solenoid valve, vibration pump plates
W6 Magnetventil Vibrationspumpe Platten
+
3x0,75 BN
P43
Operating hour meter 6
h plates
Betriebsstundenzähler X29
- 6
Platten
BN Splice
=DBL/35.8 / X105:10 1,5 mm² Spleiss
24
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 14.12.2017 BW 219-226 D, DH, BVC-5 Vibratory plate compactor Higher-level function
=
Anlage VPL 518
Checked
Circuit diagrams

Geprüft Deutz TCD 4.1_6.1 Tier 4f Anbauplatten Einbauort + EBOX
14.12.2017
869
EPE / 000 / 00
870
+EBOX
Floating position plates

Schwimmstellung Anbauplatten
DO_8
A34
OUT19 / 2,5A curr.-feedb.
X35 45
Circuit diagrams
X35 45
X105 16
=DBL+EBOX/35.8 / X105:2
=DBL+EBOX/35.8 / X105:1
=DBL+EBOX/35.8 / X105:6
Y145
=DBL+EBOX/35.8 / X105:5
Y143
=DBL+EBOX/35.8 / X105:4
=DBL+EBOX/35.8 / X105:3 Y142
Y122
BW 219 D-5 / BW 219 PD-5

Y123
1 1 1 1
Y122 Y142 Y145 Y144
b1 a2 a c2
2 2 2 2
1 1 1
Y123 Y143 Y60
a1 b2 c1
2 2 2
Y144
Y60
BN Splice
=DBL+EBOX/35.8 / 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 14.12.2017 BW 219-226 D, DH, BVC-5 Vibratory plate compactor Higher-level function
=
Anlage VPL 518
Geprüft Deutz TCD 4.1_6.1 Tier 4f Anbauplatten Einbauort + REFR
14.12.2017 EPE / 000 / 00
=SUPL/13.6 / AGND_MC
=DRIV+REFR/30.4 / F91:2
X5.E 7
X5.E2 7
X5.E2 7
X5.E 7
RxD Printer TxD Printer Power supply GPS

RxD Drucker TxD Drucker Spannungsversorgung GPS
X107 1 2
RxD TxD DO_3
A83 A83 A83
RxD_1 TxD_1 OUT11 / 2,5A curr.-feedb.
+DRUM WH WH X88 4 X88 5 X88 25
1,5 mm² 1,5 mm²
Splice
Spleiss 7 X88 4 X88 5 X88 25
=EXC/34.6 / X86:2
Splice
Spleiss 6
W1
LÜTZE SUPERFLEX® N PUR
12x0,75 1 2 5 6
X5.E 5 3 8
X5.E2 5
X20 1 2 X21 1 2
BK GNYE BK GNYE
+ +
- - X5.E2 5 3 8
B62 15g
B171 15g
X5.E 5 3 8
front 20g rear 20g
vorne hinten
BN BU BN BU
Transducer, acceleration
Aufnehmer Beschleunigung
X20 4 3 X21 4 3
BW 219 D-5 / BW 219 PD-5

15_GPS / =OPT+CAB/49.1
TxD / =OPT+CAB/49.1
W1
RxD / =OPT+CAB/49.1
12x0,75 4 3 8 7
X107 3 4 5 6
X88 31 X88 29 X88 7 X88 30
X88 31 X88 29 X88 7 X88 30

A83 A83 A83 A83
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 14.12.2017 BW 219-226 D, DH, BVC-5 Measurement equipment Higher-level function
=
Anlage MEAS 518
Checked
Circuit diagrams

Geprüft Deutz TCD 4.1_6.1 Tier 4f Messtechnik Einbauort + EBOX
14.12.2017
871
EPE / 000 / 00
872
Splice 17
=COM/15.8 / X5.E:12 Spleiss X5.E:12 / 40.1
Splice 18
=COM/15.8 / X5.E:15 Spleiss X5.E:15 / 40.1
Splice 1
=SUPL/12.1 / X5.E:4 Spleiss X5.E:4 / 40.1
+REFR
XA103 1 XA103 2
XA103 1 XA103 2
CAN low CAN high
Circuit diagrams
A103
A103 CANL CANH
module ECONOMIZER
Modul ECONOMIZER
XA103 13 CAN low CAN high
Power supply (8...32V) Supply 5V sensors Transducer acceleration Ground Ground
A103 Versorgung 5V Sensoren Beschleunigungsaufnehmer Masse Masse
UE
5Vana_REF Analog_IN0 GND GND

Power supply A103 A103 A103 A103
Stromversorgung +5V supply Sensors 0...5V Ground Ground
Ground XA103 6 XA103 5 XA103 24 XA103 25
Masse XA103 6 XA103 5 XA103 24 XA103 25
Shielding
Schirm 9
GND
A103
Ground W18
XA103 26 3x0,75 1 2 3 SH
XA103 26
-XA103 Shielding
Plug, monitoring module Schirm 10
+EBOX X109.m 1 2 3 4
X109.f 1 2 3 4
Shielding
Schirm 7
W17
BW 219 D-5 / BW 219 PD-5

3x0,75 1 2 3 SH
+DRUM Shielding
Schirm 8
X39 1 2 3 4
=SUPL/8.5 / 31_Econ 31_Econ / 40.1 1 2 3 4

WH
0,5
1 GNYE 2 SH
3x0,5
+
-B84 OUT
sensor acceleration left
Sensor Beschleunigung links -
0 1 2 3 4 5 6 7 8 9
Created MFS Funktion == SDR Blatt 39 von 98
Erstellt
14.12.2017
BW 219-226 D, DH, BVC-5 Economizer Higher-level function
=
Anlage MEAS 518
Deutz TCD 4.1_6.1 Tier 4f Economizer Einbauort + EBOX
Geprüft 14.12.2017 EPE / 000 / 00
39.8 / X5.E:12
39.8 / X5.E:15
39.8 / X5.E:4
A161
module CAN Gateway
Modul CAN Gateway
XA161 2 XA161 4 XA161 8 XA161 7 XA161 9

2 4 8 7 9
Power supply (9-30V) Analog Input 1 Analog Input 2 Can high 1 Can low 1
-A161 -A161 A162 -A161 -A161
30 - Vcc 15 AE H1 L1
-A161:2
Power supply Power supply CAN high IN CAN low IN
Stromversorgung Stromversorgung CAN high Eingang CAN low Eingang
Ground CAN high OUT CAN low OUT

Masse CAN high Ausgang CAN low Ausgang
31 - Gnd H2 L2
-A161 -A161 -A161
Ground Can high 2 Can low 2
6 1 3
XA161 6 XA161 1 XA161 3
BW 219 D-5 / BW 219 PD-5

Only at option preliminary setup VM31/VM38
Nur bei Option Vorrüstung VM31/VM38
39.2 / 31_Econ
=COM/16.9 / X5.E:1
=COM/16.9 / X5.E:2
0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
BW 219-226 D, DH, BVC-5 Economizer Higher-level function
=
Anlage MEAS 518
Circuit diagrams

Deutz TCD 4.1_6.1 Tier 4f Economizer Einbauort + EBOX
Geprüft 14.12.2017
873
EPE / 000 / 00
874
=SUPL/9.9 / F22:2 +ARC
S26:13 / 42.0
=SUPL/9.9 / F19:2
=SUPL/10.9 / F05:2
+CAB/49.1
X4.E:9
Circuit diagrams
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
Illumination
X7.C-2 6 Beleuchtung
X22
X7.C-2 6
2 X7.C 6
X6.B 2 4 1
1 X22
+DPL +ROPS
WH WH
1,5 mm² 1,5 mm²
1 1 1 1
E23 E25 E27 E28
12V 55W 2 12V 55W 2 12V 55W 2 12V 55W 2
+ 86 1
XS
BW 219 D-5 / BW 219 PD-5

K06
green
D118
12V / max. 20A 12V/30A 2

- 85
BN
2,5 mm²
X22 2
Splice
Spleiss 87
BN
2,5 mm²
=DRIV+REFR/32.5 / 31_Db 31_Db / 42.0 X4.E 3 6
=VIB/33.8 / Gnd_PB Gnd_PB / 42.0
87
87a 30 =SUPL/9.4
Socket Working headlight, front left Working headlight, rear left Relay, headlights rear
Steckdose Arbeitsscheinwerfer vorne links Arbeitsscheinwerfer hinten links Relais Scheinwerfer hinten
Working headlight, front right Working headlight, rear right
Arbeitsscheinwerfer vorne rechts Arbeitsscheinwerfer hinten rechts
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 14.12.2017 BW 219-226 D, DH, BVC-5 Rops - Lighting, Socket Higher-level function
=
Anlage OPT 518
Geprüft Deutz TCD 4.1_6.1 Tier 4f Rops - Beleuchtung, Steckdose Einbauort + EBOX
14.12.2017 EPE / 000 / 00
=SUPL/9.9 / F07:2
=SUPL/10.9 / F08:2
X4.D 6
=SUPL/9.9 / F11:2 +ARC
+ARC
=SUPL/8.9 / S15:23
=SUPL/8.9 / S15:11
30 13 23 13 23
K16 S14 S37
WH Indicator lights
1,5 mm² /42.3 87a 87 Switch, hazard light 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
41.9 / S26:13
WH +CAB/49.1 X33 8
1,5 mm² X1
H06 X33 8 Wb LE RE 30
X2
X4.D 7 A02
10 1 module flasher
X4.D Modul Blinker
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
X79 5 X82 5 X79 2 X82 2
E13 E12 E14 E15 K16
D16
green
LED 5W 5W LED 12V/20A 1 1 1 1 1 1
BW 219 D-5 / BW 219 PD-5

2 2 2 2 85 2 30
E16 E17 E08 E09 E10 E11
/42.4
55W 2 55W 2 21W 2 21W 2 21W 2 21W 2
X80 4 X81 4
X79 6 X82 6 2 2
X80 X81
BN BN
1,5 mm² 1,5 mm²
41.1 / 31_Db 31_Db

+CAB/48.1
31_Db_2
+REFR
+REFR
=DRIV+SEAT/29.2 X11
31_RFr BN 11 BN Splice
1,5 mm² 1,5 mm² Spleiss
=VIB/33.8 Splice 64
8 BN Spleiss
1,5 mm²
63
41.9 / Gnd_PB Gnd_PB
43.1
Tail light, left Parking light, right Relay, headlights front Headlight, left Indicator, front left Indicator, front right
Schlussleuchte links Parkleuchte rechts Relais Scheinwerfer vorne Scheinwerfer links Blinkleuchte vorne links Blinkleuchte vorne rechts
Parking light, left Tail light, right Headlight, right Indicator, rear left Indicator, rear right
Parkleuchte links Schlussleuchte rechts Scheinwerfer rechts Blinkleuchte hinten links Blinkleuchte hinten rechts
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 14.12.2017 BW 219-226 D, DH, BVC-5 StVZO illumination Higher-level function
=
Anlage OPT 518
Checked
Circuit diagrams

Geprüft Deutz TCD 4.1_6.1 Tier 4f StVZO Beleuchtung Einbauort + EBOX
14.12.2017
875
EPE / 000 / 00
876
=COM/17.8 / CAN1+ CAN1+ / +CAB/49.1
=COM/17.8 / CAN1- CAN1- / +CAB/49.1
42.9 / Gnd_PB Gnd_PB / 45.1
=COM/15.9 / F84:2
Circuit diagrams
=COM/17.8 / F148:2
X7.B 3 2 1 4 6
+DPL
A67
Keyboard
Tastatur
BW 219 D-5 / BW 219 PD-5

X16
1
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 14.12.2017 BW 219-226 D, DH, BVC-5 Electronical Burglary protection Higher-level function
=
Anlage OPT 518
Geprüft Deutz TCD 4.1_6.1 Tier 4f Elektronische Diebstahlsicherung Einbauort + EBOX
14.12.2017 EPE / 000 / 00
RD
=SUPL/9.9 / X400:A 1,5 mm²
=COM/16.9 / A162:L1
=COM/16.9 / A162:H1
WH
=SUPL/10.9 / A162:30 1,5 mm²
WH
1,5 mm²
WH
1,5 mm²
A162
module CAN Gateway 2 4 7 9
Modul CAN Gateway Power supply (9-30V) Analog Input 1 Can high 1 Can low 1
A162 A162 A162 A162
30 - Vcc 15 H1 L1
+DPL-X400:B
Ground CAN high OUT CAN low OUT +DPL

31 - Gnd H2 L2
A162 A162 A162
Ground Can high 2 Can low 2 X400
6 1 3 X110 1 A
WH
1,5 mm²
R33 + Ub pot. 30
1 2 2 WH B
1,5 mm²
+ Ub pot. 15
‎121Ω/0,6W
5 F
CAN low
1 D
R34 CAN high
‎121Ω/0,6W E
2
4 Gnd
BN 3 BN
BW 219 D-5 / BW 219 PD-5

1,5 mm² 1,5 mm²
BN
1,5 mm²
=SUPL/8.7 / A162:31
0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
BW 219-226 D, DH, BVC-5 Interface measurement Higher-level function
=
Anlage OPT 518
Circuit diagrams

Deutz TCD 4.1_6.1 Tier 4f Schnittstelle Messtechnik Einbauort + EBOX
Geprüft 14.12.2017
877
EPE / 000 / 00
878
A124
ECU BOMAG TELEMATIC
ECU BOMAG TELEMATIC
+ARC
T14
antenna BOMAG TELEMATIC
Antenne BOMAG TELEMATIC
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
BW 219 D-5 / BW 219 PD-5

X6.D
8 8
=COM/17.8 / CAN2-_TM X6.D:8 / +MOT/46.0
7
=COM/17.8 / CAN2+_TM X6.D:7 / +MOT/46.0
4
=SUPL/10.9 / F243:2 X6.D:4 / +MOT/46.0
1
=SUPL/10.9 / F244:2
2
=MON/27.1 / D+ X6.D:2 / +MOT/46.0
D+ / +CAB/49.1
5
=ENGI/20.8 / StU_TM
6
=ENGI/19.8 / VIB_TM
3
43.9 / Gnd_PB X6.D:3 / +MOT/46.0
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 14.12.2017 BW 219-226 D, DH, BVC-5 BOMAG Telematics Higher-level function
=
Anlage OPT 518
Geprüft Deutz TCD 4.1_6.1 Tier 4f BOMAG Telematik Einbauort + EBOX
14.12.2017 EPE / 000 / 00
-A175
Electronic system, Morey Telematics
Elektronik Morey Telematik
-A177
ECU ZTR telematics
ECU ZTR Telematik
GPS Diagnostic SAT Cellular
Power
Ground
D+
Can H
Can L
8 10 16 1 2 4 11 12
-XA175 8 10 16 -XA177 1 2 4 11 12
RD WH BK
RD WH BK
-X51 1 3 2
BW 219 D-5 / BW 219 PD-5

+EBOX/45.5 / X6.D:4
fuse MD+
Sicherung MD+
F129
Splice 88 1 2 Splice 89
+EBOX/45.5 / X6.D:2 Spleiss Spleiss
3A
+EBOX/45.5 / X6.D:3
+EBOX/45.5 / X6.D:7
+EBOX/45.5 / X6.D:8
0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
BW 219-226 D, DH, BVC-5 Morey Telematics, ZTR Telematics Higher-level function
=
Anlage OPT 518
Circuit diagrams

Deutz TCD 4.1_6.1 Tier 4f Morey Telematic, ZTR Telematic Einbauort + MOT
Geprüft 14.12.2017
879
EPE / 000 / 00
880
WH
=SUPL+EBOX/10.9 / F103:2 1,5 mm²
WH
=SUPL+EBOX/9.9 / F68:2 2,5 mm²
A B
F320 F321
5A 1 5A 2
Fuse, timer additional heater Fuse, timer additional heater
(potential 30) (potential 15)
Sicherung Schaltuhr Sicherung Schaltuhr
Zusatzheizung (Potential 30) Zusatzheizung (Potential 15)
Circuit diagrams
Start Low Medium High

POWER
Start niedrig Medium Hoch XS28.f 10
Power consumption
Energiebedarf [W] <100 8 16 30 40
12V
E30
heating unit XS28.f XS28.m 0,35RD
Heizgerät 1 1 0,22GYBK -S28 1 Kl 30
0,22GYBK
Kl 30
1 11 11 0,35RD Timer 2 Kl 58
1 0,22BN
S+
4 6 6 Schaltuhr 3 Kl 31
4 0,22BUWH
Temp. (+)
7 9 9 4 Diagnose
7 0,22VT
DIAG
8 8 8 0,22BUWH 5 DAT-Leitung
8 0,35YE
Temp. (-)
6 12 12 0,22BN 6 S+
6 0,22BNYE
PUMP
5 0,22VT 7 ADR
5 0,22WHRD
Kl 31
10 0,35YE 8 ADR
10 0,22BNWH
0,22BNYE 9 Temp. (-)
0,22GY
0,22WHRD 10 Temp. (+)
0,22BNWH
0,22GY
WH
2,5 mm²
4
X207.m X207.f XS28.f 2
1 RD 1 1
1,5 mm²
4 YE 4 4
0,5 mm²
7 GRRD 7 7
0,5 mm²
8 BUYE 8 8
0,5 mm²
6 BNWH 6 6
0,5 mm²
5 GNRD 5 5
1 mm²
10 BN 10 10
1,5 mm²
BW 219 D-5 / BW 219 PD-5

+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 14.12.2017 BW 219-226 D, DH, BVC-5 Cabin - Additional heater Higher-level function
=
Anlage OPT 518
Geprüft Deutz TCD 4.1_6.1 Tier 4f Kabine - Zusatzheizung Einbauort + DPL
14.12.2017 EPE / 000 / 00
+EBOX
=SUPL+EBOX/10.9 / F29:2 WWF / 49.1
=SUPL+EBOX/10.9 / F40:2 WWR / 49.1
X6.C 2 4 X4.B 3 6 X6.B 3 1
WH WH
1,5 mm² 1,5 mm²
30
K09 Splice
Spleiss 9
=SUPL+EBOX/8.7 87 87a
Relay, air conditioning
WH
Relais Klimaanlage 2,5 mm²
+SEAT
+DPL
X1.A 5
A108 -X10 1
Heating climatic unit
Heiz-Klima-Einheit Supply
WH
RD
X87, X99
1,5 mm²
+REFR
X68 1
2
-X68 1
BK BK/GN BK
-B104 1
pressure switch air conditioning P
LP HP Out Gnd
BK/YE
WH WH
-X68 2 1,5 mm² 1,5 mm²
-X10 4 2
X68 2
X87 1 X99 1
WH
1,5 mm²
WH Option
1,5 mm²
3 Option 3
+MOT S29 S25
X12 1
Switch, suspension seat 4 Switch, heating operators seat 4
WH BN Schalter Luftfedersitz Schalter Fahrersitzheizung
X12 1 2 1,5 mm² 2,5 mm²
1 V04
BW 219 D-5 / BW 219 PD-5

Y15 1 + +
3,5A 1
1 1 1 1
XY15.Gnd X6.C
M10
M R06 M06 M07
BN
1,5 mm² 12V / < 9A 12V / 6,85A 2 2 3,5A 3,5A
Delivery equipment Sitz
Lieferumfang Sitz
31_Eng BN - -
1,5 mm² 2
=MON+EBOX/27.8
Only at air conditioning X87 2 X99 2

Nur bei Klimaanlage
BN BN
1,5 mm² 1,5 mm²
=EXC+EBOX/34.2 / 31_Ar
+EBOX/42.3 / 31_Db
Compressor, suspension operators seat Motor, windscreen washer front

Magnetic clutch, air conditioning compressor Kompressor Luftfedersitz Scheibenwaschermotor vorne
Magnetkupplung Klimakompressor Heating, operators seat Motor, windscreen washer rear
Heizung Fahrersitz Scheibenwaschermotor hinten
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 14.12.2017 BW 219-226 D, DH, BVC-5 Cabin - Heating, Air conditioning, Washer pumps Higher-level function
=
Anlage OPT 518
Checked
Circuit diagrams

Geprüft Deutz TCD 4.1_6.1 Tier 4f Kabine - Heizung, Klimaanlage, Wascherpumpen Einbauort + CAB
14.12.2017
881
EPE / 000 / 00
882
+EBOX
X4.E X4.E
14 14
=MEAS+EBOX/38.8 / RxD RxD / 54.6
4 4
=MEAS+EBOX/38.8 / TxD TxD / 54.6
8 8 WH
=MEAS+EBOX/38.8 / 15_GPS 1,5 mm² 15_GPS / 55.0
10 10
Circuit diagrams
=COM+EBOX/16.9 / CAN3+ CAN3+ / 55.0

7 7
=COM+EBOX/16.9 / CAN3- CAN3- / 55.0
11 11
=DRIV+REFR/32.6 / Rev Rev / 56.1
X202 X202 -A178

1 1 9 9 module operator terminal cabin 1 Additional working lights left zusätzliche Arbeitsbeleuchtung links
+EBOX/43.9 / CAN1+
Modul Bedienkonsole Kabine
2 Illumination drum Bandagenbeleuchtung
2 2 10 10
+EBOX/43.9 / CAN1- Start Start
3
17 17 6 6 Stop Stop
+EBOX/45.1 / D+ 4
Print Drucken
DIG In
5
High active
5 5 4 4 Delete Löschen
+EBOX/42.4 / EN_WL 6
Reserve Reserve
DIG In
X7.C-2 X7.C-2 X7.C 7
High active
7 WH 7 7 9 9 WH 5 5 Additional working lights right zusätzliche Arbeitsbeleuchtung rechts
1,5 mm² 1,5 mm² 8
Windscreen wiper front Scheibenwischer vorne
DIG Out
+EBOX/41.2 / X4.E:9
9
10 Windscreen wiper rear Scheibenwischer hinten
15 15 WH 8 8
=SUPL+EBOX/8.9 / 15_CAB 1,5 mm² 15_PB_CAB / 50.1
11 Windscreen wascher front Scheibenwascher vorne
13 13 3 3 Rotary beacon Rundumkennleuchte
48.9 / WWF WWF_PB_CAB / 52.1 12
12 12 1 1 13 Working headlights front Arbeitsscheinwerfer vorne
48.9 / WWR WWR_PB_CAB / 52.1
14 Cabin inside light Kabineninnenbeleuchtung
15 Working headlights rear Arbeitsscheinwerfer hinten

X8.A X8.A X200 X200
BW 219 D-5 / BW 219 PD-5

30 30 RD 30 30 Rear screen heating Heckscheibenheizung
=SUPL+EBOX/8.6 / X8.A 16 mm² 30_PB_CAB / 50.1 16
RADSOK® 8mm Amphenol RADSOK® 6mm
17 Windscreen wascher rear Scheibenwascher hinten
X8.B X8.B X201 X201
31 31 BN BN 31 31
=SUPL+EBOX/8.9 / X8.B 16 mm² 10 mm² GND_PB_CAB / 50.1
RADSOK® 6mm Amphenol RADSOK® 3,6mm
1 8
Optional
Optional
2 7
3 4 5 6
not used
GND_CAB / 51.0 wird nicht genutzt
9 10
1 2 3
-U200
Ground cabin
Masse Kabine
11 12 13 14 15 16 17
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 14.12.2017 BW 219-226 D, DH, BVC-5 Cabin - Supply Higher-level function
=
Anlage OPT 518
Geprüft Deutz TCD 4.1_6.1 Tier 4f Kabine - Versorgung Einbauort + CAB
14.12.2017 EPE / 000 / 00
49.4 / 30_PB_CAB
49.4 / 15_PB_CAB
1 1 1
30 F17 F264 F271
K32 5A 2 10A 2 10A 2
/50.1 87 87a
Relay, cabin
Relais Kabine
Fuse, radio
Fuse, BCM05
Fuse, BCM-Net
Sicherung Radio
Sicherung BCM05
Sicherung BCM-Net
Fuses cabin
Sicherungen Kabine
F271:2 / 55.1
F264:2 / 55.1
F17:2 / 54.1
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
BW 219 D-5 / BW 219 PD-5

Fuse, reserve
terminal cabin
86
Sicherung Reserve
Fuse, GPS receiver
D2.1
Sicherung Controller
Bedienkonsole Kabine
K32
Fuse, controller console

Sicherung GPS Receiver
Fuse, radio / tachograph

green
12V/20A 85
Relay, cabin
Fuse, rear screen heating unit

Sicherung Radio / Tachograph
Relais Kabine
Sicherung Heckscheibenheizung
F279:2 / 52.1
Sicherung Wischer und Wascher vorne

Sicherung Wischer und Wascher hinten
F150:2 / 55.1
Fuse, windscreen wiper and washer rear
Fuse, windscreen wiper and washer front

F266:2 / 54.1
F143:2 / 53.1
49.4 / GND_PB_CAB GND_PB_CAB / 51.0
F28:2 / 53.1
87
87a 30 /50.2 F27:2 / 53.1
F272:2 / 51.0
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 14.12.2017 BW 219-226 D, DH, BVC-5 Cabin - Fuse protection Higher-level function
=
Anlage OPT 518
Checked
Circuit diagrams

Geprüft Deutz TCD 4.1_6.1 Tier 4f Kabine - Absicherung Einbauort + CAB
14.12.2017
883
EPE / 000 / 00
884
A178
/49.5
module operator terminal cabin
Circuit diagrams
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
50.9 / F272:2 E29 E29
Inside light, cabin 2 1 2
Innenleuchte Kabine E72
Illumination, 2
switches
Beleuchtung
Bedienschalter
X206 1 6 2 4 9 X203 2 5 1 4 3 6
BW 219 D-5 / BW 219 PD-5

+ 1 1 1 1
E32 E27 E28 E23 E25
12V 70W - 12V 55W 2 12V 55W 2 12V 55W 2 12V 55W 2
49.3 / GND_CAB GND_CAB / 53.1
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 14.12.2017 BW 219-226 D, DH, BVC-5 Cabin - Lighting Higher-level function
=
Anlage OPT 518
Geprüft Deutz TCD 4.1_6.1 Tier 4f Kabine - Beleuchtung Einbauort + CAB
14.12.2017 EPE / 000 / 00
A178
/49.5
DIG Out DIG Out DIG Out DIG Out DIG Out DIG Out
86 86 86
D2.2 D2.3 D2.4
K141 K20 K21
green green green
12V/20A 85 12V/20A 85 12V/20A 85
Automotive Micro Relay on socket Automotive Micro Relay on socket Automotive Micro Relay on socket
Automotive Mircrorelais auf Sockel Automotive Mircrorelais auf Sockel Automotive Mircrorelais auf Sockel
49.4 / WWF_PB_CAB Relay, heating rear screen Relay, windscreen wiper front Relay, windscreen wiper rear
Relais Heckscheibenheizung Relais Wischer vorne Relais Wischer hinten
49.4 / WWR_PB_CAB
50.9 / F279:2
max. 150 mA
X206 3 7 8
BW 219 D-5 / BW 219 PD-5

87 87 87
87a 30 /53.7 87a 30 /53.3 87a 30 /53.5
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 14.12.2017 BW 219-226 D, DH, BVC-5 Cabin - Cabin equipment Higher-level function
=
Anlage OPT 518
Checked
Circuit diagrams

Geprüft Deutz TCD 4.1_6.1 Tier 4f Kabine - Kabinenausrüstung Einbauort + CAB
14.12.2017
885
EPE / 000 / 00
886
50.9 / F143:2
50.9 / F28:2
50.9 / F27:2
Circuit diagrams
87a 87 87a 87 30
K20 Relay, windscreen wiper front K21 Relay, windscreen wiper rear K141
/52.5 30 Relais Wischer vorne /52.6 30 Relais Wischer hinten /52.3 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
BW 219 D-5 / BW 219 PD-5

[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 14.12.2017 BW 219-226 D, DH, BVC-5 Cabin - Cabin equipment Higher-level function
=
Anlage OPT 518
Geprüft Deutz TCD 4.1_6.1 Tier 4f Kabine - Kabinenausrüstung Einbauort + CAB
14.12.2017 EPE / 000 / 00
50.9 / F266:2
50.9 / F17:2
52.8 / GND_PB_CAB
A178
/49.5
PWM Out PWM Out PWM Out
X205 1 2 3 4 6 5 X202 2
X205 1 2 3 4 6 5
X202:2 / 56.1
Splice
Spleiss 58
Splice
Spleiss 57
49.4 / TxD
Splice
Spleiss 56
49.4 / RxD
XP09.A
1 A1 Splice
antenna radio Spleiss 59
XP09.A P09 -T21 Antenne Radio
2 A2
XP09.A 8 7 4
3 A3 XA12.A
XP09.A XA12.A
5 A5 -A12 8 7 4 5 Ant
31 15 30 Ctrl Ant
XP09.A 12V
BW 219 D-5 / BW 219 PD-5

6 A6 module radio
Modul Radio 1 2 5 4
XP09.C
3 C3
X94 1 2 5 4
A = white
XP09.B B = yellow RxD TxD Gnd Ub
3 B3 P11
C = red
rl+ rl- fl+ fl- fr+ fr- rr+ rr-
XP09.B 7 8 5 6 3 4 1 2
4 B4
XA12.B
Printer
Drucker
Tachograph XA12.B 7 8 1 2
Tachograph
B51.L B51.R
+ -
- +
Speaker radio Speaker radio

Lautsprecher Radio Lautsprecher Radio
AGND Only at VM29-Printer
Nur bei VM29-Drucker
X94 3
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 14.12.2017 BW 219-226 D, DH, BVC-5 Cabin - Radio, Tachograph, Printer measurement Higher-level function
=
Anlage OPT 518
Checked
Circuit diagrams

Geprüft Deutz TCD 4.1_6.1 Tier 4f Kabine - Radio, Tachograph, Drucker Messtechnik Einbauort + CAB
14.12.2017
887
EPE / 000 / 00
888
50.9 / F271:2
50.9 / F150:2
50.9 / F264:2
Circuit diagrams
X204 1 2 3 4
49.4 / 15_GPS
BN BN
1,5 mm² 1,5 mm²
X85 1 X85 2
USB-CAN Interface BCM 3 -A93
A87 USB-CAN Schnittstelle BCM GPS receiver
GPS Receiver
X85 X95.A X91
4 7 1
49.4 / CAN3+ 2
X85 3
4
5 2 2 SH
49.4 / CAN3-
12 6 7 2 11
X211 -X93 C -X97
4 B A A B C D E
Gnd2
2
RxD2
BW 219 D-5 / BW 219 PD-5

3
TxD2
P15 X96.A
BCM05 Ub 1 1 -X210 -X92
Supply
BCM05 Versorgung 1 A
AGnd 1 A
2
Gnd 2
Splice
2 2 B B
Spleiss 200
X90
Gnd1 5 5 3 3 C C
GPS receiver
GPS Receiver 2 4 D
RxD1 2 4 D
3 5 E
TxD1 3 5 E
W10
7x1,0
0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 14.12.2017 BW 219-226 D, DH, BVC-5 BOMAG Compaction Management BCM, GPS Higher-level function
=
Anlage OPT 518
Geprüft Deutz TCD 4.1_6.1 Tier 4f BOMAG Verdichtungsmanagement BCM, GPS Einbauort + CAB
14.12.2017 EPE / 000 / 00
54.8 / X202:2
55.7 / GND_CAB
49.4 / Rev
P42
display back up monitoring
Anzeige Rückraumüberwachung
Pin 1 - 12/24V DC
Pin 2 - Gnd
Pin 3 - Trigger Cam 1
X50.f X50.m Pin 5 - Trigger Cam 3
P32 1 1 RD
camera back up monitoring 2 2 BK
Kamera Rückraumüberwachung 3 3 WH
4 BU
5 BN
CA1 CA1
CA2
CA3
BW 219 D-5 / BW 219 PD-5

0 1 2 3 4 5 6 7 8 9
Function Page from
Erstellt 14.12.2017 BW 219-226 D, DH, BVC-5 Back up monitoring Higher-level function
=
Anlage OPT 518
Checked
Circuit diagrams

Geprüft Deutz TCD 4.1_6.1 Tier 4f Rückraumüberwachung Einbauort + CAB
14.12.2017
889
EPE / 000 / 00
890
Device tag list
Betriebsmittelliste
Higher-level
Device tag Page Path Mounting location characteristics
function
BMK Blatt Pfad Einbauort
Function text Funktionstext Techn.-Kenngrößen
Anlage
A02 42 8 +EBOX module flasher Modul Blinker

Circuit diagrams
A12 54 4 +CAB module radio Modul Radio 12V

A15 14 2 +ARC Monitoring module Überwachungsmodul ---> Pin overview
A34 11 3 +EBOX Driving Controller Fahrsteuerung ---> Pin overview
A48 21 0 +EBOX ECU engine controller ECU Motorsteuergerät
A48-D2.1 23 7 +EBOX
A67 43 5 +DPL Keyboard Tastatur
A83 12 3 +EBOX Measurement controller Messtechnik Steuerung ---> Pin overview
A87 55 2 +CAB USB-CAN Interface BCM USB-CAN Schnittstelle BCM
A93 55 7 +CAB GPS receiver GPS Receiver
A103 39 2 +REFR module ECONOMIZER Modul ECONOMIZER ---> Pin overview
A108 48 2 +CAB Heating climatic unit Heiz-Klima-Einheit
A124 45 3 +EBOX ECU BOMAG TELEMATIC ECU BOMAG TELEMATIC
A161 40 0 +EBOX module CAN Gateway Modul CAN Gateway ---> Pin overview
A162 44 0 +EBOX -"- -"- ---> Pin overview
A175 46 1 +MOT Electronic system, Morey Telematics Elektronik Morey Telematik
A177 46 5 +MOT ECU ZTR telematics ECU ZTR Telematik
B03 27 4 +MOT Maintenance switch, air cleaner Wartungsschalter Luftfilter
B11.1 32 1 +REFR Warning horn Signalhorn max. 3,5A
B11.2 32 4 +REFR -"- -"- max. 3,5A
B11.3 32 1 +REFR -"- -"- max. 3,5A
B11.4 32 5 +REFR -"- -"- max. 3,5A
BW 219 D-5 / BW 219 PD-5

B21 27 5 +REFR Differential pressure switch, hydraulic oil filter Differenzdruckschalter Hydraulikölfilter
B51.L 54 4 +CAB Speaker radio Lautsprecher Radio
B51.R 54 5 +CAB -"- -"-
B55 27 2 +MOT Floating switch, coolant expansion tank Schwimmerschalter Kühlmittelausgleichsbehälter
B57 28 1 +EBOX sensor slope speed range selection Neigungssensor Stufenumschaltung 0,5-4,5V
B59 28 7 +DRUM Speed sensor, drum Drehzahlsensor Bandagengeschwindigkeit
B60 28 4 +REFR Speed sensor, axle Drehzahlsensor Achsgeschwindigkeit
B62 38 1 +DRUM Transducer, acceleration Aufnehmer Beschleunigung
B84 39 5 +DRUM sensor acceleration left Sensor Beschleunigung links
B88 23 4 +MOT EMR engine oil pressure EMR Motoröldruck
B93 23 1 +MOT EMR Fuel pressure rail EMR Kraftstoffdruck Rail
B97 34 5 +DRUM Sensor, adjustable motor Sensor Verstellmotor
B104 48 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
0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
BW 219-226 D, DH, BVC-5 Device tag list Higher-level function
=
Anlage 518
Deutz TCD 4.1_6.1 Tier 4f Betriebsmittelliste Einbauort + DTLE
Geprüft 14.12.2017 EPE / 000 / 00
Device tag list
Betriebsmittelliste
Higher-level
function
Anlage
B124 21 1 +MOT Sensor, water trap fuel Sensor Wasserabscheider Kraftstoff

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
B208 23 8 +MOT EMR Sensor, delta p venturi EMR Sensor Delta p Venturi
B209 23 9 +MOT EMR Sensor, temperature EGR behind venturi EMR Sensor Temperatur EGR nach Venturi
B214 25 2 +MOT EMR Sensor, temperature exhaust gas before oxy cat EMR Temperatursensor Abgas vor Oxy Kat
B215 25 3 +MOT EMR Sensor, temperature exhaust gas after oxy cat EMR Temperatursensor Abgas nach Oxy Kat
B216 25 3 +MOT EMR Sensor, differential pressure DPF EMR Sensor Differenzdruck DPF
B218 21 3 +MOT Temperature sensor, ambient temperature Temperatursensor Umgebungstemperatur
B221 25 5 +REFR Sensor, urea pressure behind pump Sensor, Ureadruck nach Pumpe
B222 24 5 +MOT Sensor, urea temperature and level Sensor Ureatemperatur und Füllstand
B223 25 2 +MOT Temperature sensor, exhaust gas before SCR kat Temperatursensor Abgas vor SCR Kat
B224 24 6 +MOT Sensor, NOx before SCR-Kat Sensor NOx vor SCR-Kat
B225 24 8 +MOT Sensor, NOx behind SCR-Kat Sensor NOx nach SCR-Kat
B234 30 2 +PUMP Pressure sensor, travel pump axle MA Drucksensor Fahrpumpe Achse MA
B235 30 3 +PUMP Pressure sensor, travel pump axle MB Drucksensor Fahrpumpe Achse MB
B236 30 4 +PUMP Pressure sensor, travel pump drum MA Drucksensor Fahrpumpe Bandage MA
B237 30 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
B305 25 1 +MOT EMR Pressure sensor, pressure after DPF EMR Drucksensor, Druck nach DPF
BW 219 D-5 / BW 219 PD-5

B312 36 5 +REFR Sensor, height adjustment plates Sensor Höhenverstellung Platten 4...20mA
B313 36 6 +REFR Sensor, lateral adjustment plates Sensor Seitenverstellung Platten 4...20mA
D2.1 50 1 +CAB Indicator light, relay K32 Meldeleuchte Relais K32 green
D05 29 9 +EBOX Indicator light, relay K05 Meldeleuchte Relais K05 green
0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
=
Anlage 518
Circuit diagrams

Geprüft 14.12.2017
891
EPE / 000 / 00
892
Device tag list
Betriebsmittelliste
Higher-level
function
Anlage
Circuit diagrams
Dx 9 1 +EBOX Indicator light, fuse test Meldeleuchte Sicherungstest green
E08 42 7 +DPL Indicator, front left Blinkleuchte vorne links 21W
E09 42 8 +REFR Indicator, rear left Blinkleuchte hinten links 21W
E10 42 8 +DPL Indicator, front right Blinkleuchte vorne rechts 21W
E11 42 8 +REFR Indicator, rear right Blinkleuchte hinten rechts 21W
E12 42 1 +DPL Parking light, left Parkleuchte links 5W
E13 42 1 +REFR Tail light, left Schlussleuchte links LED
E14 42 2 +DPL Parking light, right Parkleuchte rechts 5W
E15 42 2 +REFR Tail light, right Schlussleuchte rechts LED
E16 42 4 +DPL Headlight, left Scheinwerfer links 55W
E17 42 5 +DPL Headlight, right Scheinwerfer rechts 55W
E23 41 3 +ROPS Working headlight, front left Arbeitsscheinwerfer vorne links 12V 55W
E23 51 8 +CAB -"- -"- 12V 55W
E25 41 3 +ROPS Working headlight, front right Arbeitsscheinwerfer vorne rechts 12V 55W
E25 51 9 +CAB -"- -"- 12V 55W
E27 41 4 +ROPS Working headlight, rear left Arbeitsscheinwerfer hinten links 12V 55W
E27 51 7 +CAB -"- -"- 12V 55W
BW 219 D-5 / BW 219 PD-5

E28 41 4 +ROPS Working headlight, rear right Arbeitsscheinwerfer hinten rechts 12V 55W
E28 51 8 +CAB -"- -"- 12V 55W
E29 51 1 +CAB Inside light, cabin Innenleuchte Kabine
E30 47 0 +DPL heating unit Heizgerät 12V
E32 51 6 +CAB Rotary beacon Rundumkennleuchte 12V 70W
E72 51 2 +CAB Illumination, switches Beleuchtung Bedienschalter
E104 26 6 +MOT Heating, pressure line Heizung Druckleitung
E105 26 5 +MOT Heating, suction line Heizung Saugleitung
E106 26 5 +MOT Heating, return flow line Heizung Rücklaufleitung
E107 25 8 +REFR Heating, supply modul Heizung Versorgungsmodul ???W
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 42 1 +EBOX Fuse, parking and tail light left Sicherung Park- und Schlussleuchte links 10A
0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
=
Anlage 518
Geprüft 14.12.2017 EPE / 000 / 00
Device tag list
Betriebsmittelliste
Higher-level
function
Anlage
F10 42 2 +EBOX Fuse, parking and tail light right Sicherung Park- und Schlussleuchte rechts 10A
F11 9 7 +EBOX Fuse, headlight left Sicherung Scheinwerfer links 15A
F13 9 1 +EBOX Fuse, ignition switch Sicherung Startschalter 15A
F17 50 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 50 4 +CAB Fuse, windscreen wiper and washer front Sicherung Wischer und Wascher vorne 15A
F28 50 4 +CAB Fuse, windscreen wiper and washer rear Sicherung Wischer und Wascher hinten 15A
F29 10 7 +EBOX Fuse, compressor suspension seat Sicherung Kompressor Luftfedersitz 15A
F39 8 6 +EBOX Fuse, main cabin Hauptsicherung Kabine 80A
F40 10 6 +EBOX Fuse, heating unit cabin Sicherung Kabinenheizung 30A
F48 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
F122 10 2 +EBOX Fuse, engine controller Sicherung Motorsteuerung 10A
F124 10 5 +EBOX Fuse, fuel-pre-heating Sicherung Kraftstoffvorheizung 25A
BW 219 D-5 / BW 219 PD-5

F129 46 5 +MOT fuse MD+ Sicherung MD+ 3A
F143 50 5 +CAB Fuse, rear screen heating unit Sicherung Heckscheibenheizung 20A
F150 50 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
F238 26 3 +BAT Fuse, exhaust gas recirculation Sicherung Abgasrückführung 15A
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
F250 26 2 +BAT Fuse, SCR control Sicherung SCR Ansteuerung 30A
F251 26 2 +BAT Fuse, NOx sensors Sicherung NOx Sensoren 10A
F264 50 4 +CAB Fuse, BCM05 Sicherung BCM05 10A
F266 50 5 +CAB Fuse, radio / tachograph Sicherung Radio / Tachograph 10A
0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
=
Anlage 518
Circuit diagrams

Geprüft 14.12.2017
893
EPE / 000 / 00
894
Device tag list
Betriebsmittelliste
Higher-level
function
Anlage
F268 9 8 +EBOX Fuse, fuel pump Sicherung Kraftstoffpumpe 20A

Circuit diagrams
F271 50 5 +CAB Fuse, BCM-Net Sicherung BCM-Net 10A

F272 50 3 +CAB Fuse, controller console terminal cabin Sicherung Controller Bedienkonsole Kabine 5A
F279 50 6 +CAB Fuse, reserve Sicherung Reserve 15A
F310 26 3 +BAT Fuse, sensor urea quality Sicherung Sensor Ureaqualität 5A
F312 26 1 +BAT Fuse, reserve Sicherung Reserve max. 20A
F313 26 2 +BAT -"- -"- max. 20A
F320 47 5 +DPL Fuse, timer additional heater (potential 30) Sicherung Schaltuhr Zusatzheizung (Potential 30) 5A
Fx 9 1 +EBOX Fuseholder, fuse test Sicherungshalter Sicherungstest
FM1 13 2 +EBOX Fuse, sensors Sicherung Sensoren 1A
FM2 13 5 +EBOX -"- -"- 1A
G01 8 2 +BAT Battery Batterie 12V / 88Ah
G02 8 5 +MOT Generator Generator 14V / 150A
H06 42 6 +ARC Indicator light, hazard light Meldeleuchte Warnblinker
H07 27 7 +ARC Warning buzzer, breakdown Warnsummer Betriebsstörung 70mA
H14 32 6 +REFR Back-up alarm buzzer Warnsummer Rückwärtsfahrt 300mA
K05 29 8 +EBOX Relay, starting current Relais Startstrom 12V/20A
K06 41 5 +EBOX Relay, headlights rear Relais Scheinwerfer hinten 12V/30A
K09 8 7 +EBOX Relay, air conditioning Relais Klimaanlage 12V/20A
K11 8 8 +EBOX Relay, potential 30 on 15 Relais Potential 30 auf 15 12V
BW 219 D-5 / BW 219 PD-5

K13 32 8 +EBOX Relay, warning horn Relais Signalhorn 12V/20A
K14.1 18 1 +MOT Relay, glow plug system Relais Vorglühen
K16 42 3 +EBOX Relay, headlights front Relais Scheinwerfer vorne 12V/20A
K20 52 5 +CAB Relay, windscreen wiper front Relais Wischer vorne 12V/20A
K21 52 6 +CAB Relay, windscreen wiper rear Relais Wischer hinten 12V/20A
K22 32 9 +EBOX Relay, shut off solenoid engine Relais Hubmagnet Abschaltung Motor 12V/20A
K32 50 1 +CAB Relay, cabin Relais Kabine 12V/20A
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/20A
K43 33 4 +EBOX Relay, vibration Relais Vibration 12V/20A
K48 29 9 +EBOX Relay, travel lever 0-position Relais, Fahrhebel 0-Stellung 12V/20A
K61 8 6 +EBOX Relay, charge control Relais Ladekontrolle 12V/20A
K141 52 3 +CAB Relay, heating rear screen Relais Heckscheibenheizung 12V/20A
K145 20 8 +EBOX Relay, solenoid starter Relais Hubmagnet Starter 12V/40A
0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
=
Anlage 518
Geprüft 14.12.2017 EPE / 000 / 00
Device tag list
Betriebsmittelliste
Higher-level
function
Anlage
K192 26 7 +BAT Relay, SCR control Relais, SCR Ansteuerung 12V

K193 26 8 +BAT Relay, heating urea feed-in modul Relais Heizung Urea-Einspeisemodul 12V
K194 26 8 +BAT Relay, heating urea suction hose Relais Heizung Urea-Saugleitung 12V
K195 26 9 +BAT Relay, heating urea restriction hose Relais Heizung Urea-Drosselleitung 12V
K196 26 9 +BAT Relay, heating urea pressure hose Relais Heizung Urea-Druckleitung 12V
K209 20 4 +EBOX Relay, fuel pump Relais Kraftstoffpumpe 12V/30A
K227 26 6 +BAT Relay, potential 30 on 15 Relais Potential 30 auf 15 12V
M01 8 4 +MOT Starter Starter
M04 53 3 +CAB Motor, windscreen wiper front Scheibenwischermotor vorne 4,7A
M05 53 5 +CAB Motor, windscreen wiper rear Scheibenwischermotor hinten 4,7A
M06 48 8 +DPL Motor, windscreen washer front Scheibenwaschermotor vorne 3,5A
M07 48 9 +DPL Motor, windscreen washer rear Scheibenwaschermotor hinten 3,5A
M10 48 6 +SEAT Compressor, suspension operators seat Kompressor Luftfedersitz 12V / < 9A
M41 25 7 +REFR Urea pump Urea Pumpe
M57 47 5 +MOT pump fuel heating unit Pumpe Kraftstoff Heizgerät
P09 54 3 +CAB Tachograph Tachograph
P11 54 6 +CAB Printer Drucker
P15 55 1 +CAB BCM05 BCM05
P32 56 1 +CAB camera back up monitoring Kamera Rückraumüberwachung
P42 56 5 +CAB display back up monitoring Anzeige Rückraumüberwachung
P43 36 4 +PLA Operating hour meter plates Betriebsstundenzähler Platten
R03 27 8 +REFR Sender, level gauge Geber Tankanzeige ‎66 Ω / 64,2 Ω
BW 219 D-5 / BW 219 PD-5

R06 48 7 +SEAT Heating, operators seat Heizung Fahrersitz 12V / 6,85A
R10 8 6 +EBOX Parallel resistor Parallelwiderstand ‎82Ω / 22W
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
R28 17 6 +EBOX -"- -"- ‎120 Ω
R29 17 6 +EBOX -"- -"- ‎120 Ω
R30 21 9 +EBOX -"- -"- ‎120 Ω
R31 24 8 +EBOX -"- -"- ‎120Ω
0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
=
Anlage 518
Circuit diagrams

Geprüft 14.12.2017
895
EPE / 000 / 00
896
Device tag list
Betriebsmittelliste
Higher-level
function
Anlage
R32 24 1 +EBOX Terminating resistor CAN Abschlußwiderstand CAN ‎120Ω

Circuit diagrams
R33 44 4 +EBOX -"- -"- ‎121Ω/0,6W

R34 44 6 +EBOX -"- -"- ‎121Ω/0,6W
R79 18 8 +MOT Fuel-pre-heater Kraftstoffvorheizung 200W
R80 53 7 +CAB Rear window heater Heizung Heckscheibe ca. 11 A
S00 8 7 +ARC switch ignition Schalter Motorstart
S01 9 4 +ARC Switch, emergency off Schalter NOT AUS
S06 28 3 +SEAT Switch, seat contact Sitzkontaktschalter
S09 29 5 +SEAT Switch, vibration front Schalter Vibration vorne
S14 42 5 +ARC Switch, hazard light Warnblinkschalter
S15 42 2 +ARC Switch, lighting StVZO Schalter Beleuchtung StVZO
S25 48 7 +SEAT Switch, heating operators seat Schalter Fahrersitzheizung
S26 41 5 +ARC Switch, working lights Schalter Arbeitsbeleuchtung
S28 47 7 +DPL Timer Schaltuhr
S29 48 6 +SEAT Switch, suspension seat Schalter Luftfedersitz
S30 8 3 +BAT Disconnect switch, battery Batterietrennschalter 250A
S35 29 7 +ARC Switch, vibration low / high Schalter Vibration klein / gross
S36 29 5 +SEAT Switch, vibration plates Schalter Vibration Anbauplatten
S37 42 8 +ARC Switch, indicator Schalter Blinker
S42 29 0 +ARC Switch, speed range selector Schalter Fahrstufen 4..20mA / 0-5V
S55 14 8 +SEAT Travel lever Fahrhebel
S64 29 6 +SEAT Pushbutton, float position plates Taster Schwimmstellung Anbauplatten
BW 219 D-5 / BW 219 PD-5

S107 34 2 +SEAT switch amplitude adjustment Schalter Amplitudenverstellung 4...20mA
S127 19 2 +ARC Switch, engine speed Schalter Motordrehzahl
S139 29 4 +SEAT Potentiometer, frequency plates Potentiometer Frequenzverstellung Anbauplatten
S299 19 4 +ARC Switch, regeneration mode Schalter Regenerationsmodus
T14 45 5 +ARC antenna BOMAG TELEMATIC Antenne BOMAG TELEMATIC
T21 54 5 +CAB antenna radio Antenne Radio
U200 49 2 +CAB Ground cabin Masse Kabine
U300 8 3 +MOT Ground engine Masse Motor
U500 8 2 +BAT Ground rear frame Masse Hinterrahmen
U600 8 3 +EBOX Ground Central Electric Masse Zentralelektrik
V01 8 6 +EBOX diode Diode S5G-E3
V02 32 2 +REFR -"- -"- SF 64
V03 32 3 +REFR -"- -"- SF 64
V04 48 2 +MOT -"- -"- SF 64
V05 42 7 +ARC -"- -"- SF 64
0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
=
Anlage 518
Geprüft 14.12.2017 EPE / 000 / 00
Device tag list
Betriebsmittelliste
Higher-level
function
Anlage
V06 42 7 +ARC diode Diode SF 64

V07 28 5 +EBOX -"- -"- S1M
V08 28 5 +EBOX -"- -"- S1M
V09 28 7 +EBOX -"- -"- S1M
V10 28 7 +EBOX -"- -"- S1M
Y04 31 7 +REFR Solenoid valve, brake Magnetventil Bremse 2,41A
Y07 33 5 +PUMP Solenoid valve, vibration front high Magnetventil Vibration vorne gross 640...1580mA
Y08 33 6 +PUMP Solenoid valve, vibration front low Magnetventil Vibration vorne klein 640...1580mA
Y15 48 1 +MOT Magnetic clutch, air conditioning compressor Magnetkupplung Klimakompressor 3,5A
Y16 31 1 +PUMP Solenoid valve, travel direction forward Magnetventil Fahrtrichtung vorwärts 640...1580mA
Y17 31 2 +PUMP Solenoid valve, travel direction backward Magnetventil Fahrtrichtung rückwärts 640...1580mA
Y30 31 8 +REFR Solenoid valve, speed range selection drum Magnetventil Fahrstufe Bandage 2,41A
Y30 31 9 +DRUM -"- -"- 1,05A
Y31 31 5 +REFR Solenoid valve, speed range selection axle Magnetventil Fahrstufe Achse 1,05A
Y60 37 5 +REFR Solenoid valve, floating position Magnetventil Schwimmstellung
Y98 36 7 +MOT Solenoid valve, vibration pump plates Magnetventil Vibrationspumpe Platten 400-1200mA
Y102 35 4 +DRUM Solenoid valve, floating position Magnetventil Schwimmstellung
Y122 37 1 +REFR Solenoid valve, lift plates Magnetventil Platten heben
Y123 37 2 +REFR Solenoid valve, let down plates Magnetventil Platten senken
Y137 23 0 +MOT EMR Actuator EMR Stellglied
BW 219 D-5 / BW 219 PD-5

Y140 34 7 +DRUM Solenoid valve, exciter up Magnetventil Erreger auf 400-1200mA
Y141 34 8 +DRUM Solenoid valve, exciter down Magnetventil Erreger ab 400-1200mA
Y142 37 3 +REFR Solenoid valve, plate displace left Magnetventil Plattenverschieben links
Y143 37 3 +REFR Solenoid valve, plate displace right Magnetventil Plattenverschieben rechts
Y144 37 5 +REFR Solenoid valve, plate floating position Magnetventil Platten Schwimmstellung
Y145 37 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
Y291 25 6 +REFR Solenoid valve, urea extraction Magnetventil Urea Absaugung
0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
=
Anlage 518
Circuit diagrams

Geprüft 14.12.2017
897
EPE / 000 / 00
898
Device tag list
Betriebsmittelliste
Higher-level
function
Anlage
Y292 25 8 +REFR Solenoid valve, urea tank heating Magnetventil Ureatank Heizung
Circuit diagrams
Y293 25 5 +MOT Solenoid valve, urea dosing Magnetventil Ureadosierung

Y378 35 3 +DRUM Solenoid valve, dozer blade priority Magnetventil Planierschild Priorität
Y379 35 5 +DRUM Solenoid valve, lift dozer blade Magnetventil Planierschild heben
Y380 35 6 +DRUM Solenoid valve, lower dozer blade Magnetventil Planierschild senken
BW 219 D-5 / BW 219 PD-5

0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
=
Anlage 518
Geprüft 14.12.2017 EPE / 000 / 00
Pin overview
Pin Übersicht
Monitoring module
A15 Überwachungsmodul
X33 2 27 8 ‎0...140Ω Fuel level Tankfüllstand

X33 1 ‎0...1500 Ω
X33 3 27 7 +UB, max 1,5A Warning buzzer, breakdown Warnsummer Betriebsstörung
X33 4 19 5 +UB, max 1,5A Vibration Telematics Vibration Telematik
X33 5 41 7 active high Illumination Beleuchtung
X33 6 configuration Pin RXD
X33 7 configuration Pin TXD
X33 8 42 7 active high Indicator lights Blinker
X33 9 19 1 active high Switch, engine speed Sx. 1 Schalter Motordrehzahl Sx. 1
X33 11 19 3 active high Switch, regeneration Sy. 1 Schalter Regeneration Sy. 1
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 high
X33 22 16 2 CAN low CAN low CAN low
BW 219 D-5 / BW 219 PD-5

X33 23 active low
X33 24 active high
0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
BW 219-226 D, DH, BVC-5 Pin overview A15 Higher-level function
=
Anlage 518
Circuit diagrams

Deutz TCD 4.1_6.1 Tier 4f Pin Übersicht A15 Einbauort + PINO
Geprüft 14.12.2017
899
EPE / 000 / 00
900
Pin overview
Pin Übersicht
Driving Controller
A34 Fahrsteuerung
Circuit diagrams
X35 1 13 2 AGND AGND Analogmasse

X35 2 31 5 OUT10 / 2,5A curr.-feedb. Travel motor axle Fahrmotor Achse
X35 3 31 8 OUT12 / 2,5A curr.-feedb. Travel motor drum Fahrmotor Bandage
X35 4 RxD_1
X35 5 TxD_1
X35 6 30 2 AIN1 / 10V 25mA Pressure sensor, travel pump axle MA Drucksensor Fahrpumpe Achse MA
X35 7 30 3 AIN3 / 10V 25mA Pressure sensor, travel pump axle MB Drucksensor Fahrpumpe Achse MB
X35 8 36 5 AIN5 / 10V 25mA Sensor, height adjustment plates Sensor Höhenverstellung Platten
X35 9 27 1 AIN7 / 10V 25mA D+ Alternator D+ Generator
X35 10 36 6 DIN18 / 0..32V Plate pump enable Freigabe Plattenpumpe
X35 11 35 4 OUT20 / 2,5A curr.-feedb. Floating position dozer blade Schwimmstellung Planierschild
X35 12 28 5 DIN2 / 0..32V, DRZ Speed axle Geschwindigkeit Achse
X35 13 28 4 DIN4 / 0..32V Direction axle Drehrichtung Achse
X35 14 29 8 DIN6 / 0..32V BTS brake BTS Bremse
X35 15 28 3 DIN8 / 0..32V Seat contact Sitzkontakt
X35 16 28 4 DIN10 / 0..32V, DRZ Proximity switch, arm rest right Näherungsinitiator Armlehne rechts
X35 17 28 7 DIN12 / 0..32V Direction drum Drehrichtung Bandage
X35 18 DIN14 / 0..32V, DRZ
X35 19 DIN16 / 0..32V, DRZ
X35 20 31 3 OUT14 / 4A curr.-measur. Travel pump drum forward Fahrpumpe Bandage vorwärts
X35 21 31 4 OUT16 / 4A curr.-measur. Travel pump drum backward Fahrpumpe Bandage rückwarts
X35 22 36 7 OUT18 / 4A curr.-measur. Vibration pump plates Vibrationspumpe Platten
BW 219 D-5 / BW 219 PD-5

X35 23 13 2 8.5VEXT 8,5V Sensor Power 8,5V Sensor Spannung
X35 24 32 9 OUT9 / 2,5A curr.-feedb. Relay, shut off solenoid engine Relais Hubmagnet Abschaltung Motor
X35 25 32 8 OUT11 / 2,5A curr.-feedb. Warning horn Signalhorn
X35 26 15 3 CAN1_L CAN 1 low CAN 1 low
X35 27 15 2 CAN1_H CAN 1 high CAN 1 high
X35 28 11 1 +Ignition / 0..32V Ignition Zündung
X35 29 30 4 AIN2 / 10V 25mA Pressure sensor, travel pump drum MA Drucksensor Fahrpumpe Bandage MA
X35 30 30 4 AIN4 / 10V 25mA Pressure sensor, travel pump drum MB Drucksensor Fahrpumpe Bandage MB
X35 31 36 6 AIN6 / 10V 25mA Sensor, lateral adjustment plates Sensor Seitenverstellung Platten
X35 32 28 2 AIN8 / 10V 25mA Slope sensor Neigungssensor
X35 34 33 3 DIN1 / 0..32V, DRZ Speed vibration drum Drehzahl Vibration Bandage
X35 35 28 6 DIN3 / 0..32V, DRZ Speed drum Geschwindigkeit Bandage
X35 36 27 3 DIN5 / 0..32V Water in Fuel Wasserabscheider
X35 37 27 5 DIN7 / 0..32V Hydraulic oil filter Hydraulikölfilter
0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
=
Anlage 518
Geprüft 14.12.2017 EPE / 000 / 00
Pin overview
Pin Übersicht
Driving Controller
A34 Fahrsteuerung
X35 38 27 4 DIN9 / 0..32V Maintenance switch, air cleaner Wartungsschalter Luftfilter

X35 39 27 2 DIN11 / 0..32V Coolant level Kühlmittelfüllstand
X35 40 DIN13 / 0..32V, DRZ
X35 41 DIN15 / 0..32V, DRZ
X35 42 35 5 OUT13 / 4A curr.-measur. Dozer blade up Planierschild anheben
X35 43 35 6 OUT15 / 4A curr.-measur. Dozer blade down Planierschild absenken
X35 44 OUT17 / 4A curr.-measur.
X35 45 37 5 OUT19 / 2,5A curr.-feedb. Floating position plates Schwimmstellung Anbauplatten
X35 46 31 1 OUT1 / 4A curr.-measur. Travel pump axle forward Fahrpumpe Achse vorwärts
X35 47 31 2 OUT2 / 4A curr.-measur. Travel pump axle backward Fahrpumpe Achse rückwärts
X35 48 33 4 OUT3 / 4A curr.-measur. Vibration pump low/high Vibrationspumpe klein/groß
X35 49 33 5 OUT4 / 4A curr.-measur. Vibration pump PWM Vibrationspumpe PWM
X35 50 35 7 OUT21 / 5A curr.-feedb. Adjustment left plates Verschiebung links Platten
X35 51 35 8 OUT22 / 5A curr.-feedb. Adjustment right plates Verschiebung rechts Platten
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 -"- -"-
BW 219 D-5 / BW 219 PD-5

X35 60 11 6 +UB / 0..32V -"- -"-
X35 61 32 6 OUT6 / 4A Back-up alarm buzzer Warnsummer Rückwärtsfahrt
X35 62 35 3 OUT7 / 2,5A curr.-feedb. Dozer blade priority Planierschild Priorität
X35 63 36 4 OUT8 / 2,5A curr.-feedb. Hour meter plates Stundenzähler Platten
X35 64 31 7 OUT5 / 4A curr.-measur. Valve brake Ventil Bremse
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
Erstellt
14.12.2017
=
Anlage 518
Circuit diagrams

Geprüft 14.12.2017
901
EPE / 000 / 00
902
Pin overview
Pin Übersicht
Measurement controller
A83 Messtechnik Steuerung
Circuit diagrams
X88 1 13 6 AGND AGND Analogmasse

X88 2 OUT10 / 2,5A curr.-feedb.
X88 4 38 6 RxD_1 RxD Printer RxD Drucker
X88 5 38 7 TxD_1 TxD Printer TxD Drucker
X88 6 AIN1 / 10V 25mA
X88 7 38 3 AIN3 / 10V 25mA Transducer Acceleration rear 20g Beschleunigungsaufn. hinten 20g
X88 8 AIN5 / 10V 25mA
X88 9 34 5 AIN7 / 10V 25mA Sensor, adjustable motor Sensor Verstellmotor
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 25 38 8 OUT11 / 2,5A curr.-feedb. Power supply GPS Spannungsversorgung GPS
BW 219 D-5 / BW 219 PD-5

X88 28 12 1 +Ignition / 0..32V Ignition Zündung
X88 29 38 2 AIN2 / 10V 25mA Transducer Acceleration front 15g Beschleunigungsaufn. vorne 15g
X88 30 38 4 AIN4 / 10V 25mA Transducer Acceleration rear 15g Beschleunigungsaufn. hinten 15g
X88 31 38 1 AIN6 / 10V 25mA Transducer Acceleration front 20g Beschleunigungsaufn. vorne 20g
X88 32 34 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
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 34 8 OUT1 / 4A curr.-measur. Exciter down Erreger ab
0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
=
Anlage 518
Geprüft 14.12.2017 EPE / 000 / 00
Pin overview
Pin Übersicht
Measurement controller
A83 Messtechnik Steuerung
X88 47 34 7 OUT2 / 4A curr.-measur. Exciter up Erreger auf

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 34 9 OUT6 / 4A Exciter priority Erreger Priorität
X88 66 12 7 GND -"- -"-
X88 67 12 8 GND -"- -"-
X88 68 12 9 GND -"- -"-
BW 219 D-5 / BW 219 PD-5

0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
=
Anlage 518
Circuit diagrams

Geprüft 14.12.2017
903
EPE / 000 / 00
904
Pin overview
Pin Übersicht
module ECONOMIZER
A103 Modul ECONOMIZER
Circuit diagrams
XA103 1 39 4 CAN low CAN low CAN low

XA103 2 39 5 CAN high CAN high CAN high
XA103 4 0...5V
XA103 5 39 5 0...5V Transducer acceleration Beschleunigungsaufnehmer
XA103 6 39 4 +5V supply Sensors Supply 5V sensors Versorgung 5V Sensoren
XA103 7 Power supply (8...32V)
XA103 8 +UB
XA103 10 active high
XA103 11 active high
XA103 13 39 1 Power supply (8...32V) Power supply Stromversorgung
XA103 24 39 6 Ground Ground Masse
XA103 25 39 7 Ground -"- -"-
XA103 26 39 1 Ground -"- -"-
BW 219 D-5 / BW 219 PD-5

0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
=
Anlage 518
Geprüft 14.12.2017 EPE / 000 / 00
Pin overview
Pin Übersicht
module CAN Gateway
A161 Modul CAN Gateway
1 40 6 Can high 2 CAN high OUT CAN high Ausgang

2 40 2 Power supply (9-30V) Power supply Stromversorgung
3 40 6 Can low 2 CAN low OUT CAN low Ausgang
4 40 3 Analog Input 1 Power supply Stromversorgung
5 LIN Bus (optional)
6 40 2 Ground Ground Masse
7 40 6 Can high 1 CAN high IN CAN high Eingang
8 Analog Input 2
9 40 6 Can low 1 CAN low IN CAN low Eingang
BW 219 D-5 / BW 219 PD-5

0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
=
Anlage 518
Circuit diagrams

Geprüft 14.12.2017
905
EPE / 000 / 00
906
Pin overview
Pin Übersicht
module CAN Gateway
A162 Modul CAN Gateway
Circuit diagrams
1 44 4 Can high 2 CAN high OUT CAN high Ausgang

2 44 2 Power supply (9-30V) Power supply Stromversorgung
3 44 5 Can low 2 CAN low OUT CAN low Ausgang
4 44 3 Analog Input 1 Power supply Stromversorgung
5 LIN Bus (optional)
6 44 2 Ground Ground Masse
7 44 4 Can high 1 CAN high IN CAN high Eingang
8 40 4 Analog Input 2
9 44 5 Can low 1 CAN low IN CAN low Eingang
BW 219 D-5 / BW 219 PD-5

0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
=
Anlage 518
Geprüft 14.12.2017 EPE / 000 / 00
Pin overview
Pin Übersicht
Travel lever
S55 Fahrhebel

X23 3 29 9 BTS signal "Brake catch" BTS brake BTS Bremse
X23 4 BTS signal "warning horn"
(prepared)
X23 5 29 3 Output voltage supply Supply analog selectors Versorgung Analoge Wahlschalter
"+5V"
X23 6 16 4 CAN bus high
X23 7 16 5 CAN bus low CAN low CAN low
X23 8 29 2 Ground / 0V / reference Ground analog selectors Masse Analoge Wahlschalter
to PIN 5
X23 9 14 6 Adressing 1 Ground Masse
X23 10 14 7 Adressing 2 -"- -"-
X23 11 29 1 Analog IN 1 Switch, speed range selector 2 Schalter Fahrstufen 2
X23 12 29 4 Analog IN 2 Frequency adjustment plates Frequenzverstellung Anbauplatten
X24 1 29 7 Digital IN 1 Switch, vibration low/off (on/off) Schalter Vibration klein/aus (an/aus)
X24 2 29 8 Digital IN 2 Switch, vibration off/high Schalter Vibration aus/groß
X24 3 29 6 Digital IN 3 Floating position plates Schwimmstellung Anbauplatten
X24 4 29 5 Digital IN 4 Vibration plates Vibration Anbauplatten
X24 5 Digital IN 5
X24 6 Digital IN 6
X24 7
BW 219 D-5 / BW 219 PD-5

Output supply voltage
+Ub
"ground" (0V)
0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
BW 219-226 D, DH, BVC-5 Pin overview S55 Higher-level function
=
Anlage 518
Circuit diagrams

Deutz TCD 4.1_6.1 Tier 4f Pin Übersicht S55 Einbauort + PINO
Geprüft 14.12.2017
907
EPE / 000 / 00
908
Plug overview
Steckerübersicht
Circuit diagrams

16 1 13 1
Kabelbaum Kabelbaum Kabelbaum EMR Kabelbaum
Page Path Page Path Page Path 18 12 9 3 Page Path 15 9 3
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
30 8 4 1 10 8 1 20 2 1 28 4
2 20 2 2 32 6
Stecker -X0.A Einbauort +EBOX Stecker -X1.A Einbauort +EBOX 4 4 28 5
Function text Plug, supply potential 30 Function text Plug, access harness engine 5 5
Funktionstext Stecker Versorgung Potential 30 Funktionstext Stecker Anschluß Kabelbaum Motor 6 6
Plug type Plug type 7 7 31 7
Amphenol RADSOK® 8mm AMP Junior Power Timer 9 pole blue
Steckertyp Steckertyp 8 8
7 1
Kabelbaum Kabelbaum Motor 10 20 7 10 30 2
Page Path Page Path 9 6 3 11 11
Contact
Kontakt
Contact
Kontakt
1 8 5 1 13 20 7 13
2 14 20 4 14 28 5
Stecker -X0.B Einbauort +EBOX 4 16 20 5
Function text Plug, supply ground 17 Plug Mounting location
5 48 1 -X2.A +EBOX
Funktionstext Stecker Versorgung Masse 18 20 8 Stecker Einbauort
6
Plug type Function text Plug, access harness rear frame
7 8 6
8 18 8 -X1.B +EBOX
Kabelbaum
Stecker -X1.A Einbauort +EBOX Plug type Kabelbaum
Contact
Kontakt
Blatt Pfad AMP Junior Power Timer 18 pole blue
31 8 6 Wire harness
Contact
Kontakt
Funktionstext Stecker Anschluß Kabelbaum Motor Blatt Pfad

Plug type Kabelbaum
Plug Mounting location AMP Junior Power Timer 9 pole blue
1 28 4
Stecker -X0.B +EBOX Steckertyp Page Path 2 32 6
Einbauort
BW 219 D-5 / BW 219 PD-5

Contact
Kontakt
Function text Plug, supply ground
Funktionstext Stecker Versorgung Masse Kabelbaum 1 20 2 4 28 5
Contact
Kontakt
Steckertyp Blatt Pfad 3 20 2 6
Wire harness 1 9 2 4 20 7 7 31 7
Kabelbaum 2 9 2 5 20 2 8
Page Path 3 18 6 6 20 3 9 28 5
7 20 8 10 30 2
Contact
Kontakt
Blatt Pfad 4 20 5
5 48 1 8 20 3 11
1 8 6 9 20 5 12 28 4
6 18 6
7 8 6 10 20 7 13 28 5
Stecker -X0.C +EBOX 8 18 8 11 20 6 14 28 5
Einbauort
9 18 8 12 20 6 15 27 8
13 20 7
14 20 4
Plug type
Steckertyp
16 20 5
Wire harness
17 20 5
Kabelbaum
18 20 8
Page Path
Contact
Kontakt
Blatt Pfad
30 10 8
0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
BW 219-226 D, DH, BVC-5 Plug overview Higher-level function
=
Anlage 518
Deutz TCD 4.1_6.1 Tier 4f Steckerübersicht Einbauort + PLGO
Geprüft 14.12.2017 EPE / 000 / 00
Plug overview
Steckerübersicht
Stecker -X2.B Einbauort +EBOX Stecker -X4.A Einbauort +EBOX Stecker -X4.B Einbauort +EBOX Stecker -X4.D Einbauort +EBOX
Function text Plug, access harness StvZO illumination hinten Function text Plug, access harness dashboard Function text Plug, access harness console seat Function text Plug, access harness StvZO illumination front
Funktionstext Stecker Anschluß Kabelbaum StvZO Beleuchtung rear Funktionstext Stecker Anschluß Kabelbaum Bedienpult Funktionstext Stecker Anschluß Kabelbaum Konsole Sitz Funktionstext Stecker Anschluß Kabelbaum StvZO Beleuchtung vorne
AMP Junior Power Timer 6 pole green AMP Junior Power Timer 21 pole grey AMP Junior Power Timer 9 pole grey AMP Junior Power Timer 12 pole grey
4 1 19 1 7 1
Kabelbaum Kabelbaum Kabelbaum Kabelbaum
Page Path 6 3 Page Path 21 12 3 Page Path 9 6 3 Page Path
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
1 42 8 18 14 1 5 1 42 2
2 42 1 19 9 4 6 48 7 2 42 8
3 42 2 20 8 8 7 14 6 3 42 7
4 42 8 21 31 7 8 34 2 4
5 9 29 8 5 42 8
6 Plug Mounting location 6 42 8
Stecker -X4.A Einbauort +EBOX Plug Mounting location 7 42 4
Plug Mounting location Function text Plug, access harness dashboard Stecker -X4.B Einbauort +EBOX 8 42 9
Stecker -X2.B Einbauort +EBOX Funktionstext Stecker Anschluß Kabelbaum Bedienpult Function text Plug, access harness console seat 9 42 2
Function text Plug, access harness StvZO illumination hinten Plug type Funktionstext Stecker Anschluß Kabelbaum Konsole Sitz 10 42 2
AMP Junior Power Timer 21 pole grey
Funktionstext Stecker Anschluß Kabelbaum StvZO Beleuchtung rear Steckertyp Plug type 11 42 8
Plug type Wire harness Steckertyp 12 42 1
AMP Junior Power Timer 6 pole green
Steckertyp Kabelbaum Wire harness
Wire harness Page Path Kabelbaum Plug Mounting location
Kabelbaum Stecker -X4.E Einbauort +EBOX
Contact
Kontakt
Blatt Pfad Page Path
Contact
Kontakt
Page Path Blatt Pfad Function text Plug, access cabin and rops
1 10 2
Funktionstext Stecker Anschluß Kabine und Rops
Contact
Kontakt
Blatt Pfad 2 32 3 1 16 4
Plug type
1 42 8 3 8 8 2 28 3 AMP Junior Power Timer 18 pole grey
Steckertyp
2 42 1 4 42 8 3 48 7
3 42 2 5 27 8 4 16 5 Wire harness
16 1
Kabelbaum
4 42 8 6 42 8 5
Page Path 18 12 9 3
5 7 31 7 6 48 7
Contact
Kontakt
6 8 7 14 6 Blatt Pfad
9 8 7 8 34 2 1 49 2
Plug Mounting location 10 9 4 9 29 8 2 49 2
Stecker -X4.A Einbauort +EBOX 11 42 3 3 41 3
Function text Plug, access harness dashboard 12 10 2 Plug Mounting location 4 49 2
Funktionstext Stecker Anschluß Kabelbaum Bedienpult 13 8 7 Stecker -X4.D Einbauort +EBOX 5 49 2
BW 219 D-5 / BW 219 PD-5

Plug type 14 16 2 Function text Plug, access harness StvZO illumination front 6 41 4
Steckertyp 15 41 5 Funktionstext Stecker Anschluß Kabelbaum StvZO Beleuchtung vorne 7 49 2
Wire harness 16 19 5 Plug type 8 49 2
19 1 AMP Junior Power Timer 12 pole grey
Kabelbaum 17 16 2 Steckertyp 9 49 2
Page Path 21 12 3 18 14 1 Wire harness 10 49 2
10 1
Kabelbaum
Contact
Kontakt
Blatt Pfad 19 9 4 11 49 2
20 8 8 Page Path 12 9 6 3 12 49 2
1 10 2
Contact
Kontakt
2 32 3 21 31 7 Blatt Pfad 13 49 2
3 8 8 1 42 2 14 49 2
Plug Mounting location 15 49 2
4 42 8 -X4.B +EBOX 2 42 8
Stecker Einbauort 16 41 3
5 27 8 3 42 7
Function text Plug, access harness console seat 17 49 2
6 42 8 4
Funktionstext Stecker Anschluß Kabelbaum Konsole Sitz 18 41 4
7 31 7 5 42 8
Plug type
8 AMP Junior Power Timer 9 pole grey 6 42 8
Steckertyp
9 8 7 7 42 4
10 9 4 Wire harness 8 42 9
7 1
Kabelbaum
11 42 3 9 42 2
Page Path 9 6 3
12 10 2 10 42 2
Contact
Kontakt
13 8 7 Blatt Pfad 11 42 8
14 16 2 1 16 4 12 42 1
15 41 5 2 28 3
16 19 5 3 48 7
17 16 2 4 16 5
0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
=
Anlage 518
Circuit diagrams

Geprüft 14.12.2017
909
EPE / 000 / 00
910
Plug overview
Steckerübersicht
Stecker -X4.E Einbauort +EBOX Stecker -X5.A Einbauort +EBOX Stecker -X5.B Einbauort +EBOX Stecker -X5.E Einbauort +EBOX
Function text Plug, access cabin and rops Function text Plug, access harness driving controller 1 Function text Plug, access harness driving controller 2 Function text Plug, access harness measurement controller
Funktionstext Stecker Anschluß Kabine und Rops Funktionstext Stecker Anschluß Kabelbaum Fahrsteuerung 1 Funktionstext Stecker Anschluß Kabelbaum Fahrsteuerung 2 Funktionstext Stecker Anschluß Kabelbaum Messtechnik Steuerung
AMP Junior Power Timer 18 pole grey AMP Junior Power Timer 21 pole brown AMP Junior Power Timer 12 pole brown AMP Junior Power Timer 15 pole brown
Circuit diagrams

Page Path Page Path Page Path Page Path
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
1 49 1 1 28 8 1 33 6 3 38 7
2 49 1 2 28 7 2 4 12 1
3 41 3 3 11 3 3 33 6 5 38 6
4 49 1 4 13 2 4 6 12 3
5 49 1 5 32 6 5 28 5 7 38 1
6 41 4 6 15 4 6 28 4 8 38 8
7 49 1 7 35 2 7 9 13 5
8 49 1 8 8 33 4 10 35 2
9 49 1 9 15 5 9 33 5 11 34 5
10 49 1 10 27 1 10 28 3 12 15 7
11 49 1 11 11 13 12 2
12 49 1 12 15 2 12 14 34 2
13 49 1 13 13 2 15 15 6
14 49 1 14 29 8 Plug Mounting location
15 49 1 15 15 3 Stecker -X5.E Einbauort +EBOX Plug Mounting location
16 41 3 16 28 7 Function text Plug, access harness measurement controller Stecker -X5.E2 Einbauort +EBOX
17 49 1 17 32 9 Funktionstext Stecker Anschluß Kabelbaum Messtechnik Steuerung Function text Plug, access harness measurement controller
18 41 4 18 11 2 Plug type Funktionstext Stecker Anschluß Kabelbaum Messtechnik Steuerung
AMP Junior Power Timer 15 pole brown
19 11 1 Steckertyp Plug type
Plug Mounting location 20 32 8 Wire harness Steckertyp
-X5.A +EBOX 13 1
Stecker Einbauort 21 31 7 Kabelbaum Wire harness
13 1
Function text Plug, access harness driving controller 1 Page Path 15 9 3 Kabelbaum
Funktionstext Stecker Anschluß Kabelbaum Fahrsteuerung 1 Plug Mounting location 15 9 3
Contact
Kontakt
Plug type Stecker -X5.B Einbauort +EBOX
Contact
Kontakt
AMP Junior Power Timer 21 pole brown 1 16 7 Blatt Pfad

Steckertyp Function text Plug, access harness driving controller 2
2 16 8 1 16 7
Wire harness Funktionstext Stecker Anschluß Kabelbaum Fahrsteuerung 2
19 1
3 38 7 2 16 8
Kabelbaum Plug type
AMP Junior Power Timer 12 pole brown 4 12 1 3 38 7
Page Path 21 12 3 Steckertyp
5 38 6 4 12 1
BW 219 D-5 / BW 219 PD-5

Contact
Kontakt
Blatt Pfad Wire harness 6 12 3 5 38 6
10 1
Kabelbaum
1 28 8 7 38 1 6 12 3
Page Path 12 9 6 3
2 28 7 8 38 8 7 38 1
Contact
Kontakt
3 11 3 Blatt Pfad 9 13 5 8 38 8
4 13 2 1 33 6 10 9 13 5
5 32 6 2 11 34 5 10
6 15 4 3 33 6 12 15 7 11 34 5
7 4 13 12 2 12 15 7
8 5 28 5 14 34 2 13 12 2
9 15 5 6 28 4 15 15 6 14 34 2
10 27 1 7 15 15 6
11 8 33 4 Plug Mounting location
14 29 8 11 Funktionstext Stecker Anschluß Kabelbaum Messtechnik Steuerung Function text Plug, access harness measurement controller
15 15 3 12 Plug type Funktionstext Stecker Anschluß Kabelbaum Messtechnik Steuerung
17 32 9 Wire harness Steckertyp
18 11 2 Kabelbaum Wire harness
1
19 11 1 Page Path Kabelbaum
3 9 15
Contact
Kontakt
20 32 8 Blatt Pfad Page Path

Contact
Kontakt
21 31 7 1 16 7 Blatt Pfad
2 16 8 1 16 7
0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
=
Anlage 518
Geprüft 14.12.2017 EPE / 000 / 00
Plug overview
Steckerübersicht
Stecker -X5.E2 Einbauort +EBOX Stecker -X6.B Einbauort +EBOX Stecker -X6.C Einbauort +EBOX Stecker -X7.A Einbauort +EBOX
Function text Plug, access harness measurement controller Function text Plug, access sockets Function text Plug, access harness heating-climatic unit Function text Plug, access CAN Gateways
Funktionstext Stecker Anschluß Kabelbaum Messtechnik Steuerung Funktionstext Stecker Anschluß Bordsteckdosen Funktionstext Stecker Anschluß Kabelbaum Heiz-Klimamodul Funktionstext Stecker Anschluß CAN Gateways
AMP Junior Power Timer 15 pole brown AMP Junior Power Timer 2 - 4 pole black AMP Junior Power Timer 2 - 6 pole black AMP Junior Power Timer 12 pole yellow
2 6 1
1 10
1 5 12 9 6 3
Page Path 3 9 15 Page Path Page Path Page Path
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
2 16 8 1 48 9 5 1
3 38 7 2 41 1 6 2
4 12 1 3 48 8 3 17 4
5 38 6 4 41 1 Plug Mounting location 4 17 4
6 12 3 Stecker -X6.D Einbauort +EBOX 5 17 4
7 38 1 Plug Mounting location Function text Plug, access telematics 6 17 4
8 38 8 Stecker -X6.B Einbauort +EBOX Funktionstext Stecker Anschluß Telematik 7 17 6
9 13 5 Function text Plug, access sockets Plug type 8 17 5
AMP Junior Power Timer 2 - 8 pole black
10 Funktionstext Stecker Anschluß Bordsteckdosen Steckertyp 9 17 6
11 34 5 Plug type Wire harness 10 17 7
AMP Junior Power Timer 2 - 4 pole black 2 8
12 15 7 Steckertyp Kabelbaum 11
1 7
13 12 2 Wire harness Page Path 12
Kabelbaum
Contact
Kontakt
14 34 2 Blatt Pfad
15 15 6 Page Path Plug Mounting location
1 -X7.A +EBOX
Stecker Einbauort
Contact
Kontakt
Blatt Pfad 2 45 2
Plug Mounting location Function text Plug, access CAN Gateways
-X5.E3 +EBOX 1 48 9 3 45 2
Stecker Einbauort Funktionstext Stecker Anschluß CAN Gateways
2 41 1 4 45 2
Function text Plug, access harness measurement controller Plug type
3 48 8 5 45 2 AMP Junior Power Timer 12 pole yellow
Funktionstext Stecker Anschluß Kabelbaum Messtechnik Steuerung Steckertyp
4 41 1 6 45 2
Plug type Wire harness
AMP Junior Power Timer 15 pole brown 7 45 2
Steckertyp Kabelbaum
Wire harness Stecker -X6.C Einbauort +EBOX Page Path
13 1
Kabelbaum Economizer
Contact
Kontakt
Function text Plug, access harness heating-climatic unit Plug Mounting location Blatt Pfad
Page Path 15 9 3 -X6.D +EBOX
Funktionstext Stecker Anschluß Kabelbaum Heiz-Klimamodul Stecker Einbauort 1 17 2
Contact
Kontakt
Blatt Pfad Plug type Function text Plug, access telematics 2 17 2
1 16 7 Steckertyp Funktionstext Stecker Anschluß Telematik 3 17 4
2 16 8 Wire harness Plug type 4 17 4
2 6 AMP Junior Power Timer 2 - 8 pole black
3 Kabelbaum Steckertyp 5 17 4
BW 219 D-5 / BW 219 PD-5

1 5
4 12 1 Page Path Wire harness 6 17 4
Kabelbaum
Contact
Kontakt
5 Blatt Pfad 7 17 6
6 1 48 3 Page Path 8 17 5
Contact
Kontakt
7 2 48 3 Blatt Pfad 9 17 6
8 3 1 45 2 10 17 7
9 4 48 3 2 45 2 11
10 5 3 45 2 12
11 6 4 45 2
12 15 8 Plug Mounting location
5 45 2 -X7.B +EBOX
13 Stecker Einbauort
14 Stecker -X6.C Einbauort +EBOX 7 45 2 Function text Plug, access keyboard electronical burglary protection
15 15 7 Funktionstext Stecker Anschluß Tastatur elektronische Diebstahlsicherung
Function text Plug, access harness heating-climatic unit 8 45 2
Funktionstext Stecker Anschluß Kabelbaum Heiz-Klimamodul Plug type
AMP Junior Power Timer 6 pole yellow
Steckertyp
Plug type
AMP Junior Power Timer 2 - 6 pole black Wire harness
Steckertyp
4 1
Kabelbaum
Wire harness
Page Path 6 3
Kabelbaum
Contact
Kontakt
Page Path Blatt Pfad
Contact
Kontakt
Blatt Pfad 1 43 3
1 48 3 2 43 3
2 48 3 3 43 3
3 4 43 3
4 48 3 5
0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
=
Anlage 518
Circuit diagrams

Geprüft 14.12.2017
911
EPE / 000 / 00
912
Plug overview
Steckerübersicht
Stecker -X7.B Einbauort +EBOX Stecker -X7.C Einbauort +EBOX Stecker -X7.C-2 Einbauort +EBOX Stecker -X7.D Einbauort +EBOX
Function text Plug, access keyboard electronical burglary protection Function text Plug, additional options Function text Plug, additional options Function text Plug, access diagnosis Interface Bomag
Funktionstext Stecker Anschluß Tastatur elektronische Diebstahlsicherung Funktionstext Stecker Zusatzoptionen Funktionstext Stecker Zusatzoptionen Funktionstext Stecker Anschluß Diagnosesteckdose Bomag
AMP Junior Power Timer 6 pole yellow AMP Junior Power Timer 2 - 14 pole black AMP Junior Power Timer 2 - 14 pole black AMP Junior Power Timer 15 pole yellow
Circuit diagrams
Wire harness Wire harness Wire harness 1 13 Wire harness

4 1
2 14
Page Path 6 3 Page Path Page Path Page Path
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
6 1 9 2 2 10 1 2 15 1
2 10 1 3 10 1 3 15 5
Stecker -X7.B Einbauort +EBOX 4 8 7 5 8 6 5 15 2
Function text Plug, access keyboard electronical burglary protection 5 8 6 6 41 6 6 15 4
Funktionstext Stecker Anschluß Tastatur elektronische Diebstahlsicherung 6 41 6 7 49 0 7 15 3
Plug type 7 49 1 8 8 15 8
Steckertyp 8 9 9
Wire harness 9 10 28 6 10 15 2
Kabelbaum 10 28 6 11 28 5 11 15 6
Page Path 11 28 5 12 31 6 12
Contact
Kontakt
Blatt Pfad 12 31 6 13 15 2 13 15 1
1 43 3 13 15 2 14 15 4 14
2 43 3 14 15 4 15 15 1
3 43 3 -X7.D +EBOX
Plug Mounting location Stecker Einbauort Plug Mounting location
4 43 3 -X7.C-2 +EBOX -X8.A +EBOX
Stecker Einbauort Function text Plug, access diagnosis Interface Bomag Stecker Einbauort
5
Function text Plug, additional options Funktionstext Stecker Anschluß Diagnosesteckdose Bomag Function text Plug, access supply cabin potential 30
6 43 3
Funktionstext Stecker Zusatzoptionen Plug type Funktionstext Stecker Anschluß Kabine Potential 30
Plug type Steckertyp Plug type
Plug Mounting location AMP Junior Power Timer 2 - 14 pole black Amphenol RADSOK® 8mm
Stecker -X7.C +EBOX Steckertyp Wire harness Steckertyp
Einbauort 1
Kabelbaum 13
Function text Plug, additional options Wire harness 2 14
Wire harness
Kabelbaum Page Path 15 9 3 Kabelbaum
Funktionstext Stecker Zusatzoptionen
1 13
Contact
Kontakt
Plug type Page Path Blatt Pfad Page Path
Contact
Kontakt
Contact
Kontakt
Steckertyp Blatt Pfad 1 Blatt Pfad

Wire harness 2 14
1 9 2 2 15 1 30 49 2
Kabelbaum 2 10 1 3 15 5
1 13
Page Path 3 10 1 4 Plug Mounting location
BW 219 D-5 / BW 219 PD-5

Stecker -X8.A Einbauort +EBOX
Contact
Kontakt
Blatt Pfad 4 8 7 5 15 2
5 8 6 6 15 4 Function text Plug, access supply cabin potential 30
1 9 2
6 41 6 7 15 3 Funktionstext Stecker Anschluß Kabine Potential 30
2 10 1
7 49 1 8 15 8 Plug type
3 Amphenol RADSOK® 8mm
8 9 Steckertyp
4 8 7
5 9 10 15 2 Wire harness
10 28 6 11 15 6 Kabelbaum
6
7 11 28 5 12 Page Path
Contact
Kontakt
8 12 31 6 13 15 1 Blatt Pfad
9 13 15 2 14 30 49 1
10 14 15 4 15 15 1
11 Plug Mounting location
Plug Mounting location Plug Mounting location Stecker -X8.B Einbauort +EBOX
12 -X7.C-2 +EBOX -X7.D +EBOX
Stecker Einbauort Stecker Einbauort
13 Function text Plug, access supply cabin potential 31
Function text Plug, additional options Function text Plug, access diagnosis Interface Bomag Funktionstext Stecker Anschluß Kabine Potential 31
14
Funktionstext Stecker Zusatzoptionen Funktionstext Stecker Anschluß Diagnosesteckdose Bomag
Plug type
Plug type Plug type Amphenol RADSOK® 6mm
AMP Junior Power Timer 2 - 14 pole black AMP Junior Power Timer 15 pole yellow Steckertyp
Steckertyp Steckertyp
Wire harness
Wire harness 1 13 Wire harness Kabelbaum
Kabelbaum Kabelbaum
2 14
Page Path
Page Path Page Path
Contact
Kontakt
Blatt Pfad
Contact
Kontakt
Contact
Kontakt
Blatt Pfad Blatt Pfad

31 49 2
1 9 2 1
0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
=
Anlage 518
Geprüft 14.12.2017 EPE / 000 / 00
Plug overview
Steckerübersicht
Stecker -X8.B Einbauort +EBOX Stecker -X11 Einbauort +REFR Stecker -X14 Einbauort +SEAT Stecker -X22 Einbauort +EBOX
Function text Plug, access supply cabin potential 31 Function text Plug, connection rear frame - engine module Function text Plug, seat contact switch Function text Plug, access rotary beacon ROPS
Funktionstext Stecker Anschluß Kabine Potential 31 Funktionstext Stecker Verbindung Hinterrahmen - Motormodul Funktionstext Stecker Sitzkontaktschalter Funktionstext Stecker Anschluß Rundumkennleuchte ROPS
Amphenol RADSOK® 6mm Deutsch DT 12 pole Deutsch DT 3 pole FASTIN-FASTON TAB housing 2 way
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
31 49 1 10 42 8 A 28 3 1 41 2
11 42 1 B 28 3 2 41 2
Plug Mounting location 12 C
Stecker -X10 Einbauort +CAB Plug Mounting location
Function text Plug, heating climatic unit Plug Mounting location Plug Mounting location Stecker -X23 Einbauort +SEAT
Funktionstext Stecker Heiz-Klima-Einheit Stecker -X11 Einbauort +REFR Stecker -X16 Einbauort +DPL Function text Plug, supply travel lever
Plug type Function text Plug, connection rear frame - engine module Function text Plug, keyboard electronical burglary protection Funktionstext Stecker Vorsorgung Fahrhebel
AMP HDSCS 4 pole Code A
Steckertyp Funktionstext Stecker Verbindung Hinterrahmen - Motormodul Funktionstext Stecker Tastatur Elektronische Diebstahlsicherung Plug type
Deutsch DT 12 pole Code A
Wire harness Plug type Plug type Steckertyp
Deutsch DT 4 pole
Kabelbaum Steckertyp Steckertyp Wire harness
Page Path Wire harness Wire harness Kabelbaum
Kabelbaum Kabelbaum
Contact
Kontakt
Contact
Kontakt
1 48 3 Page Path Page Path Blatt Pfad
Contact
Kontakt
Contact
Kontakt
2 48 4 Blatt Pfad Blatt Pfad 1 14 6
3 1 27 8 1 43 5 2 14 5
4 48 3 2 27 8 2 43 5 3 29 9
3 3 43 5 4
Stecker -X10 Einbauort +CAB 5 6 16 4
Function text Plug, heating climatic unit 6 42 1 Plug Mounting location 7 16 5
Funktionstext Stecker Heiz-Klima-Einheit 7 42 8 Stecker -X20 Einbauort +DRUM 8 29 2
Plug type 8 42 1 Function text Plug, transducer acceleration front 9 14 6
Steckertyp 9 42 2 Funktionstext Stecker Beschleunigungsaufnehmer vorne 10 14 7
Deutsch DT 4 pole
Page Path 12 Wire harness
Kabelbaum Plug
Contact
Kontakt
Blatt Pfad Mounting location
Plug Mounting location Page Path Stecker -X24 Einbauort +SEAT
1 48 3
BW 219 D-5 / BW 219 PD-5

Stecker -X12 Einbauort +MOT
Contact
Kontakt
Blatt Pfad Function text Plug, IO´s travel lever
2 48 4
Function text Plug, compressor air conditioning Funktionstext Stecker Ein-/Ausgänge Fahrhebel
3 1 38 1
Funktionstext Stecker Kompressor Klimaanlage Plug type
4 48 3 2 38 2 Deutsch DT 8 pole
Plug type Steckertyp
Circular connector 4,6mm 3 38 2
Steckertyp Wire harness
Stecker -X11 Einbauort +REFR Wire harness Kabelbaum
Function text Plug, connection rear frame - engine module Kabelbaum Motor Plug Page Path
Mounting location
-X21 +DRUM
Contact
Kontakt
Funktionstext Stecker Verbindung Hinterrahmen - Motormodul Page Path Stecker Einbauort Blatt Pfad
Contact
Kontakt
Plug type Blatt Pfad Function text Plug, transducer acceleration rear 1 29 7
Deutsch DT 12 pole
Steckertyp 1 48 1 Funktionstext Stecker Beschleunigungsaufnehmer hinten 2 29 8
Wire harness Plug type 3 29 6
Deutsch DT 4 pole
Kabelbaum Plug Mounting location Steckertyp 4 29 5
Page Path Stecker -X12 Einbauort +MOT Wire harness 5
Kabelbaum
Contact
Kontakt
Blatt Pfad Function text Plug, compressor air conditioning 6
Funktionstext Stecker Kompressor Klimaanlage Page Path 7
1 27 8
Plug type
Contact
Kontakt
2 27 8 Circular connector 4,6mm

Blatt Pfad 8
Steckertyp
3 31 7 1 38 3
Kabelbaum
5 31 7 3 38 4
6 42 1 Page Path 4 38 3
Contact
Kontakt
7 42 8 Blatt Pfad
8 42 1 1 48 1
9 42 2
0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
=
Anlage 518
Circuit diagrams

Geprüft 14.12.2017
913
EPE / 000 / 00
914
Plug overview
Steckerübersicht
Stecker -X25 Einbauort +REFR Stecker -X26 Einbauort +SEAT Stecker -X29 Einbauort +REFR Stecker -X31 Einbauort +REFR
Function text Plug, access double pump Function text Plug, potentiometer frequency plates Function text Plug, access lifting unit plates Function text Plug, boost module SCR-System
Funktionstext Stecker Anschluß Doppelpumpe Funktionstext Stecker Potentiometer Frequenzverstellung Anbauplatten Funktionstext Stecker Anschluß Hubwerk Platten Funktionstext Stecker Fördermodul SCR-System
Deutsch DTM 8 pole AMP Mateń´loc 3 pole white Deutsch DTM 6 pole AMP HDSCS 12 pole
Circuit diagrams

Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
6 31 3 1 29 4 1 36 7 2 25 6
1 30 2 2 29 4 2 36 6 3 25 6
2 30 3 3 29 4 3 36 6 4 25 5
3 30 4 4 36 4 5 25 8
4 30 4 Plug Mounting location 5 36 6 6 25 8
5 30 2 Stecker -X27 Einbauort +PLA 6 36 6 8 25 7
7 31 3 Function text Plug, quick connect coupling plates 9 25 7
8 31 4 Funktionstext Stecker Schnellverschlußkupplung Platten Plug Mounting location 10 25 7
Plug type Stecker -X29 Einbauort +REFR 11 25 6
Plug Mounting location Steckertyp Function text Plug, access lifting unit plates 12 25 6
Stecker -X25 Einbauort +REFR Wire harness Funktionstext Stecker Anschluß Hubwerk Platten
Function text Plug, access double pump Kabelbaum Plug type Plug Mounting location
Deutsch DTM 6 pole -X33 +ARC
Funktionstext Stecker Anschluß Doppelpumpe Page Path Steckertyp Stecker Einbauort
Plug type
Contact
Kontakt
Blatt Pfad Wire harness Function text Plug, monitoring module
Deutsch DTM 8 pole
Steckertyp Kabelbaum Funktionstext Stecker Überwachungsmodul
1 36 5
Wire harness Page Path Plug type
2 36 5 AMP Superseal 26 pole
Kabelbaum Steckertyp
Contact
Kontakt
3 36 4 Blatt Pfad
Page Path 1 36 7 Wire harness
Kabelbaum
Contact
Kontakt
Blatt Pfad Plug Mounting location 2 36 6
1 30 2 Stecker -X28 Einbauort +REFR 3 36 6 Page Path
Contact
Kontakt
2 30 3 Function text Plug, sensor height adjustment plates 4 36 4 Blatt Pfad

3 30 4 Funktionstext Stecker Sensor Höhenverstellung Platten 5 36 6 1
4 30 4 Plug type 6 36 6 2 27 8
Deutsch DTM 3 pole
5 30 2 Steckertyp 3 27 7
6 31 3 Wire harness Plug Mounting location 4 19 5
7 31 3 Kabelbaum Stecker -X30 Einbauort +REFR 5 41 7
8 31 4 Page Path Function text Plug, backup alarm buzzer 6
Funktionstext Stecker Rückfahrwarnsummer
Contact
Kontakt
Blatt Pfad 7
BW 219 D-5 / BW 219 PD-5

Plug Mounting location Plug type 8 42 7
-X26 +SEAT 1 36 5 Deutsch DT 2 pole
Stecker Einbauort Steckertyp 9 19 1
2 36 5
Function text Plug, potentiometer frequency plates Wire harness 10 19 2
3 36 5
Funktionstext Stecker Potentiometer Frequenzverstellung Anbauplatten Kabelbaum 11 19 3
Plug type Plug Page Path 12 19 4
AMP Mateń´loc 3 pole white Mounting location
Steckertyp -X28 +REFR
Contact
Kontakt
Stecker Einbauort Blatt Pfad 13
Wire harness Function text Plug, sensor height adjustment plates 1 32 6 14
Kabelbaum Funktionstext Stecker Sensor Höhenverstellung Platten 15
2 32 6
Page Path Plug type 16
Deutsch DTM 3 pole
Contact
Kontakt
Blatt Pfad Steckertyp Plug Mounting location 17
1 29 4 Wire harness Stecker -X30 Einbauort +REFR 18
2 29 4 Kabelbaum Function text Plug, backup alarm buzzer 19
3 29 4 Page Path Funktionstext Stecker Rückfahrwarnsummer 20
Plug type 21 16 2
Contact
Kontakt
Blatt Pfad Deutsch DT 2 pole
Steckertyp 22 16 2
1 36 5 23
2 36 5 Wire harness
Kabelbaum 24
3 36 5 25 14 1
Page Path
26 14 1
Contact
Kontakt
Blatt Pfad
1 32 6
2 32 6
0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
=
Anlage 518
Geprüft 14.12.2017 EPE / 000 / 00
Plug overview
Steckerübersicht
Stecker -X34 Einbauort +EBOX Stecker -X35 Einbauort +EBOX Stecker -X36 Einbauort +MOT Stecker -X39 Einbauort +DRUM
Function text Diagnosis interface BOMAG Function text Plug, ECU propulsion Function text Plug, access sensors exhaust aftertreatment Function text Plug, transducer Economizer
Funktionstext Diagnosesteckdose BOMAG Funktionstext Stecker ECU Fahrantrieb Funktionstext Stecker Anschluß Sensoren Abgasnachbehandlung Funktionstext Stecker Aufnehmer Economizer
Burndy 19 pole AMP 68 pole AMP MCP 39 pole (green) Deutsch DTM 4 pole
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
A 15 2 22 36 7 3 25 2 1 39 5
B 15 3 23 13 2 4 25 3 2 39 5
C 15 4 24 32 9 5 25 4 3 39 6
D 15 5 25 32 8 8 25 1 4 39 6
E 15 6 26 15 3 9 25 1
F 15 8 27 15 2 10 25 1 Plug Mounting location
G 28 11 1 11 26 7 Stecker -X41 Einbauort +EBOX
H 29 30 4 13 24 8 Function text Plug, access external supply engine
J 15 2 30 30 4 14 25 4 Funktionstext Stecker Anschluß externe Versorgung Motor
K 31 36 6 15 25 3 Plug type
AMP MCP 2.8 39 pole
L 32 28 2 16 25 6 Steckertyp
M 33 15 5 18 25 2 Wire harness
N 15 1 34 33 3 19 25 2 Kabelbaum
P 15 1 35 28 6 20 26 9 Page Path
Contact
Kontakt
R 15 1 36 27 3 21 26 9 Blatt Pfad
S 37 27 5 22 25 5 1 22 8
T 38 27 4 23 26 8 2 22 8
U 39 27 2 24 25 6 3 22 8
V 40 25 25 8 6 22 8
41 28 25 4 28 24 1
Plug Mounting location 42 35 5 29 25 6
-X35 +EBOX 29 24 1
Stecker Einbauort 43 35 6 30 25 6 32 25 1
Function text Plug, ECU propulsion 44 31 26 8 33 25 1
Funktionstext Stecker ECU Fahrantrieb 45 37 5 32 26 8 34 25 1
Plug type 46 31 1 33 25 5
AMP 68 pole 35 24 8
Steckertyp 47 31 2 34 26 7 36 24 8
Wire harness 48 33 4 35 25 7 38 24 1
Kabelbaum 49 33 5 36 25 7 39 24 1
BW 219 D-5 / BW 219 PD-5

Page Path 50 35 7 37 24 8
Contact
Kontakt
Blatt Pfad 51 35 8 38 24 5 Plug Mounting location
1 13 2 52 39 24 5 Stecker -X44 Einbauort +EBOX
2 31 5 53 15 4 Function text Plug, engine-controller motor-part
54 11 2 Plug Mounting location Funktionstext Stecker Motorsteuergerät Motorseite
3 31 8 -X39 +DRUM
55 11 5 Stecker Einbauort
4 Plug type
56 11 3 Function text Plug, transducer Economizer Bosch 105 pole
5 Steckertyp
57 11 4 Funktionstext Stecker Aufnehmer Economizer
6 30 2 Wire harness
58 11 5 Plug type Kabelbaum
7 30 3 Deutsch DTM 4 pole
59 11 6 Steckertyp
8 36 5 Page Path
60 11 6 Wire harness
Contact
Kontakt
9 27 1 Blatt Pfad
61 32 6 Kabelbaum Aufnehmer Economizer
10 36 6 1
11 35 4 62 35 3 Page Path
2 23 7
Contact
Kontakt
12 28 5 63 36 4 Blatt Pfad
64 31 7 3 26 7
13 28 4 1 39 5 4 26 8
14 29 8 65 11 6 2 39 5
66 11 7 5 25 6
15 28 3 3 39 6 6
16 28 4 67 11 8 4 39 6
68 11 9 7
17 28 7 8 23 9
18 9 25 2
19 10
20 31 3 11 23 4
21 31 4 12
0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
=
Anlage 518
Circuit diagrams

Geprüft 14.12.2017
915
EPE / 000 / 00
916
Plug overview
Steckerübersicht
Stecker -X44 Einbauort +EBOX Stecker -X44 Einbauort +EBOX Stecker -X45 Einbauort +EBOX Stecker -X45 Einbauort +EBOX
Function text Plug, engine-controller motor-part Function text Plug, engine-controller motor-part Function text Plug, engine-controller machine-part Function text Plug, engine-controller machine-part
Funktionstext Stecker Motorsteuergerät Motorseite Funktionstext Stecker Motorsteuergerät Motorseite Funktionstext Stecker Motorsteuergerät Maschinenseite Funktionstext Stecker Motorsteuergerät Maschinenseite
Bosch 105 pole Bosch 105 pole Tyco MQS 94 pole Tyco MQS 94 pole
Circuit diagrams

Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
13 23 3 65 22 1 1 21 0 53
14 66 22 2 2 21 9 54
15 25 2 67 23 7 3 21 0 55
16 68 4 21 9 56
17 23 2 69 5 21 0 57
18 23 8 70 25 5 6 21 9 58 21 2
19 25 6 71 7 59
20 25 4 72 23 4 8 60
21 23 4 73 23 4 9 61
22 22 1 74 23 3 10 21 3 62
23 22 2 75 22 6 11 63
24 22 3 76 23 8 12 64 21 5
25 23 1 77 24 3 13 21 5 65
26 25 5 78 23 1 14 66
27 25 4 79 15 67 21 5
28 80 26 8 16 68
29 25 3 81 17 69
30 82 25 6 18 21 5 70 21 1
31 83 19 71
32 25 3 84 20 72
33 85 22 0 21 73
34 86 22 2 22 74 21 4
35 23 2 87 22 2 23 21 4 75
36 23 1 88 22 9 24 76
37 26 9 89 25 7 25 77
38 90 26 21 1 78
39 91 27 79
40 92 25 8 28 80
BW 219 D-5 / BW 219 PD-5

41 26 7 93 29 81
42 94 22 8 30 82 21 8
43 22 1 95 22 8 31 21 5 83 21 8
44 22 2 96 32 84
45 22 3 97 33 85 21 8
46 23 0 98 24 3 34 86 21 8
47 25 4 99 22 6 35 87
48 25 2 100 22 6 36 88 21 4
49 101 22 7 37 89
50 102 22 7 38 90
51 23 9 103 39 91 21 2
52 104 40 92
53 23 6 105 41 93
54 23 5 23 22 5 42 94
55 23 7 24 22 5 43 21 3
56 45 22 4 44
57 25 6 64 22 4 45
58 22 9 66 22 4 46
59 25 7 85 22 4 47
60 48
61 26 9 49
62 26 8 50 21 3
63 22 8 51
64 22 1 52
0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
=
Anlage 518
Geprüft 14.12.2017 EPE / 000 / 00
Plug overview
Steckerübersicht
Stecker -X46.1 Einbauort +MOT Stecker -X46.2 Einbauort +MOT Stecker -X50.f Einbauort +CAB Stecker -X51 Einbauort +MOT
Function text Plug, engine EMR 1 Function text Plug, engine EMR 2 Function text Plug, access display back up monitoring Function text Plug, electronic system ZTR telematics
Funktionstext Stecker Motor EMR 1 Funktionstext Stecker Motor EMR 2 Funktionstext Stecker Anschluß Monitor Rückraumüberwachung Funktionstext Stecker Elektronik System ZTR Telematic
AMP MCP 39 pole AMP MCP 62 pole Deutsch DT 6 pole Deutsch DT 8 pole Code A
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
1 22 7 22 24 2 1 56 5 1 46 2
2 22 8 23 24 2 2 56 5 2 46 2
3 22 8 24 23 8 3 56 5 3 46 2
6 22 8 28 24 1 4 4
7 22 9 29 24 1 5 5
8 22 9 30 23 9 6 6
9 22 6 37 23 8 7
13 22 6 41 23 9 Plug Mounting location 8
14 22 6 46 23 6 Stecker -X50.m Einbauort +CAB
15 22 7 57 24 1 Function text Plug, access display back up monitoring Plug Mounting location
17 23 5 59 24 1 Funktionstext Stecker Anschluß Monitor Rückraumüberwachung Stecker -X55 Einbauort +PUMP
19 23 0 Plug type Function text Plug, pressure sensor travel pump axle MA
Deutsch DT 6 pole
20 23 1 Plug Mounting location Steckertyp Funktionstext Stecker Drucksensor Fahrpumpe Achse MA
21 22 7 Stecker -X47.1 Einbauort +MOT Wire harness Plug type
AMP Superseal 3pol
22 23 4 Function text Plug, injectors 1 Kabelbaum Steckertyp
23 23 4 Funktionstext Stecker Injektoren 1 Page Path Wire harness
Plug type Kabelbaum
Contact
Kontakt
24 23 3 Blatt Pfad
25 23 1 Steckertyp Page Path
1 56 5
Wire harness
Contact
Kontakt
26 23 4 2 56 5 Blatt Pfad
27 23 2 Kabelbaum
3 56 5 1 30 2
28 23 3 Page Path 4 56 5 2 30 2
Contact
Kontakt
29 23 4 Blatt Pfad 5 56 5 3
30 23 1 1 22 0 6
32 22 2 2 22 1 Plug Mounting location Stecker -X56 Einbauort +PUMP
32 22 5 2 22 4 Stecker -X51 Einbauort +MOT Function text Plug, pressure sensor travel pump axle MB
33 22 3 3 22 1 Function text Plug, electronic system ZTR telematics Funktionstext Stecker Drucksensor Fahrpumpe Achse MB
33 22 5 3 22 5 Funktionstext Stecker Elektronik System ZTR Telematic Plug type
AMP Superseal 3pol
BW 219 D-5 / BW 219 PD-5

34 22 0 4 22 2 Plug type Steckertyp
34 22 4 Deutsch DT 8 pole Code A
4 22 5 Steckertyp Wire harness
35 22 1 5 22 4 Wire harness Kabelbaum
35 22 4 Kabelbaum Page Path
Contact
Kontakt

37 22 2 Stecker -X47.2 Einbauort +MOT
Contact
Kontakt
Blatt Pfad 1 30 3
37 22 4 Function text Plug, injectors 2
38 22 1 1 46 2 2 30 3
Funktionstext Stecker Injektoren 2
39 22 3 2 46 2 3
Plug type
3 46 2
Steckertyp
Plug Mounting location -X57 +PUMP
-X46.2 +MOT Wire harness 5 Stecker Einbauort
Stecker Einbauort Kabelbaum Function text Plug, pressure sensor travel pump drum MA
Function text Plug, engine EMR 2 6
Page Path 7 Funktionstext Stecker Drucksensor Fahrpumpe Bandage MA
Funktionstext Stecker Motor EMR 2
Contact
Kontakt
Blatt Pfad 8 Plug type
Plug type AMP Superseal 3pol
AMP MCP 62 pole 1 22 3 Steckertyp
Steckertyp
2 22 1 Wire harness
Wire harness
3 22 2 Kabelbaum
Kabelbaum
Page Path 4 22 3 Page Path
Contact
Kontakt
Blatt Pfad
Contact
Kontakt
Blatt Pfad
13 23 7 1 30 4
18 23 7 2 30 4
19 23 7 3
0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
=
Anlage 518
Circuit diagrams

Geprüft 14.12.2017
917
EPE / 000 / 00
918
Plug overview
Steckerübersicht
Stecker -X58 Einbauort +PUMP Stecker -X67 Einbauort +MOT Stecker -X72 Einbauort +MOT Stecker -X78 Einbauort +MOT
Function text Plug, pressure sensor travel pump drum MB Function text Plug, fuel pre heater Function text Plug, floating switch coolant expansion tank Function text Plug, access potential 15 Powerboard SCR-System
Funktionstext Stecker Drucksensor Fahrpumpe Bandage MB Funktionstext Stecker Kraftstoffvorheizung Funktionstext Stecker Schwimmerschalter Kühlmittelausgleichsbehälter Funktionstext Stecker Anschluß Potential 15 Powerboard SCR-System
AMP Superseal 3pol Deutsch DT 2 pole Deutsch DTM 2 pole Deutsch DT 2 pole
Circuit diagrams

Kabelbaum Kabelbaum Kabelbaum Motor Kabelbaum
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
1 30 4 1 18 8 1 27 2 1 18 9
2 30 4 2 18 8 2 27 2 2
3
Plug Mounting location Plug Mounting location Plug Mounting location
Plug Mounting location Stecker -X68 Einbauort +REFR Stecker -X73 Einbauort +MOT Stecker -X79 Einbauort +DPL
Stecker -X65 Einbauort +CAB Function text Plug, pressure switch air conditioning Function text Plug, WaterInFuel Sensor Function text Plug, headlight front left
Function text Plug, windscreen wiper motor rear Funktionstext Stecker Druckschalter Klimaanlage Funktionstext Stecker Sensor Wasser im Kraftstoff Funktionstext Stecker Scheinwerfer vorne links
Funktionstext Stecker Scheibenwischermotor hinten Plug type Plug type Plug type
Deutsch DT 4 pole AMP Junior Power Timer 2 pole Deutsch DT 6 pole
Plug type Steckertyp Steckertyp Steckertyp
P4NAT
Steckertyp Wire harness Wire harness Wire harness
Wire harness Kabelbaum Motor Kabelbaum Kabelbaum
Kabelbaum Page Path Page Path Page Path
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Page Path Blatt Pfad Blatt Pfad Blatt Pfad
Contact
Kontakt
Blatt Pfad 1 48 1 1 21 1 1
1 53 5 2 48 1 2 21 1 2 42 7
2 53 5 3 3 42 1
3 53 5 4 Plug Mounting location 4
4 53 5 Stecker -X76 Einbauort +MOT 5 42 4
Plug Mounting location Function text Plug, access fuel pump additional heater 6 42 1
Plug Mounting location Stecker -X68 Einbauort +REFR Funktionstext Stecker Anschluss Kraftstoffpumpe Zusatzheizung
Stecker -X66 Einbauort +CAB Function text Plug, pressure switch air conditioning Plug type Plug Mounting location
Deutsch DTM 2 pole -X80 +REFR
Function text Plug, windscreen wiper motor front Funktionstext Stecker Druckschalter Klimaanlage Steckertyp Stecker Einbauort
Funktionstext Stecker Scheibenwischermotor vorne Plug type Wire harness Function text Plug, tail light rear left
Deutsch DT 4 pole
Plug type Steckertyp Kabelbaum Funktionstext Stecker Rückleuchte links
P6SNAT
Steckertyp Wire harness Page Path Plug type
Deutsch DT 4 pole
Wire harness Kabelbaum Steckertyp
Contact
Kontakt
Blatt Pfad
Kabelbaum Page Path Wire harness
1 47 5
Kabelbaum
Contact
Kontakt
Page Path Blatt Pfad 2 47 5
BW 219 D-5 / BW 219 PD-5

Contact
Kontakt
Blatt Pfad 1 48 1 Page Path
Contact
Kontakt
1 53 3 2 48 1 Plug Mounting location Blatt Pfad

2 53 3 3 Stecker -X76 Einbauort +MOT 1 42 8
3 53 3 4 Function text Plug, access fuel pump additional heater 2 42 8
4 Funktionstext Stecker Anschluss Kraftstoffpumpe Zusatzheizung 3 42 1
5 53 3 Plug Mounting location Plug type 4 42 1
-X69 +REFR Deutsch DTM 2 pole
6 Stecker Einbauort Steckertyp
Function text Plug, sender level gauge Wire harness Plug Mounting location
Plug Mounting location Funktionstext Stecker Tauchrohrgeber Kabelbaum Stecker -X80 Einbauort +REFR
Stecker -X67 Einbauort +MOT Plug type Page Path Function text Plug, tail light rear left
AMP Superseal 3pol
Function text Plug, fuel pre heater Steckertyp Funktionstext Stecker Rückleuchte links
Contact
Kontakt
Blatt Pfad
Funktionstext Stecker Kraftstoffvorheizung Wire harness Plug type
1 47 5 Deutsch DT 4 pole
Plug type Kabelbaum Steckertyp
Deutsch DT 2 pole 2 47 5
Steckertyp Page Path Wire harness
Wire harness Kabelbaum
Contact
Kontakt
Blatt Pfad
Kabelbaum Motor Page Path
1
Contact
Kontakt
Page Path 2 27 8 Blatt Pfad
Contact
Kontakt
Blatt Pfad 3 27 8 1 42 8
1 18 8 2 42 8
2 18 8 3 42 1
4 42 1
0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
=
Anlage 518
Geprüft 14.12.2017 EPE / 000 / 00
Plug overview
Steckerübersicht
Stecker -X81 Einbauort +REFR Stecker -X85 Einbauort +CAB Stecker -X88 Einbauort +EBOX Stecker -X88 Einbauort +EBOX
Function text Plug, tail light rear right Function text Plug, access BCM-system Function text Plug, measurement controller Function text Plug, measurement controller
Funktionstext Stecker Rückleuchte rechts Funktionstext Stecker Anschluß BCM-System Funktionstext Stecker Messtechniksteuerung Funktionstext Stecker Messtechniksteuerung
Deutsch DT 4 pole AMP 68 pole AMP 68 pole
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
1 42 8 5 55 1 1 13 6 53 16 7
2 42 8 6 2 54 12 2
3 42 2 3 55 12 5
Stecker -X85 Einbauort +CAB 5 38 7 57 12 4
Plug Mounting location Function text Plug, access BCM-system 6 58 12 5
Stecker -X81 Einbauort +REFR Funktionstext Stecker Anschluß BCM-System 7 38 3 59 12 6
Function text Plug, tail light rear right Plug type 8 60 12 6
Deutsch DT 6 pole
Funktionstext Stecker Rückleuchte rechts Steckertyp 9 34 5 61 34 9
Plug type Wire harness 10 62
Deutsch DT 4 pole
Steckertyp Kabelbaum 11 63
Wire harness Page Path 12 64
Kabelbaum
Contact
Kontakt
Blatt Pfad 13 65 12 6
Page Path 1 14 66 12 7
Contact
Kontakt
Blatt Pfad 2 55 5 15 67 12 8
1 42 8 3 55 6 16 68 12 9
2 42 8 4 55 1 17
3 42 2 5 55 1 -X90 +CAB
4 42 2 6
20 Function text Plug, access GPS - BCM
21 Funktionstext Stecker Anschluß GPS - BCM
Plug Mounting location Plug Mounting location
Stecker -X82 Einbauort +DPL Stecker -X86 Einbauort +DRUM 22 Plug type
SUB-D 9 pole
23 13 5 Steckertyp
Function text Plug, headlight front right Function text Plug, sensor adjustable motor
Funktionstext Stecker Scheinwerfer vorne rechts Funktionstext Stecker Sensor Verstellmotor 24 Wire harness
Plug type Plug type 25 38 8 Kabelbaum
Deutsch DT 6 pole Deutsch DTM 3 pole 26 15 7 Page Path
Contact
Kontakt
Wire harness Wire harness 27 15 6 Blatt Pfad

Kabelbaum Kabelbaum 28 12 1 1
BW 219 D-5 / BW 219 PD-5

Page Path Page Path 29 38 2 2 55 5
30 38 4
Contact
Kontakt
Contact
Kontakt
Blatt Pfad Blatt Pfad 3 55 5
31 38 1 4
1 1 34 5 32 34 2
2 42 8 2 34 5 5 55 5
33 16 8 6
3 42 2 3 34 5 34
4 7
35 8
Stecker -X87 +SEAT 36 9
6 42 2 Einbauort
37
Function text Plug, suspension seat
Funktionstext Stecker Luftfedersitz
Plug Mounting location -X90 +CAB
Stecker -X85 +CAB 39 Stecker Einbauort
Einbauort Plug type
P2NAT 40 Function text Plug, access GPS - BCM
Function text Plug, access BCM-system Steckertyp
Funktionstext Stecker Anschluß BCM-System
41 Funktionstext Stecker Anschluß GPS - BCM
Wire harness
42 Plug type
Plug type Kabelbaum SUB-D 9 pole
Steckertyp
43 Steckertyp
Page Path 44
Wire harness Wire harness
Contact
Kontakt
Blatt Pfad 45
Kabelbaum Kabelbaum
1 48 6 46 34 8 Page Path
Page Path 2 48 6 47 34 7
Contact
Kontakt
Blatt Pfad
Contact
Kontakt
Blatt Pfad 48
1 55 5 49 1
2 55 5 50 2 55 5
3 55 6 51 3 55 5
4 55 1 52 4
0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
=
Anlage 518
Circuit diagrams

Geprüft 14.12.2017
919
EPE / 000 / 00
920
Plug overview
Steckerübersicht
Stecker -X90 Einbauort +CAB Stecker -X92 Einbauort +CAB Stecker -X94 Einbauort +CAB Stecker -X96.A Einbauort +CAB
Function text Plug, access GPS - BCM Function text Plug, access GPS-Receiver Function text Plug, printer Function text Plug, supply BCM
Funktionstext Stecker Anschluß GPS - BCM Funktionstext Stecker Anschluß GPS-Antenne Funktionstext Stecker Drucker Funktionstext Stecker Versorgung BCM
SUB-D 9 pole Burndy 12 pole AMP Mateń´loc 6 pole white Deutsch DT 2 pole
Circuit diagrams

Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
5 55 5 A 55 8 1 54 6 1 55 5
6 B 55 8 2 54 7 2 55 5
7 C 55 8 3 54 7
8 D 55 8 4 54 8 Plug Mounting location
9 E 55 8 5 54 7 Stecker -X96.A Einbauort +CAB
F 6 Function text Plug, supply BCM
Plug Mounting location G Funktionstext Stecker Versorgung BCM
Stecker -X91 Einbauort +CAB H Plug Mounting location Plug type
-X95.A +CAB Deutsch DT 2 pole
Function text Plug, USB BCM Dongle J Stecker Einbauort Steckertyp
Funktionstext Stecker USB BCM Dongle K Function text Plug, CAN BCM Dongle Wire harness
Plug type L Funktionstext Stecker CAN BCM Dongle Kabelbaum
USB
Steckertyp M Plug type Page Path
SUB-D 9 pole
Wire harness Steckertyp
Contact
Kontakt
Blatt Pfad
Kabelbaum Plug Mounting location Wire harness
-X93 +CAB 1 55 5
Page Path Stecker Einbauort Kabelbaum
2 55 5
Contact
Kontakt
Blatt Pfad Function text Plug, supply GPS System Page Path
Funktionstext Stecker Spannungsversorgung GPS System
Contact
Kontakt
1 55 4 Blatt Pfad Plug Mounting location
Plug type Stecker -X97 Einbauort +CAB
2 55 4 Deutsch DT 3 pole 1
Steckertyp
3 55 4 2 55 2 Function text Plug, GPS-Receiver StarFire
4 55 4 Wire harness 3 Funktionstext Stecker GPS-Antenne StarFire
Kabelbaum Plug type
SH 55 4 4 Deutsch DT 12 pole
Page Path 5 Steckertyp
Contact
Kontakt
Plug Mounting location Blatt Pfad 6 Wire harness
Stecker -X92 Einbauort +CAB A 55 6 7 55 2 Kabelbaum
Function text Plug, access GPS-Receiver B 55 6 8 Page Path
Funktionstext Stecker Anschluß GPS-Antenne
Contact
Kontakt
C 55 6 9 Blatt Pfad
Plug type
Burndy 12 pole 2 55 9
Steckertyp Plug Mounting location Plug Mounting location 6 55 9
BW 219 D-5 / BW 219 PD-5

Wire harness Stecker -X94 Einbauort +CAB Stecker -X95.A Einbauort +CAB
7 55 9
Kabelbaum Function text Plug, printer Function text Plug, CAN BCM Dongle
11 55 9
Page Path Funktionstext Stecker Drucker Funktionstext Stecker CAN BCM Dongle
12 55 8
Plug type Plug type
Contact
Kontakt
Blatt Pfad AMP Mateń´loc 6 pole white SUB-D 9 pole
A 55 7 Plug Mounting location
B 55 7 Wire harness Wire harness Stecker -X99 Einbauort +SEAT
Kabelbaum Kabelbaum Function text Plug, heating operators seat
C 55 7
D 55 7 Page Path Page Path Funktionstext Stecker Sitzheizung
Contact
Kontakt
Contact
Kontakt
E 55 7 Blatt Pfad Blatt Pfad Plug type

P2NAT
F 1 54 6 1 Steckertyp
G 2 54 7 2 55 2 Wire harness
H 3 3 Kabelbaum
J 4 54 8 4 Page Path
Contact
Kontakt
T 5 54 7 5 Blatt Pfad
L 6 6 1 48 7
M 7 55 2 2 48 7
8
9
0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
=
Anlage 518
Geprüft 14.12.2017 EPE / 000 / 00
Plug overview
Steckerübersicht
Function text Plug, connection Driving controller - Console seat Function text Plug, connection Driving controller - Engine Function text Plug, connection Armatures - Console seat Function text Plug, connection Driving controller - Rear frame
Funktionstext Stecker Verbindung Fahrsteuerung - Konsole Sitz Funktionstext Stecker Verbindung Fahrsteuerung - Motor Funktionstext Stecker Verbindung Armaturen - Konsole Sitz Funktionstext Stecker Verbindung Fahrsteuerung - Hinterrahmen
AMP Junior Power Timer 6 pole grey AMP Junior Power Timer 12 pole blue AMP Junior Power Timer 15 pole grey AMP Junior Power Timer 18 pole green
1 1 1 1
Kabelbaum 4 Kabelbaum Kabelbaum Kabelbaum
Page Path 6 3 Page Path 3 6 9 12 Page Path 3 9 15 Page Path 3 9 12 18
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
1 1 27 2 3 29 1 1 30 2
2 2 27 3 4 29 1 2 30 3
3 3 27 4 5 29 3 3 30 4
4 4 6 29 7 4 30 4
5 5 7 29 7 5 31 1
6 6 8 6 31 2
7 9 7 31 3
Plug Mounting location 8 10 8 31 4
Stecker -X100 Einbauort +EBOX 9 11 9 31 5
Function text Plug, connection Driving controller - Console seat 10 12 10 31 8
Funktionstext Stecker Verbindung Fahrsteuerung - Konsole Sitz 11 13 11 27 5
Plug type 12 14 12 33 5
Steckertyp 15 13 33 6
Wire harness Plug Mounting location 14
1 -X102 +EBOX
Kabelbaum Stecker Einbauort Plug Mounting location 15
Page Path 3 6 Function text Plug, connection Armatures - Console seat Stecker -X103 Einbauort +EBOX 16
Funktionstext Stecker Verbindung Armaturen - Konsole Sitz
Contact
Kontakt
Blatt Pfad Function text Plug, connection Driving controller - Rear frame 17
Plug type Funktionstext Stecker Verbindung Fahrsteuerung - Hinterrahmen 18
1 28 4 AMP Junior Power Timer 15 pole grey
Steckertyp Plug type
2 AMP Junior Power Timer 18 pole green
Wire harness Steckertyp Plug Mounting location
3 13 1 -X104 +EBOX
Kabelbaum Wire harness Stecker Einbauort
4 16 1
Page Path 15 9 3 Kabelbaum Function text Plug, connection Driving controller - Front frame
5
18 12 9 3 Funktionstext Stecker Verbindung Fahrsteuerung - Vorderrahmen
Contact
Kontakt
6 Blatt Pfad Page Path
Plug type
Contact
Kontakt
1 29 1 Blatt Pfad AMP Junior Power Timer 9 pole purple
Steckertyp
Plug Mounting location 2 1 30 2
Stecker -X101 Einbauort +EBOX 3 29 1 2 30 3 Wire harness
7 1
Function text Plug, connection Driving controller - Engine Kabelbaum
4 29 1 3 30 4
Page Path 9 6 3
Funktionstext Stecker Verbindung Fahrsteuerung - Motor 5 29 3 4 30 4
BW 219 D-5 / BW 219 PD-5

Contact
Kontakt
Plug type 6 29 7 5 31 1 Blatt Pfad

Steckertyp 7 29 7 6 31 2 1 28 7
Wire harness 8 7 31 3 2
10 1
Kabelbaum Motor 9 8 31 4 3 28 7
Page Path 12 9 6 3 10 9 31 5 4
Contact
Kontakt
Blatt Pfad 11 10 31 8 5 28 6
1 27 2 12 11 27 5 6 28 7
2 13 12 33 5 7 31 9
3 27 4 14 13 33 6 8 31 9
4 15 14 9
5 15
Plug Mounting location 16 Plug Mounting location
6 -X102 +EBOX -X104 +EBOX
Stecker Einbauort 17 Stecker Einbauort
7
Function text Plug, connection Armatures - Console seat 18 Function text Plug, connection Driving controller - Front frame
8
Funktionstext Stecker Verbindung Armaturen - Konsole Sitz Funktionstext Stecker Verbindung Fahrsteuerung - Vorderrahmen
9
Plug type Plug type
10 AMP Junior Power Timer 15 pole grey AMP Junior Power Timer 9 pole purple
11
12 Wire harness Wire harness
1 1
Kabelbaum Kabelbaum
Page Path 3 9 15 Page Path 3 6 9
Contact
Kontakt
Contact
Kontakt

1 29 1 1 28 7
2 29 1 2 28 7
0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
=
Anlage 518
Circuit diagrams

Geprüft 14.12.2017
921
EPE / 000 / 00
922
Plug overview
Steckerübersicht
Function text Plug, connection Driving controller - Front frame Function text Plug, connection Driving controller - Front frame dozer blade Function text Plug, connection Measurement controller - Front frame Function text Plug, connection Engine - Engine Controller
Funktionstext Stecker Verbindung Fahrsteuerung - Vorderrahmen Funktionstext Stecker Verbindung Fahrsteuerung - Vorderrahmen PlanierschildFunktionstext Stecker Verbindung Messrechner - Vorderrahmen Funktionstext Stecker Verbindung Motor - Motorsteuergerät
AMP Junior Power Timer 9 pole purple AMP Junior Power Timer 18 pole purple AMP Junior Power Timer 12 pole purple AMP Junior Power Timer 15 pole blue
Circuit diagrams

1 1 1 13 1
Kabelbaum Kabelbaum Kabelbaum 10 Kabelbaum Motor
Page Path 3 6 9 Page Path 3 9 12 18 Page Path 12 9 6 3 Page Path 15 9 3
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
3 28 7 5 35 7 10 34 8 15
4 28 8 6 35 8 11
5 28 6 7 35 3 12 34 7 Plug Mounting location
6 28 7 8 36 7 Stecker -X108 Einbauort +EBOX
7 31 9 9 36 4 Plug Mounting location Function text Plug, connection Engine - Engine Controller
8 31 9 10 35 4 Stecker -X107 Einbauort +EBOX Funktionstext Stecker Verbindung Motor - Motorsteuergerät
9 11 36 1 Function text Plug, connection Measurement controller - Front frame Plug type
12 35 4 Funktionstext Stecker Verbindung Messrechner - Vorderrahmen Steckertyp
Plug Mounting location 13 36 5 Plug type Wire harness
-X105 +EBOX AMP Junior Power Timer 12 pole purple 1
Stecker Einbauort 14 36 6 Steckertyp Kabelbaum EMR
Function text Plug, connection Driving controller - Front frame dozer blade 15 36 6 Wire harness Page Path 3 9 15
1
Funktionstext Stecker Verbindung Fahrsteuerung - Vorderrahmen Planierschild Kabelbaum
Contact
Kontakt
16 37 5 Blatt Pfad
Plug type 17 Page Path 3 6 9 12
AMP Junior Power Timer 18 pole purple 1 21 1
Steckertyp
Contact
Kontakt
18 Blatt Pfad 2 21 1
Wire harness 1 38 1 3 21 3
16 1
Kabelbaum Plug Mounting location
-X106 +EBOX 2 38 2 4 21 3
Page Path 18 12 9 3 Stecker Einbauort
3 38 1 5 21 4
Contact
Kontakt
Blatt Pfad Function text Plug, connection Driving controller - Front frame sensor speed vibration
4 38 2 6
Funktionstext Stecker Verbindung Fahrsteuerung - Vorderrahmen Drehzahlaufnehmer Vibration
1 35 3 5 38 3 7
Plug type
2 35 4 AMP Junior Power Timer 6 pole purple 6 38 4 8
Steckertyp
3 35 5 7 34 5 9
4 35 6 Wire harness 8 34 5 10
1
Kabelbaum
5 35 7 9 34 7 11
Page Path 3 6
6 35 8 10 34 8 12
Contact
Kontakt
7 35 3 Blatt Pfad 11 34 9 13
8 36 7 1 33 2 12 34 7 14
9 36 4 2 33 1 15
BW 219 D-5 / BW 219 PD-5

11 36 1 4 Stecker -X108 Einbauort +EBOX Plug Mounting location
12 35 4 5 33 2 Function text Plug, connection Engine - Engine Controller Stecker -X109.f Einbauort +EBOX
13 36 5 6 33 2 Funktionstext Stecker Verbindung Motor - Motorsteuergerät Function text Plug, access transducer acceleration Economizer
14 36 6 Plug type Funktionstext Stecker Anschluss Beschleunigungsaufnehmer Economizer
15 36 6 Plug Mounting location Steckertyp Plug type
-X107 +EBOX AMP Junior Power Timer 12 pole purple
16 37 5 Stecker Einbauort Wire harness Steckertyp
13 1
17 Function text Plug, connection Measurement controller - Front frame Kabelbaum Motor Wire harness
10 1
18 Funktionstext Stecker Verbindung Messrechner - Vorderrahmen Page Path 15 9 3 Kabelbaum Economizer
Plug type 12 9 6 3
Contact
Kontakt
AMP Junior Power Timer 12 pole purple

Plug Mounting location Steckertyp
Contact
Kontakt
1 21 1 Blatt Pfad
Stecker -X105 Einbauort +EBOX Wire harness
10 1 2 21 1 1 39 5
Function text Plug, connection Driving controller - Front frame dozer blade Kabelbaum
3 21 3 2 39 5
Funktionstext Stecker Verbindung Fahrsteuerung - Vorderrahmen Planierschild Page Path 12 9 6 3
4 21 3 3 39 6
Plug type
Contact
Kontakt
Blatt Pfad 5 4 39 6
Steckertyp
1 38 1 6 5
1
Kabelbaum
3 38 1 8 7
Page Path 3 9 12 18
4 38 2 9 8
Contact
Kontakt
Blatt Pfad 5 38 3 10 9
1 35 3 6 38 4 11 10
2 35 4 7 34 5 12 11
3 35 5 8 34 5 13 12
4 35 6 9 34 7 14
0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
=
Anlage 518
Geprüft 14.12.2017 EPE / 000 / 00
Plug overview
Steckerübersicht
Stecker -X109.m Einbauort +EBOX Stecker -X200 Einbauort +CAB Stecker -X202 Einbauort +CAB Stecker -X203 Einbauort +CAB
Function text Plug, access transducer acceleration Economizer Function text Plug, supply potential 30 Function text Plug, signals from/to central electric Function text Plug, access cabin equipment
Funktionstext Stecker Anschluss Beschleunigungsaufnehmer Economizer Funktionstext Stecker Versorgung Potential 30 Funktionstext Stecker, Signale von/zur Zentralelektrik Funktionstext Stecker Anschluß Kabinenausrüstung
AMP Junior Power Timer 12 pole purple Amphenol RADSOK® 6mm AMP Junior Power Timer 2 - 10 pole black AMP Junior Power Timer 2 - 14 pole black
Wire harness Wire harness Wire harness Wire harness 2 14
1 2 10
Kabelbaum Aufnehmer Economizer Kabelbaum Kabelbaum Kabelbaum
1 9 1 13
Page Path 3 6 9 12 Page Path Page Path Page Path
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
1 39 5 30 49 3 3 49 3 12 53 5
2 39 5 4 49 3 13 53 7
4 39 6 Stecker -X200 Einbauort +CAB 6 49 3
5 Function text Plug, supply potential 30 7 Plug Mounting location
6 Funktionstext Stecker Versorgung Potential 30 8 49 3 Stecker -X203 Einbauort +CAB
7 Plug type 9 49 3 Function text Plug, access cabin equipment
8 Steckertyp 10 49 3 Funktionstext Stecker Anschluß Kabinenausrüstung
9 Wire harness Plug type
10 Kabelbaum Plug Mounting location Steckertyp
11 Page Path Stecker -X202 Einbauort +CAB Wire harness
Kabelbaum
Contact
Kontakt
12 Blatt Pfad Function text Plug, signals from/to central electric
Funktionstext Stecker, Signale von/zur Zentralelektrik Page Path
30 49 3
Contact
Kontakt

Blatt Pfad
Stecker -X110 Einbauort +EBOX Steckertyp
Function text Plug, access interface meassurement Stecker -X201 Einbauort +CAB Wire harness 2 51 6
Funktionstext Stecker Anschluß Schnittstelle Messtechnik Kabelbaum
Function text Plug, supply ground 3 51 8
Plug type Funktionstext Stecker Versorgung Masse Page Path
Steckertyp
Contact
Kontakt
Plug type Blatt Pfad 5 51 7
Wire harness Amphenol RADSOK® 3,6mm
Steckertyp 1 49 3 6 51 9
4 1
Kabelbaum
Wire harness 2 54 8 7 53 3
Page Path 6 3
Kabelbaum 3 49 3 8 53 3
Contact
Kontakt
Blatt Pfad Page Path 4 49 3 9 53 3
Contact
Kontakt
1 44 7 Blatt Pfad 5 49 3 10 53 5
2 44 7 31 49 3 6 49 3 11 53 5
3 44 7 7 12 53 5
5 44 7 Stecker -X201 Einbauort +CAB 9 49 3 14 53 7
BW 219 D-5 / BW 219 PD-5

6 Function text Plug, supply ground 10 49 3
Funktionstext Stecker Versorgung Masse Plug Mounting location
Plug Mounting location Plug Mounting location Stecker -X204 Einbauort +CAB
-X110 +EBOX Plug type -X203 +CAB
Stecker Einbauort Amphenol RADSOK® 3,6mm Stecker Einbauort Function text Plug, supply BCM System, printer
Steckertyp
Function text Plug, access interface meassurement Function text Plug, access cabin equipment Funktionstext Stecker Versorgung BCM System, Drucker
Wire harness
Funktionstext Stecker Anschluß Schnittstelle Messtechnik Funktionstext Stecker Anschluß Kabinenausrüstung Plug type
Kabelbaum AMP Junior Power Timer 2 - 4 pole black
Plug type Plug type Steckertyp
AMP Junior Power Timer 6 pole brown Page Path AMP Junior Power Timer 2 - 14 pole black
Steckertyp Steckertyp Wire harness
Contact
Kontakt
Blatt Pfad 2 6
Wire harness Wire harness Kabelbaum
2 14
1 31 49 3 1 5
Kabelbaum Kabelbaum Page Path
1 13
3 6
Contact
Kontakt
Page Path Page Path Blatt Pfad

Contact
Kontakt
Contact
Kontakt
Blatt Pfad -X202 +CAB Blatt Pfad 1 55 5

Stecker Einbauort
1 44 7 Function text Plug, signals from/to central electric 1 51 7 2 55 6
2 44 7 Funktionstext Stecker, Signale von/zur Zentralelektrik 2 51 6 3 55 6
3 44 7 Plug type 3 51 8 4
4 44 7 AMP Junior Power Timer 2 - 10 pole black 4 51 8
Steckertyp
5 44 7 Wire harness 5
2 10
6 Kabelbaum 6 51 9
1 9 7 53 3
Page Path
8 53 3
Contact
Kontakt
Blatt Pfad
9 53 3
1 49 3 10 53 5
2 54 8 11 53 5
0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
=
Anlage 518
Circuit diagrams

Geprüft 14.12.2017
923
EPE / 000 / 00
924
Plug overview
Steckerübersicht
Stecker -X204 Einbauort +CAB Stecker -X206 Einbauort +CAB Stecker -X207.m Einbauort +DPL Stecker -X301 Einbauort +BAT
Function text Plug, supply BCM System, printer Function text Plug, access additional headlights, reserve funktions Function text Plug, heating unit additional heater Function text Plug, distribution box SCR-heating 1
Funktionstext Stecker Versorgung BCM System, Drucker Funktionstext Stecker Anschluß Zusatzscheinwerfer, Reservefunktionen Funktionstext Stecker Heizgerät Zusatzheizung Funktionstext Stecker Verteiler SCR-Heizung 1
AMP Junior Power Timer 2 - 4 pole black AMP Junior Power Timer 9 pole grey AMP Junior Power Timer 16 pole AMP Junior Power Timer 15 pole blue
Circuit diagrams

Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
1 55 5 3 52 7 10 47 2 1 26 4
2 55 6 4 51 5 2 26 6
3 55 6 5 Plug Mounting location 3 26 5
4 55 7 6 51 4 Stecker -X210 Einbauort +CAB 4 26 3
7 52 7 Function text Plug, access GPS-Receiver 5 26 4
Plug Mounting location 8 52 7 Funktionstext Stecker Anschluß GPS-Antenne 6 26 5
Stecker -X205 Einbauort +CAB 9 51 5 Plug type 7 26 4
Deutsch DTM 6 pole
Function text Plug, access radio and tachograph Steckertyp 8 26 4
Funktionstext Stecker Anschluß Radio und Tachograph Plug Mounting location Wire harness 9 26 6
Plug type Stecker -X207.f Einbauort +DPL Kabelbaum 10 26 6
Steckertyp Function text Plug, heating unit additional heater Page Path 12 26 2
Wire harness Funktionstext Stecker Heizgerät Zusatzheizung
Contact
Kontakt
Blatt Pfad 13 26 7
2 6
Kabelbaum Plug type 14 26 3
1 5
AMP Junior Power Timer 16 pole 1 55 7
Page Path Steckertyp 15 26 3
2 55 7
Contact
Kontakt
Blatt Pfad Wire harness 3 55 7
Kabelbaum Plug Mounting location
1 54 0 4 55 7 -X302 +BAT
Page Path Stecker Einbauort
2 54 1 5 55 7
Contact
Kontakt
Blatt Pfad Function text Plug, distribution box SCR-heating 2
3 54 1 6
Funktionstext Stecker Verteiler SCR-Heizung 2
4 54 2 1 47 3
Plug Plug type
5 54 2 2 Mounting location AMP Junior Power Timer 9 pole blue
Stecker -X211 +CAB Steckertyp
6 54 2 3 Einbauort
4 47 3 Function text Plug, access temperature sensor asphalt Wire harness
Plug Funktionstext Stecker Anschluß Asphalttemperatursensor Kabelbaum
Mounting location 5 47 3
Stecker -X205 Einbauort +CAB 6 47 3 Plug type Page Path
DTM 4 pole
Contact
Kontakt
Function text Plug, access radio and tachograph 7 47 3 Steckertyp Blatt Pfad
Funktionstext Stecker Anschluß Radio und Tachograph 8 47 3 Wire harness 1 26 7
Plug type 9 Kabelbaum 2 26 7
Steckertyp 10 47 3 Page Path 3 26 8
BW 219 D-5 / BW 219 PD-5

Wire harness
Contact
Kontakt
Kabelbaum 12 5 26 8
1
Page Path 13 2 55 5 6 26 9
Contact
Kontakt
Blatt Pfad 14 3 55 5 7 26 9
1 54 0 15 4 55 5
2 54 1 -X400 +DPL
Stecker Einbauort
Plug Mounting location Stecker -X300 Einbauort +BAT Function text Interface measurement
4 54 2 +DPL
Stecker -X207.m Einbauort Funktionstext Schnittstelle Messtechnik
5 54 2 Function text Plug, supply distribution box SCR-heating
Function text Plug, heating unit additional heater Funktionstext Stecker Versorgung Verteiler SCR-Heizung Plug type
6 54 2 Burndy 12 pole
Funktionstext Stecker Heizgerät Zusatzheizung Steckertyp
Plug type
Plug type Amphenol RADSOK® 6mm Wire harness
Plug Mounting location AMP Junior Power Timer 16 pole Steckertyp
Stecker -X206 +CAB Steckertyp Kabelbaum
Einbauort Wire harness
Function text Plug, access additional headlights, reserve funktions Wire harness Kabelbaum Page Path
Kabelbaum
Contact
Kontakt
Funktionstext Stecker Anschluß Zusatzscheinwerfer, Reservefunktionen Page Path Blatt Pfad

Plug type Page Path
Contact
Kontakt

Blatt Pfad A 44 8
Contact
Kontakt
Steckertyp Blatt Pfad B 44 8
30 26 1
Wire harness 1 47 2 C
Kabelbaum 4 47 2 D 44 8
Page Path 5 47 2 E 44 8
Contact
Kontakt
Blatt Pfad 6 47 2 F 44 8
1 51 3 7 47 2 G
2 51 4 8 47 2 H
0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
=
Anlage 518
Geprüft 14.12.2017 EPE / 000 / 00
Plug overview
Steckerübersicht
Stecker -X400 Einbauort +DPL Stecker -XA12.B Einbauort +CAB Stecker -XA124 Einbauort +EBOX Stecker -XA177 Einbauort +MOT
Function text Interface measurement Function text Plug, B radio speaker Function text Plug, ECU BOMAG TELEMATIC Function text Plug, ECU ZTR telematics
Funktionstext Schnittstelle Messtechnik Funktionstext Stecker B Radio Lautsprecher Funktionstext Stecker ECU BOMAG TELEMATIC Funktionstext Stecker ECU ZTR Telematik
Burndy 12 pole ISO-speaker 8 pole Deutsch DTM 12 pole Code A Deutsch DT 12 pole Code A
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
J 5 1 45 4 1 46 5
T 6 2 45 3 2 46 6
L 7 54 4 3 45 3 3
M 8 54 5 4 45 3 4 46 6
5 5
Stecker -XB218 Einbauort +MOT Stecker -XA103 Einbauort +REFR 7 7
Function text Plug, sensor ambient temperature Function text Plug, monitoring module 8 45 4 8
Funktionstext Stecker Sensor Umgebungstemperatur Funktionstext Stecker Überwachungsmodul 9 9
Plug type Plug type 10 10
Bosch Kompakt 1.1a 2 pole black Code 1 AMP Superseal 26 pole
Steckertyp Steckertyp 11 45 4 11 46 6
Wire harness Wire harness 12 45 3 12 46 6
Kabelbaum Kabelbaum Economizer
Page Path Page Path Plug Mounting location Plug Mounting location
Stecker -XA161 Einbauort +EBOX Stecker -XB03 Einbauort +MOT
Contact
Kontakt
Contact
Kontakt
Function text Relay socket, gateway economizer Function text Plug, maintenance switch air cleaner
1 21 3 1 39 4
Funktionstext Relaissockel Gateway Economizer Funktionstext Stecker Wartungsschalter Luftfilter
2 21 3 2 39 5
Plug type Plug type
3 Car minirelay socket Tyco Junior Power Timer 2 pole
Plug Mounting location 4
Stecker -XA12.A Einbauort +CAB 5 39 5 Wire harness Wire harness
Function text Plug, A radio supply Kabelbaum Economizer Kabelbaum Motor
6 39 4
Funktionstext Stecker A Radio Versorgung 7 Page Path Page Path
Contact
Kontakt
Contact
Kontakt
Plug type 8 Blatt Pfad Blatt Pfad

ISO-Current 8 pole
Steckertyp 9 1 40 6 1 27 4
Wire harness 10 2 40 2 2 27 4
Kabelbaum 11 3 40 6
Stecker -XM01.50 Einbauort +MOT
Contact
Kontakt
Blatt Pfad 13 39 1 5
BW 219 D-5 / BW 219 PD-5

14 6 40 2 Function text Plug, starter terminal 50
1
15 7 40 6 Funktionstext Stecker Starter Anschluss 50
2
16 8 40 4 Plug type
3 FASTON 6,3mm
17 9 40 6 Steckertyp
4 54 5
5 18 Wire harness
19 Plug Mounting location Kabelbaum Motor
6 -XA175 +MOT
20 Stecker Einbauort Page Path
7 54 5
Function text Plug, electronic system Morey telematics
Contact
Kontakt
8 54 4 21 Blatt Pfad
22 Funktionstext Stecker Elektronik System Morey Telematic
1 8 4
Plug 23 Plug type
Mounting location 16 pole Morey
Stecker -XA12.B +CAB 24 39 6 Steckertyp
Einbauort Plug Mounting location
Function text Plug, B radio speaker 25 39 7 Wire harness Stecker -XP09.A Einbauort +CAB
Funktionstext Stecker B Radio Lautsprecher 26 39 1 Kabelbaum Function text Plug, A tachograph
Plug type Page Path Funktionstext Stecker A Tachograph
ISO-speaker 8 pole
Contact
Kontakt
Steckertyp Blatt Pfad Plug type

Tyco JPT 8 pole white
Wire harness 8 46 2 Steckertyp
Kabelbaum 10 46 2 Wire harness
Page Path 16 46 2 Kabelbaum Radio_Tachograph
Contact
Kontakt
Contact
Kontakt
1 54 5 Blatt Pfad
2 54 5 1 54 3
3 2 54 3
4 3 54 3
0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
=
Anlage 518
Circuit diagrams

Geprüft 14.12.2017
925
EPE / 000 / 00
926
Plug overview
Steckerübersicht
Stecker -XP09.A Einbauort +CAB Stecker -XR79 Einbauort +MOT Stecker -XS28.f Einbauort +DPL Stecker -XU600.2 Einbauort +EBOX
Function text Plug, A tachograph Function text Plug, fuel pre heater Function text Plug, timer additional heater Function text Plug, ground harness ground powerboard
Funktionstext Stecker A Tachograph Funktionstext Stecker Kraftstoffvorheizung Funktionstext Stecker Schaltuhr Zusatzheizung Funktionstext Stecker Masse Kabelbaum Masse Powerboard
Tyco JPT 8 pole white AMP 2,5mm 4 way black Code 1 AMP Junior Power Timer 12 pole grey Tubular cable lug M10
Circuit diagrams

10 1
Kabelbaum Radio_Tachograph Kabelbaum Kabelbaum Kabelbaum Economizer
Page Path Page Path Page Path 12 9 6 3 Page Path
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
4 1 18 8 10 47 6 1 8 4
5 54 3 2 18 8 11 47 6
6 54 3 3 12 47 6 Plug Mounting location
7 4 Stecker -XU600.3 Einbauort +EBOX
8 Plug Mounting location Function text Plug, ground harness engine
Plug Mounting location Stecker -XS28.m Einbauort +DPL Funktionstext Stecker Masse Kabelbaum Motor
Plug Mounting location Stecker -XR79 Einbauort +MOT Function text Plug, heating unit additional heater Plug type
-XP09.B +CAB Cable lug ring form A10
Stecker Einbauort Function text Plug, fuel pre heater Funktionstext Stecker Heizgerät Zusatzheizung Steckertyp
Function text Plug, B tachograph Funktionstext Stecker Kraftstoffvorheizung Plug type Wire harness
Funktionstext Stecker B Tachograph Plug type Steckertyp Kabelbaum Motor
AMP 2,5mm 4 way black Code 1
Plug type Steckertyp Wire harness Page Path
Tyco JPT 8 pole yellow 1
Steckertyp Wire harness Kabelbaum
Contact
Kontakt
Blatt Pfad
Wire harness Kabelbaum Page Path 3 6 9 12
1 8 4
Kabelbaum Radio_Tachograph
Contact
Kontakt
Contact
Kontakt
Page Path Blatt Pfad 1 47 6 Plug Mounting location
+EBOX
Contact
Kontakt
Blatt Pfad 1 18 8 2 Stecker -XU600.4 Einbauort
1 2 18 8 3 Function text Plug, ground harness engine controller
2 3 4 Funktionstext Stecker Masse Kabelbaum Motorsteuergerät
3 54 3 4 5 Plug type
Cable lug ring form A10
4 54 3 6 47 6 Steckertyp
5 Plug Mounting location 7 Wire harness
6 Stecker -XS Einbauort +DPL 8 47 6 Kabelbaum EMR
7 Function text Socket 9 47 6 Page Path
Funktionstext Steckdose
Contact
Kontakt
8 10 Blatt Pfad
Plug type 11 47 6 1 8 4
Plug Mounting location Steckertyp 12 47 6
Stecker -XP09.C Einbauort +CAB Wire harness Plug Mounting location
Function text Plug, C tachograph Kabelbaum Plug Mounting location Stecker -XU600.10 Einbauort +EBOX
BW 219 D-5 / BW 219 PD-5

Funktionstext Stecker C Tachograph Page Path Stecker -XS42 Einbauort +ARC
Function text Plug, ground harness economizer
Plug type
Contact
Kontakt
Blatt Pfad Function text Plug, switch speed range selector Funktionstext Stecker Masse Kabelbaum Economizer
Tyco JPT 8 pole red
Steckertyp Funktionstext Stecker Schalter Fahrstufen
41 1 Plug type
Wire harness Plug type Cable lug ring form A10
AMP GET 6 way Steckertyp
Kabelbaum Radio_Tachograph Steckertyp
Plug Mounting location Wire harness
Page Path Stecker -XS28.f Einbauort +DPL Wire harness Kabelbaum Economizer
Kabelbaum
Contact
Kontakt
Blatt Pfad Function text Plug, timer additional heater Page Path
Funktionstext Stecker Schaltuhr Zusatzheizung Page Path
Contact
Kontakt
1 Contact Blatt Pfad

Kontakt
2 Plug type Blatt Pfad

AMP Junior Power Timer 12 pole grey 1 8 4
3 54 3 Steckertyp 1 29 0
4 Wire harness 2 29 1 Plug Mounting location
10 1
5 Kabelbaum 3 29 1 Stecker -XY15.Gnd Einbauort +MOT
6 Page Path 12 9 6 3 4 29 1 Function text Plug, ground compressor air conditioning(Kopie)
Contact
Kontakt
7 Blatt Pfad 5 29 1 Funktionstext Stecker Masse Kompressor Klimaanlage
8 1 47 6 6 29 1 Plug type
Cable lug ring form A4
2 47 4 Steckertyp
3 Wire harness
4 47 5 Kabelbaum Motor
5 Page Path
Contact
Kontakt
6 47 6 Blatt Pfad
7 1 48 1
8 47 6
9 47 6
0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
=
Anlage 518
Geprüft 14.12.2017 EPE / 000 / 00
A48 S55
A15 A178 P15
+EBOX +SEAT +ARC +CAB +CAB
+EBOX
X34
CAN 2
CAN 1
A87
BW 219 D-5 / BW 219 PD-5

A67
+DPL +CAB
+DPL
A161 A162
A103 X400
CAN 4
A124 CAN 3
0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
BW 219-226 D, DH, BVC-5 Overview CAN Communication Higher-level function
=
Anlage 518
Circuit diagrams

Deutz TCD 4.1_6.1 Tier 4f Übersicht CAN Kommunkikation Einbauort + VIEW
Geprüft 14.12.2017
927
EPE / 000 / 00
928
Circuit diagrams
BW 219 D-5 / BW 219 PD-5

0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
BW 219-226 D, DH, BVC-5 Overview Central Electric Higher-level function
=
Anlage 518
Deutz TCD 4.1_6.1 Tier 4f Übersicht Zentralelektrik Einbauort + VIEW
Geprüft 14.12.2017 EPE / 000 / 00
Top view
Draufsicht
BW 219 D-5 / BW 219 PD-5

0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
BW 219-226 D, DH, BVC-5 Overview plugs X100 - X110 Higher-level function
=
Anlage 518
Circuit diagrams

Deutz TCD 4.1_6.1 Tier 4f Übersicht Stecker X100 - X110 Einbauort + VIEW
Geprüft 14.12.2017
929
EPE / 000 / 00
930
Circuit diagrams
BW 219 D-5 / BW 219 PD-5

0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
BW 219-226 D, DH, BVC-5 Overview Powerboard Higher-level function
=
Anlage 518
Deutz TCD 4.1_6.1 Tier 4f Übersicht Powerboard Einbauort + VIEW
Geprüft 14.12.2017 EPE / 000 / 00
BW 219 D-5 / BW 219 PD-5
0 1 2 3 4 5 6 7 8 9
Erstellt
14.12.2017
BW 219-226 D, DH, BVC-5 Overview Powerboard Higher-level function
=
Anlage 518
Circuit diagrams

Deutz TCD 4.1_6.1 Tier 4f Übersicht Powerboard Einbauort + VIEW
Geprüft 14.12.2017
931
EPE / 000 / 00
Circuit diagrams
A.2 Circuit diagram 642

Validity of circuit diagrams
– BW 219 D-5
101 587 32 1001 ⇒ 101 587 32 9999

– BW 219 D-5
101 586 95 1001 ⇒ 101 586 95 9999
– BW 219 PD-5
101 586 96 1001 ⇒ 101 586 96 9999
– BW 213 DH-5
101 587 50 1001 ⇒ 101 587 50 9999
– BW 213 PDH-5
101 587 51 1001 ⇒ 101 587 51 9999
– BW 213 DH+P-5
101 587 53 1001 ⇒ 101 587 53 9999
– BW 216 DH-5
101 587 57 1001 ⇒ 101 587 57 9999
932 BW 219 D-5 / BW 219 PD-5

Circuit diagrams
BW 219 D-5 / BW 219 PD-5 933

934
Table of contents
Inhaltsverzeichnis BO_F06_001

1 Cover sheet Deckblatt
Circuit diagrams

7 Layout mounting locations Anordnung Einbauorte
8 =SUPL Supply, Starting unit Versorgung, Starten
9 =SUPL Fuse protection potential 30 Absicherung Potential 30
10 =SUPL Fuse protection potential 15 Absicherung Potential 15
11 =SUPL Supply Driving Controller Versorgung Fahrsteuerung
12 =SUPL Supply Measurement controller Versorgung Messtechniksteuerung
13 =SUPL Supply 8,5V sensors Versorgung 8,5V Sensoren
14 =SUPL Supply Monitoring module, Travel lever Versorgung Überwachungsmodul, Fahrhebel
15 =COM Communication, Diagnosis Kommunikation, Diagnose
16 =COM Communication Kommunikation
17 =COM Communication Kommunikation
18 =ENGI Pre-heating, Fuel lift pump, Fuel-pre-heating Vorglühen, Kraftstoffförderpumpe, Kraftstoffvorwärmung
19 =ENGI Engine speed, Regeneration mode Motordrehzahl, Regenerationsmodus
20 =ENGI Engine - Machine-part Motor - Fahrzeugseite
21 =ENGI2 Deutz TCD 4.1/6.1 Tier 4 final / Stage V Deutz TCD 4.1/6.1 Tier 4 final / Stage V
BW 219 D-5 / BW 219 PD-5

24 =EAT2 Deutz TCD 4.1/6.1 Tier 4 final / Stage V - Exhaust aftertreatment Deutz TCD 4.1/6.1 Tier 4 final / Stage V - Abgasnachbehandlung
27 =MON Monitoring, Failure indicators Überwachung, Störmeldungen
28 =DRIV Slope sensor, Speed sensors Neigungssensor, Geschwindigkeitsaufnehmer
29 =DRIV Travel lever Fahrhebel
30 =DRIV Pressure sensors Drucksensoren
31 =DRIV Travel pumps Fahrpumpen
32 =DRIV Brake, Speed ranges Bremse, Fahrstufen
33 =DRIV Warning horns, Back up alarm, Warnhörner, Rückfahralarm,
34 =VIB Vibration Vibration
35 =EXC Variocontrol Variocontrol
36 =EXC Variocontrol Variocontrol
37 =DBL Dozer blade Planierschild
38 =VPL Vibratory plate compactor Anbauplatten
39 =VPL Vibratory plate compactor Anbauplatten
0 1 2 3 4 5 6 7 8 9
Page from
Created M. Vogt Blatt2 von
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Table of contents Kind of Document
Dokumentenart &AAB
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Inhaltsverzeichnis 642 EPE /00
Table of contents

40 =MEAS Measurement equipment Messtechnik
41 =MEAS Economizer Economizer
42 =MEAS Economizer Economizer
43 =MEAS Interface measurement Schnittstelle Messtechnik
44 =OPT Rops - Lighting, Socket Rops - Beleuchtung, Steckdose
45 =OPT StVZO illumination StVZO Beleuchtung
46 =OPT Electronical Burglary protection Elektronische Diebstahlsicherung
47 =OPT BOMAG Telematics BOMAG Telematik
48 =OPT Morey Telematics, ZTR Telematics Morey Telematic, ZTR Telematic
49 =OPT Cabin - Additional heater Kabine - Zusatzheizung
50 =OPT Cabin - Heating, Air conditioning, Washer pumps Kabine - Heizung, Klimaanlage, Wascherpumpen
51 =OPT Cabin - Supply Kabine - Versorgung
52 =OPT Cabin - Fuse protection Kabine - Absicherung
53 =OPT Cabin - Lighting Kabine - Beleuchtung
54 =OPT Cabin - Cabin equipment Kabine - Kabinenausrüstung
55 =OPT Cabin - Cabin equipment Kabine - Kabinenausrüstung
56 =OPT Cabin - Radio, Tachograph, Printer measurement Kabine - Radio, Tachograph, Drucker Messtechnik
57 =OPT BOMAG Compaction Management BCM, GPS BOMAG Verdichtungsmanagement BCM, GPS
58 =OPT Back up monitoring Rückraumüberwachung
BW 219 D-5 / BW 219 PD-5

0 1 2 3 4 5 6 7 8 9
Page from
107
Dokumentenart &AAB
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Inhaltsverzeichnis
935
642 EPE /00
936
Table of contents

Circuit diagrams

90 Cable diagram W1, W2, W3 Kabelplan W1, W2, W3
91 Cable diagram W4, W6, W7, W8 Kabelplan W4, W6, W7, W8
92 Cable diagram W8, W9, W10, W17 Kabelplan W8, W9, W10, W17
93 Cable diagram W18 Kabelplan W18
BW 219 D-5 / BW 219 PD-5

102 Pin overview S55 Pin Übersicht S55
103 Overview CAN communication Übersicht CAN Kommunikation
104 Overview central electric Übersicht Zentralelektrik
105 Overview plugs X100 - X110 Übersicht Stecker X100 - X110
0 1 2 3 4 5 6 7 8 9
Page from
107
Dokumentenart &AAB
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Inhaltsverzeichnis 642 EPE /00
Strukturkennzeichenübersicht BO_F24_001
Higher-level function Range

Anlage Bereich
Description Beschreibung
=COM Communication Kommunikation
=DBL Dozer blade Planierschild
=DRIV Drive functions Antriebsfunktionen
Exhaust aftertreatment Deutz TCD 4.1 and 6.1 Tier 4 final Abgasnachbehandlung Deutz TCD 4.1 and 6.1 Tier 4 final /
=EAT2
/ Stage V Stage V
=ENGI Engine Antriebsmaschine
=ENGI2 Engine Deutz TCD 4.1 and 6.1 Tier 4 final / Stage V Motor Deutz TCD 4.1 and 6.1 Tier 4 final / Stage V
=EXC Exciter displacement Erregerverstellung
=MEAS Measurement equipment Messtechnik
=MON Monitoring, Failure indicators Überwachung, Störmeldungen
=OPT Optional functions Optionale Funktionen
=SUPL Supply Versorgung
=VIB Vibration and compaction Vibration und Verdichtung
=VPL Vibratory plate Vibrationsplatte
Mounting location Range
Einbauort Bereich
+ARC Armature carrier Armaturenträger
+BAT Battery-box Batteriekasten
+CAB Cabin Kabine
+DPL Drivers platform Fahrerstand
+DRUM Drum Bandage
+EBOX Central electric Zentralelektrik
+FRFR Front frame Vorderrahmen
BW 219 D-5 / BW 219 PD-5

+MOT Engine and attachment parts Motor und Anbauteile
+PLA Vibratory plate compactor Anbauplatten
+PUMP Pump mounting Pumpenanbau
+REFR Rear frame Hinterrahmen
+ROPS Roll-Over Protection System Überrollschutz System
+SEAT Seat console Sitzkonsole
Kind of Document Range
Dokumentenart Bereich
&AAA Title page / cover sheet Titel- / Deckblatt
&AAB Table of contents Inhaltsverzeichnis
&ADB Structure identifier overview Strukturkennzeichenübersicht
&ALU Layout mounting locations Anordnung Einbauorte
&EFA1 Pin overview ECU Pin Übersichten Steuerungen
&EFA2 Overview CAN communication Übersicht CAN Kommunikation
0 1 2 3 4 5 6 7 8 9
Page from
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Structure identifier overview Kind of Document
Dokumentenart &ADB
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Strukturkennzeichenübersicht
937
642 EPE /00
938
Strukturkennzeichenübersicht BO_F24_001
Kind of Document Range

Dokumentenart Bereich
&EFS Circuit diagram Schaltpläne
&EMA3 Plug overview Steckerübersicht
Circuit diagrams
&EMB2 Cable diagram Kabelplan

&EPB Device tag list electrical engineering Betriebsmittelliste Elektrotechnik
&ETL1 Overview central electric Übersicht Zentralelektrik
BW 219 D-5 / BW 219 PD-5

0 1 2 3 4 5 6 7 8 9
Page from
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Structure identifier overview Kind of Document
Dokumentenart &ADB
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Strukturkennzeichenübersicht 642 EPE /00
+FRFR
+DRUM +REFR
+PLA
+CAB
+ROPS
+DPL
+SEAT
+MOT
+ARC +PUMP
+BAT
BW 219 D-5 / BW 219 PD-5

+EBOX
0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage = Blatt7 von
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Layout mounting locations Mounting location Kind of Document
Einbauort + Dokumentenart &ALU
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Anordnung Einbauorte
939
642 EPE /00
940
F13:2 / 9.0
+REFR X4.A 9
RD
4 mm² F95:2 / 10.0
X0.A
RD 1 +ARC RD
25 mm² 30_PB / 9.0 1,5 mm²
RADSOK® 8mm RD
1,5 mm² S15:11 / =OPT/45.0
30
P 0 IIIIII
RD
50 mm² S00 P,0,I
1 switch ignition 58 15/54 19 17 50a

Circuit diagrams
Schalter Motorstart
WH
F39 1,5 mm²
80A
MAXI Fuse
2
Fuse, main cabin WH
MAXI Sicherung
1,5 mm² S15:23 / =OPT/45.0
Hauptsicherung WH WH WH
1,5 mm² 1,5 mm² 1,5 mm²
RD Kabine
70 mm²
X8.A

Fuse, main battery
Hauptsicherung Batterie
Fuse, B+ charge
Sicherung B+ Ladeleitung
=OPT+CAB/51.1
G02:B+ X4.A 13 3 20
=ENGI/18.1
S00:50a / 10.0
2 2 2
F95 4 F00 3 F164 1 S00:19 / =ENGI/20.1

30A 125A 150A 1
1 1 1
V01 15_CAB
=OPT+CAB/51.1
S5G-E3 2
+MOT 30
86 1 1
K61
RD
70 mm² K61 R10 /8.6 87 87a
D61
green
/8.7 2 82Ω / 22W Relay, charge control
85 2 Relais Ladekontrolle
12V/20A

K39:2 / =ENGI2/22.8
K39:1 / =ENGI2/22.8
D+ / =MON/27.0
(86)
4 88a 2
S30 K39 X1.A 7 X7.C 5

250A K15 =MEAS/43.0
3 88 1
Disconnect switch, battery (85)
X1.A_f 7X7.C-2 5 X7.C:4
RD Batterietrennschalter
4 mm²
=OPT+DPL/49.1
X7.C-2
5 31_AH
BW 219 D-5 / BW 219 PD-5

1
RD
XG02.D+
+BAT 70 mm² 30 50 B+ D+
86 1 86 1
X7.C 4
RD G
70 mm²
M01 G02 K09 K11
D09
D11
green
green
M1 14V / 150A X7.C-2 4 12V/20A 2 12V 2

XG01.+_2 85 85
X300:30 Starter - Generator B- W BN
1,5 mm²
1 =EAT2/26.1 Starter Relay, starter Generator
G03 + G01 + -U300
Ground engine Relais Anlasser
12V / 88Ah Battery
1Masse Motor 2 Ground engine 3 X7.C-2 4
Battery - Batterie -
at BW 219-226 XG01.-_2
-U300 = Masse Motor
Batterie 12V / 88Ah X300:31
bei BW 219-226 X7.C 4
1 =EAT2/26.1
at BW 211-216
Only at BW 219-226
Nur bei BW 219-226
12V / 110Ah
X0.B
bei BW 211-216 BN 1
16 mm² Gnd_PB / 9.0
BK XU600.3 RADSOK® 6mm
70 mm² 31_Eng / =ENGI/18.0
BK
3 XU600.4
70 mm²
XU600.2
4 31_EMR / =ENGI2/21.0 X8.B / =OPT+CAB/51.1
BK
70 mm² -U600 31_DCtrl / 11.0
Ground central electric 2 5
Ground rear frame 1Masse Zentralelektrik 87 30 87 /10.0
-U500 = Masse Hinterrahmen 6 31_MCtrl / 12.0 87a 30 =OPT+CAB/50.1
1Ground rear frame 2 3 -U600

Masse Hinterrahmen
Ground central electric 7 31_RFr / =DRIV+REFR/31.1
-U500 Relay, air conditioning Relay, potential 30 on 15
Masse Zentralelektrik -XU600.8 Relais Klimaanlage Relais Potential 30 auf 15
8 1 31_Ar / 14.6
9 31_Db / 14.1
XU600.10
10 1 31_Econ / =MEAS/41.1
0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage =SUPL Blatt 8 von
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Supply, Starting unit Mounting location Kind of Document
Einbauort +EBOX Dokumentenart &EFS
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Versorgung, Starten 642 EPE /00
8.6 / 30_PB 30_PB / 10.0
30
K06
=OPT/44.5 87 87a
Relay, headlights rear
Relais Scheinwerfer hinten
F13 F157 F68 F22 F19 F84 F23 F67 F146 F11 F07 F268
15A 30A 15A 15A 15A 10A 15A 15A 15A 15A 10A 20A
Fuse, fuel pump
Fuse, hazard light
Fuse, potential 30
Fuse, signal horns
Fuse, headlight left
Fuse, ignition switch

Sicherung Warnblinker
Sicherung Startschalter
Sicherung Signalhörner
Fuse, controller (Pin 54)
Fuse, working lights rear

Sicherung Kraftstoffpumpe
Fuse, solenoid switch starter

Sicherung Scheinwerfer links

Fuse, working headlight front left

Sicherung Steuerung (Kontakt 54)
Sicherung Magnetschalter Anlasser

Sicherung Arbeisscheinwerfer hinten

X4.A 19 F268:2
Sicherung Arbeitsscheinwerfer vorne links

=ENGI/18.0
8.9 / F13:2 30 F07:2

+ARC WH =OPT/45.0
K145 1,5 mm²
=ENGI/20.8 87a 87 X7.C 1

Relay, solenoid starter F11:2
1
XS01.11
Relais Hubmagnet Starter X7.C-2 1 =OPT/45.0
11 21 A1
-S01 F146:2
switch emergency off 12.0
30 12 22 A2
RD Schalter Not Aus
K38 1,5 mm² 1
F67:2
/10.2
=ENGI/20.6 87a 87
Relay, starter control 11.0
X7.C-2 1
XS01.12
X7.C 1 F23:2
WH =DRIV+REFR/33.2
=DRIV+REFR/32.5
1,5 mm²
1 2 F84:2
BW 219 D-5 / BW 219 PD-5

X1.A
1 =COM/15.0
Fx X4.A 10
Fuseholder, fuse test S01:12
2 11.0
Sicherungshalter Sicherungstest
F19:2
=OPT/44.0
1 F22:2
=OPT/44.0
Dx
green 2
Indicator light, fuse test X7.C:1
Meldeleuchte Sicherungstest =MEAS/43.0
F68:2
=OPT+DPL/49.1
8.9 / Gnd_PB Gnd_PB / =COM/15.0
0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage =SUPL Blatt9 von
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Fuse protection potential 30 Mounting location Kind of Document
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Absicherung Potential 30
941
642 EPE /00
BW 219 D-5 / BW 219 PD-5 942
Erstellt
Geprüft
Created
Checked
0
9.9 / 30_PB
8.9 / S00:50a
8.6 / F95:2
M. Vogt
K. Brand
16.07.2019
16.07.2019
/8.8
K11
87
30
X7.C-2
X7.C-2
X7.C
X7.C
2
2
2
2
WH
1,5 mm²
15A
F103
Fuse, potential 15
1
+ARC
BW11RH - F41
3
3
3
Schalter Not Aus
switch emergency off
/9.4
-S01
10A
F122
X4.A
X4.A
XS01.22 XS01.21 Fuse, engine controller

1
1
1
22
21
WH
WH
12
1,5 mm²
1,5 mm²
Deutz TCD 4.1_6.1

2
10A
F148

BW11RH - F25
BW 213-226 D, DH, BVC-5
10A
F24
Fuse, monitoring module

Sicherung Überwachungsmodul
3
5A
F91
Fuse, sensors
Sicherung Sensoren
20A
F05
Fuse, socket
Sicherung Steckdose
4
10A
F08
Fuse, indicators
Sicherung Blinker
Absicherung Potential 15
25A
F124
Fuse, fuel-pre-heating
Fuse protection potential 15

Sicherung Kraftstoffvorheizung
5A
F244

6
30A
F40
Fuse, heating unit cabin

Sicherung Kabinenheizung
15A
F29
Fuse, compressor suspension seat

Sicherung Kompressor Luftfedersitz
7
5A
F169
Fuse, starting current

Sicherung Startstrom
Anlage
Einbauort
Mounting location
8
7,5A
F243
X0.C

30
30
=SUPL
+EBOX
Blatt
Page
RADSOK® 3,6mm
14.0
11.0
14.0
F24:2
F91:2
F05:2
F08:2
F40:2
F29:2
10
X7.C:2
F103:2
F148:2
F124:2
F244:2
F169:2
F243:2
S01:22
642
Dokumentenart
=OPT/44.0
=OPT/45.0
=OPT/47.1
=OPT/47.1
Kind of Document
=DRIV/28.0
=ENGI/18.0
=ENGI/20.1
=MEAS/43.0
X0.C / =ENGI/20.1
9
=OPT+DPL/49.1
=OPT+CAB/50.1
=OPT+CAB/50.1
von
from
&EFS
107
EPE /00
Circuit diagrams
9.9 / S01:12 S01:12 / 12.0
10.9 / F148:2 F148:2 / 12.0
9.9 / F67:2
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, ECU propulsion
Stecker ECU Fahrantrieb
WH
2,5 mm²
Splice
Spleiss 38
B57:2 / =DRIV/28.0
Splice
Spleiss 39
BW 219 D-5 / BW 219 PD-5

X35 28 X35 54 X35 56 X35 57 X35 58 X35 59 X35 60
X35 28 X35 54 X35 56 X35 57 X35 58 X35 59 X35 60

A34 A34 A34 A34 A34 A34 A34

8.5 / 31_DCtrl 31_DCtrl / =DRIV/28.0
0 1 2 3 4 5 6 7 8 9
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Supply Driving Controller Mounting location Kind of Document
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Versorgung Fahrsteuerung
943
642 EPE /00
944
11.9 / F148:2 F148:2 / =COM/15.0
9.9 / F146:2
11.9 / S01:12
Circuit diagrams
Measurement controller GND GND GND GND GND

Messtechnik Steuerung A83 A83 A83 A83 A83
GND GND GND GND GND
X5.E 4 13 6
X88 55 X88 65 X88 66 X88 67 X88 68
X5.E2 4 13 6
X88 55 X88 65 X88 66 X88 67 X88 68
A83
X5.E2 4 13 6
X5.E 13 6 X88
Plug, measurement controller
Stecker Messtechniksteuerung
X5.E 4 X5.E3 4 WH
2,5 mm²
Splice
Spleiss 43
=MEAS/41.1 / X5.E:4
BW 219 D-5 / BW 219 PD-5

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

A83 A83 A83 A83 A83 A83 A83
8.5 / 31_MCtrl 31_MCtrl / =EXC/36.1
0 1 2 3 4 5 6 7 8 9
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Supply Measurement controller Mounting location Kind of Document
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Versorgung Messtechniksteuerung 642 EPE /00
FM1 / =DRIV/28.0
AGND_DC / =COM/15.0
FM2 / =EXC/36.1
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
X5.E2 9
X5.E2 9
X5.E 9
AGND / =DRIV/28.0 AGND_MC / =MEAS/40.1

Splice
Spleiss 42
BW 219 D-5 / BW 219 PD-5

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
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Supply 8,5V sensors Mounting location Kind of Document
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Versorgung 8,5V Sensoren
945
642 EPE /00
946
10.9 / S01:22 S01:22 / =ENGI/20.1
10.9 / F24:2
X4.A 18 X4.B 7
Circuit diagrams
+ARC +SEAT Splice

Spleiss 51
=DRIV+SEAT/29.0
15_Ar / =EXC/35.1
Splice
Spleiss 48
15_Db / =ENGI/19.1 X23 1
X23.B 1
A15
module monitoring K189:30 / =DRIV+SEAT/29.8
Modul Überwachung
X33 26 1
X23.A
X33 26 X23 1
Power supply (8...32V) Power supply (8...32V)
A15 S55
+UB +Ub
switch control lever travel

Schalter Steuerhebel Fahren
Power supply Power supply
Stromversorgung Stromversorgung
-S55
Ground Ground Ground Ground

Masse Masse Masse Masse
Ground housing
GND
GND Gnd 0V ADR 1 ADR 2
A15 S55 -S55 -S55 -XGnd 1
Ground Ground Digital IN 7 Digital IN 8
X33 25 X23 2 X23 9 X23 10
X33 25 X23.A 2 X23.A 9 X23.A 10
X33 K189:85
Splice =DRIV+SEAT/29.8
#1
BW 219 D-5 / BW 219 PD-5

Plug, module monitoring Spleiss
Stecker Modul Überwachung
31_Db_2 / =MON/27.0
Splice
Spleiss 67 X23.B 2 X23.B 9 X23.B 10
X23 2 X23 9 X23 10 -XS55.Gnd 1
BN Splice
2,5 mm² Spleiss 83
8.5 / 31_Db 31_Db / =DRIV+REFR/33.1

8.5 / 31_Ar 31_Ar / =DRIV/28.0
0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage =SUPL Blatt 14 von
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Supply Monitoring module, Travel lever Mounting location Kind of Document
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Versorgung Überwachungsmodul, Fahrhebel 642 EPE /00
=SUPL/9.9 / F84:2 F84:2 / =OPT/46.1
=SUPL/12.9 / F148:2 F148:2 / 17.0
=SUPL/13.9 / AGND_DC AGND_DC / =DRIV/28.0
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
Pot. 30 - 12V
Pot. 15 - 12V
Gnd 1
N A B C D E F X34 = Diagnosesteckdose BOMAG
P R J
Gnd
CAN 1 low
CAN 2 low
CAN 3 low
CAN 1 high
CAN 2 high
CAN 3 high
bestückt
Widerstände nicht
X7.D 2 10 R20 7 6 R22 3 11 R24 8

1 2 1 2 1 2
120 Ω 120 Ω 120 Ω

=SUPL/9.1 / Gnd_PB Gnd_PB / 17.0
R21
1 2 R25
1 2
120 Ω
X7.C 13 X7.C 14 120 Ω
X7.C-2 13 X7.C-2 14
X5.A 12 15 6 9 X5.E 15 12
BW 219 D-5 / BW 219 PD-5

X5.E2 15 12
X7.C-2 13 X7.C-2 14 X5.E2 15 12
X5.E 15 X5.E3 15 X5.E 12 X5.E3 12
X5.E:12 / =MEAS/41.1
X5.E:15 / =MEAS/41.1
X35 27 X35 26 X35 53 X35 33 X88 27 X88 26
X35 27 X35 26 X35 53 X35 33 X88 27 X88 26

A34 A34 A34 A34 A83 A83
0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage =COM Blatt15 von
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Communication, Diagnosis Mounting location Kind of Document
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Kommunikation, Diagnose
947
642 EPE /00
948
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/51.1
Circuit diagrams
CAN3- / =OPT+CAB/51.1
R26
1 2
120 Ω
R27
1 2
120 Ω
X5.E 1 2
X5.E2 1 2
X5.E:2_2 / =MEAS/43.0
X4.A 14 17 X4.B 1 4
X5.E:1_2 / =MEAS/43.0
X5.E2 1 2
X5.E 1 X5.E3 1 X5.E 2 X5.E3 2

+ARC +SEAT X5.E:2 / =MEAS/42.1
X23 6 X23 7
X5.E:1 / =MEAS/42.1
X23.B 6 X23.B 7
BW 219 D-5 / BW 219 PD-5

X33 21 X33 22 6 7 X88 53 X88 33
X23.A X23.A
X33 21 X33 22 X23 6 X23 7 X88 53 X88 33
CAN high CAN low CAN bus high CAN bus low CAN2_H CAN2_L
A15 A15 S55 A83 A83
CANH CANL CAN + CAN - CAN2_H CAN2_L
CAN high CAN low CAN high CAN low CAN 3 high CAN 3 low
CAN high CAN low CAN high CAN low CAN 3 high CAN 3 low
0 1 2 3 4 5 6 7 8 9
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Communication Mounting location Kind of Document
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Kommunikation 642 EPE /00
16.9 / CAN2+ CAN2+ / =ENGI/20.1
16.9 / CAN2- CAN2- / =ENGI/20.1
16.9 / CAN1+ CAN1+ / =OPT/46.1
16.9 / CAN1- CAN1- / =OPT/46.1
15.1 / Gnd_PB Gnd_PB / =ENGI/20.1
15.9 / F148:2 F148:2 / =OPT/46.1
15.9 / M_CAN1+ CAN2+_TM / =OPT/47.1
15.9 / M_CAN1- CAN2-_TM / =OPT/47.1
R28
1 2
120 Ω

Widerstände nicht bestückt
R29
1 2
120 Ω
BW 219 D-5 / BW 219 PD-5

X7.A 1 2 6 5 3 4 8 7 9 10
0 1 2 3 4 5 6 7 8 9
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Communication Mounting location Kind of Document
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Kommunikation
949
642 EPE /00
950
=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
K14:2_4.1_6.1
=ENGI2/22.9
K14:1_4.1_6.1
=ENGI2/22.8
(85) (88a)
1 WH WH
4 1,5 mm² 1,5 mm²
K 14
K2 /18.1 2 3
Fitted on the engine

Am Motor angebaut
(88) Splice
(86) 84 X78.f X78.m
Spleiss
WH 1 1 X78:1
Relay, glow plug system 2,5 mm²
Relais Vorglühen K14:3_4.1_6.1 =EAT2/26.0

=ENGI2/22.9 WH
2,5 mm²
X67.f 1
1 WH
R19 2,5 mm²
167A 1
R4 XR79
Heating flange 2
1
BW 219 D-5 / BW 219 PD-5

Heizflansch 4 1
-U300
Ground engine R79
Masse Motor 200W 2
heating prefilter fuel
Heizung Vorfilter Kraftstoff
2
XR79 2
BN
2,5 mm²
X67.f 2
BN
2,5 mm²
BN Splice
=SUPL/8.5 / 31_Eng 6 mm² Spleiss 31_Eng / =MON/27.0
74
0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage =ENGI Blatt18 von
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Pre-heating, Fuel lift pump, Fuel-pre-heating Mounting location Kind of Document
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Vorglühen, Kraftstoffförderpumpe, Kraftstoffvorwärmung 642 EPE /00
+ARC
=SUPL/14.2 / 15_Db VIB_TM / =OPT/47.1
XS127.13
XS127.23
-XS299.13
-XS299.23
1 1 1 1
13 23 23
low
eco
high
-S127 S299 X4.A 16
switch engine speed 14 24 switch regeneration mode 24
Schalter Motordrehzahl Schalter Regenerationsmodus
1 1 1 1
XS127.14
XS127.24
-XS299.14
-XS299.24
BW 219 D-5 / BW 219 PD-5

X33 9 X33 10 X33 11 X33 12 X33 4
X33 9 X33 10 X33 11 X33 12 X33 4

active high active high active high active high +UB, max 1,5A
A15 A15 A15 A15 A15
DIN3 DIN4 DIN5 DIN6 DOUT2
+ARC-S127:14 +ARC-S127:24 +ARC-XS299.14:1 +ARC-S299:24 -A124:11

Switch, engine speed Sx. 1 Switch, engine speed Sx. 2 Switch, regeneration Sy. 1 Switch, regeneration Sy. 2 Vibration Telematics
Schalter Motordrehzahl Sx. 1 Schalter Motordrehzahl Sx. 2 Schalter Regeneration Sy. 1 Schalter Regeneration Sy. 2 Vibration Telematik
0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage =ENGI Blatt19 von
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Engine speed, Regeneration mode Mounting location Kind of Document
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Motordrehzahl, Regenerationsmodus
951
642 EPE /00
952
Circuit diagrams
X1.B:1 / =ENGI2/21.0
X1.B:2 / =ENGI2/21.0
X1.B:14 / =ENGI2/21.4
X1.B:9 / =ENGI2/21.4
X1.B:16 / =ENGI2/21.5
X1.B:12 / =ENGI2/21.5
X1.B:10 / =ENGI2/21.6
X1.B:13 / =ENGI2/21.6
X1.B:15 / =ENGI2/21.2
X1.B:18 / =ENGI2/21.3
X1.B_f 1 2 X1.B_f 14 9 16 X1.B_f 12 10 13 15 18
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 86 1 12V/40A 86 87 87a 86 1

2 2
CN403
D41
green
green
green
87a 87
D209
D145
K41 K05
12V/25A 30 86 1 2 Relay, starter control =DRIV+REFR/32.2 30 2
K209 85 K145 85
BW 219 D-5 / BW 219 PD-5

CN413 12V/30A 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 Relais Startstrom Relais Hubmagnet Starter
87 87
!!! There is still power supply even if the battery disconnector switch is turned off 87a 30 /18.6 87a 30 =SUPL/9.2
!!! Auch bei ausgeschaltetem Batterietrennschalter unter Spannung 87 87a
K22
=DRIV+REFR/33.9
Relay, shut off solenoid engine 30
Relais Hubmagnet Abschaltung Motor
=SUPL/8.9 / S00:19
=SUPL/10.9 / F169:2
=SUPL/14.9 / S01:22
=COM/17.8 / CAN2+
=COM/17.8 / CAN2- StU_TM / =OPT/47.1
=COM/17.8 / Gnd_PB Gnd_PB / =DRIV/28.0
0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage =ENGI Blatt 20 von
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Engine - Machine-part Mounting location Kind of Document
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Motor - Fahrzeugseite 642 EPE /00
A48
EDC 17 CV-52

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
-A48 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 WH WH WH BN BN BN
2,5 mm² 2,5 mm² 2,5 mm² X45:13 / =EAT2/25.0 2,5 mm² 2,5 mm² 2,5 mm²
X45:31 / =EAT2/25.0
Splice
Spleiss 68
X45:18 / =EAT2/25.0
WH WH
2,5 mm² 2,5 mm²
K22:87a / =EAT2/24.0
X108.m 1 2 3 4 5
X108.f 1 2 Splice
Spleiss 33
+MOT +MOT
X73 1 2
1
XB218
1
X73 1 2 1 R30
X48 2 1 2
1 2120 Ω
Plug engine stop
B124 Stecker Motor Stop
B218 R23
2
BW 219 D-5 / BW 219 PD-5

120 Ω 1
2
Sensor, water trap fuel
XB218
Sensor Wasserabscheider Kraftstoff
Temperature sensor, ambient temperature

Temperatursensor Umgebungstemperatur
Ubat
CAN 2 high
CAN 2 low
CAN 1 high
CAN 1 low
31-GND
A M F H G B
X32
X22
CAN 1 = Diagnosis CAN
CAN 2 = Customer CAN
=ENGI/20.2 / X1.B:1
=ENGI/20.2 / X1.B:2
=ENGI/20.5 / X1.B:9
=ENGI/20.7 / X1.B:15
=ENGI/20.8 / X1.B:18
=ENGI/20.4 / X1.B:14
=ENGI/20.5 / X1.B:16
=ENGI/20.6 / X1.B:12
=ENGI/20.7 / X1.B:10
=ENGI/20.7 / X1.B:13
Diagnosis interface EMR

Diagnoseschnittstelle EMR
BN Splice
=SUPL/8.5 / 31_EMR 6 mm² Spleiss 31_AGR / =EAT2/24.0
69
0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage =ENGI2 Blatt 21 von
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Deutz TCD 4.1/6.1 Tier 4 final / Stage V Mounting location Kind of Document
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Deutz TCD 4.1/6.1 Tier 4 final / Stage V
953
642 EPE /00
954
A48
EDC 17 CV-52
Circuit diagrams


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
-A48 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
BW 219 D-5 / BW 219 PD-5

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
/22.0
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 /22.0
1
X17.1
B130 n
B40.2
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
Injector A4 Injector A5 Injector A6 Injector A4 Injector A2 EMR Motordrehzahlsensor 1
=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
EMR Motordrehzahlsensor 2
at Deutz TCD 6.1 at Deutz TCD 4.1 Crankshaft
Kurbelwelle
=ENGI/18.1 / K14:1_4.1_6.1
=ENGI/18.1 / K14:2_4.1_6.1
=ENGI/18.1 / K14:3_4.1_6.1
bei Deutz TCD 6.1 bei Deutz TCD 4.1

0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage =ENGI2 Blatt 22 von 107
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Deutz TCD 4.1/6.1 Tier 4 final / Stage V 642 EPE /00
A48
EDC 17 CV-52


D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1
-A48 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 2 55 18 76 51 8
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
BW 219 D-5 / BW 219 PD-5

1
2 1 1
2 4 2
Y137 B93 B133 3
B145 3 1
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 3
B238 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
Created M. Vogt Anlage =ENGI2 Blatt23 von
107
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Deutz TCD 4.1/6.1 Tier 4 final / Stage V
955
642 EPE /00
956
A48
EDC 17 CV-52

1 Plug, Plug, Kabelbaum EMR - Motorschnittstelle
Circuit diagrams
engine-controller engine-controller 1
R32 motor-part machine-part
120Ω 2 Stecker Stecker R31
Motorsteuergerät Motorsteuergerät 120Ω 2
Motorseite = X44 D2.1 (A) D2.2 (K) -X45 = Maschinenseite
D2.1 D2.1
X41 38 39 -A48 98 77 X41 36 35
X23 X23
X44 98 77
D2.1
=ENGI2/21.9 / 31_AGR
X39 X36 39 38 37 13
=ENGI2/21.6 / K22:87a
3 Splice
Spleiss 31_EAT / 26.0
F310:2 / 26.0
F251:2 / 26.0
X41 28 29 WH
1,5 mm²
X23
+MOT
Splice
Spleiss 14
BW 219 D-5 / BW 219 PD-5

Splice Splice
X46.2 57 59 28 29 23 22 Spleiss 15 Spleiss 16
X17.2
Splice
Spleiss 19
Splice
Spleiss 20
+

Ub Gnd CAN L CAN H CAN L CAN H 1 Can L

Y174 1 2 6 3 4 5 2
Ub
Ub
Y20
Gnd
Gnd
OUT IN B224 4 3 2 1 B225 4 3 2 1

Can L
Can L
Can H
Can H
Can H
EMR Exhaust gas recirculation B54 B56

3
EMR Abgasrückführung 4 grey black
ECU B222 grau schwarz
-
B90 ECU ECU
M
Sensor, urea temperature and level Sensor, NOx before SCR-Kat Sensor, NOx behind SCR-Kat
Sensor Ureatemperatur und Füllstand Sensor NOx vor SCR-Kat Sensor NOx nach SCR-Kat
0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage =EAT2 Blatt24 von
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Deutz TCD 4.1/6.1 Tier 4 final / Stage V - Exhaust aftertreatment Mounting location Kind of Document
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Deutz TCD 4.1/6.1 Tier 4 final / Stage V - Abgasnachbehandlung 642 EPE /00
A48
EDC 17 CV-52


Stecker Motorsteuergerät Motorseite = X44 D2.1 (A) D2.2 (K) -X45 = Stecker Motorsteuergerät Maschinenseite
D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1
-A48 15 48 09 32 29 20 27 47 26 70 57 19 82 05 89 59 92
X44 15 48 9 32 29 20 27 47 26 70 57 19 82 5 89 59 92
=ENGI2/21.6 / X45:18
D2.1
=ENGI2/21.6 / X45:31
=ENGI2/21.6 / X45:13
X36 18 19 3 4 15 14 5 28 22 33 29 24 30 16 36 35 25
X39
X41 32 33 34
X23 WH WH
1,5 mm² 1,5 mm²
M41:9 / 26.0
+MOT E107:+ / 26.0
X36 10 9 8 +REFR
X39
E107:- / 26.0
BW 219 D-5 / BW 219 PD-5

Y292:4 / 26.0
WH WH WH
1,5 mm² 1,5 mm² 1,5 mm²
Splice
Spleiss 13
X31 4 3 2 12 11 8 10 9 5 6
3 2 2 2 3
2 2
3 3 4 -E107
P P 1 2 + 4
1 1 1 1 1 2
B305 B223 B214 B215 B216
B88 B78 B65 B66 B58 P R
2 1 M41 - 1
black grey 1
schwarz grau
Y293 B221 Y291 5 M10 ???W
Y292
Y24 B63 Y30 Y31
Boost module
Fördermodul
EMR Pressure sensor, pressure after DPF EMR Sensor, temperature exhaust gas before oxy cat
EMR Drucksensor, Druck nach DPF EMR Temperatursensor Abgas vor Oxy Kat Solenoid valve, urea dosing Solenoid valve, urea extraction Heating, supply modul
Magnetventil Ureadosierung Magnetventil Urea Absaugung Heizung Versorgungsmodul
EMR Sensor, temperature exhaust gas after oxy cat
EMR Temperatursensor Abgas nach Oxy Kat Sensor, urea pressure behind pump Urea pump Solenoid valve, urea tank heating
Sensor, Ureadruck nach Pumpe Urea Pumpe Magnetventil Ureatank Heizung
Temperature sensor, exhaust gas before SCR kat EMR Sensor, differential pressure DPF
Temperatursensor Abgas vor SCR Kat EMR Sensor Differenzdruck DPF
0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage =EAT2 Blatt25 von
107
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Deutz TCD 4.1/6.1 Tier 4 final / Stage V - Abgasnachbehandlung
957
642 EPE /00
958
+MOT
25.9 / M41:9
A48
=ENGI/18.9 / X78:1 EDC 17 CV-52
25.9 / E107:- ECU Motorsteuergerät
Plug,
engine-controller
25.9 / E107:+ Plug, engine-controller machine-part
motor-part Stecker
25.9 / Y292:4 Stecker Motorsteuergerät Motorsteuergerät
Motorseite = X44 D2.2 (K) X45 = Maschinenseite
Circuit diagrams
D2.1 (A)
24.7 / F310:2
D2.1 D2.1 D2.1 D2.1 D2.1 D2.1 D2.1

24.7 / F251:2 -E105 -E106 -E104 62 80 37 61
1+ 1+ 1+ -A48 03 41 04
R R R X44 3 41 4 62 80 37 61
2- 2- 2-
D2.1
24.7 / 31_EAT X36 34

11 23 31 32 21 20
X39
Heating, suction line

Heizung Saugleitung
Heizung Druckleitung
Heating, pressure line
BN
2,5 mm²
Heizung Rücklaufleitung
Heating, return flow line
+BAT WH WH WH WH WH WH WH
1 2,5 mm² 2,5 mm² 2,5 mm² 2,5 mm² 2,5 mm² 2,5 mm² 2,5 mm²
X303 X300:30
=SUPL/8.2 X303 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
X303 1
BN X300:31
2,5 mm² X303 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
=SUPL/8.2 BN RD WH WH WH WH WH WH WH WH WH WH WH
10 mm² 10 mm² 1,5 mm² 1,5 mm² 2,5 mm² 2,5 mm² 2,5 mm² 2,5 mm² 2,5 mm² 2,5 mm² 1,5 mm² 2,5 mm² 1,5 mm²
X300 31 X300 F312 2 F313 2 X301 12 15 14 4 5 1 7 8 6 3 2 9 10 13 X302 1 2 3 4 5 6 7

30
M6
M5
M5
Stud bolt
Stud bolt
Stud bolt
BW 219 D-5 / BW 219 PD-5

Gewindebolzen
Gewindebolzen
Gewindebolzen

Fuse, reserve
Sicherung Reserve
Fuse, SCR control
Sicherung SCR Ansteuerung
Fuse, reserve
Sicherung Reserve
Fuse, NOx sensors
Sicherung NOx Sensoren
Fuse, sensor urea quality
Sicherung Sensor Ureaqualität
Fuse, exhaust gas recirculation
Sicherung Abgasrückführung
Relay, SCR control
2 2 2 2 2 2
Relay, SCR control

5A
K227 K192 K193 K194 K195 K196
30A
10A
15A
F312
F250
F313
F251
F310
F238
87 87 87a 87 87a 87 87a 87 87a 12V 86 12V 86 12V 12V 12V 12V
max. 20A
max. 20A
1 1 1 1 1 1 85 85 85 85
K192 K194 K195 K196 K193
K31 30 K28 30 K29 30 K30 30 K27 30 K31 K27 86 K28 86 K29 86 K30 86
85 85
/26.7 /26.8 /26.9 /26.9 /26.8
87
K227
87
87a
87
87a
87
87a
87
87a
87
30 87
30
Relay, potential 30 on 15 /26.1

30
30
30
30
30
/26.6
/26.4 /26.6 /26.5 /26.5 /26.6
0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage =EAT2 Blatt 26 von
107
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Deutz TCD 4.1/6.1 Tier 4 final / Stage V - Abgasnachbehandlung 642 EPE /00
+ARC
D+ Alternator Coolant level Water in Fuel Maintenance switch, air cleaner Hydraulic oil filter Warning buzzer, breakdown Fuel level
D+ Generator Kühlmittelfüllstand Wasserabscheider Wartungsschalter Luftfilter Hydraulikölfilter Warnsummer Betriebsstörung Tankfüllstand
AIN_7 DIN_11 DIN_5 DIN_7 +ARC-H07:+
DOUT1 AIN 2
DIN_9
A34 A34 A34 A34 A34 A15 A15
AIN7 / 10V 25mA DIN11 / 0..32V DIN5 / 0..32V DIN9 / 0..32V DIN7 / 0..32V +UB, max 1,5A 0...140Ω
X35 9 X35 39 X35 36 X35 38 X35 37 X33 3 2
X35 9 X35 39 X35 36 X35 38 X35 37 X33 3 X33 2
X4.A 5
X4.A 5
X5.A 10
X101.m 1 2 3 X103 11
X5.A 10 X2.A 15
X101.f 1 3 X103 11
X2.A 15
=SUPL/8.6 / D+ D+ / =OPT/47.1
+REFR
X11 1
1
+MOT +REFR
X72.f 1
X69 2
X72.m 1 XB03
1 1
1 3 (1) +
3
BW 219 D-5 / BW 219 PD-5

B55 B03 P B21 P H07 R03
4
2 4 (2) 70mA - BW 211-216 = 66 Ω 2
2 2 BW 219-226 = 64,2 Ω
X72.m XB03
X69 3
X72.f 2
X11 2
=ENGI/18.8 / 31_Eng 31_Eng / =OPT+CAB/50.1
=SUPL/14.2 / 31_Db_2 31_Db_2 / =DRIV+SEAT/29.0
=DRIV+REFR/31.2 / 31_RFr.2
Floating switch, coolant expansion tank Maintenance switch, air cleaner Warning buzzer, breakdown Sender, level gauge
Schwimmerschalter Kühlmittelausgleichsbehälter Wartungsschalter Luftfilter Warnsummer Betriebsstörung Geber Tankanzeige
Differential pressure switch, hydraulic oil filter
Differenzdruckschalter Hydraulikölfilter
0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage =MON Blatt27 von
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Monitoring, Failure indicators Mounting location Kind of Document
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Überwachung, Störmeldungen
959
642 EPE /00
960
=SUPL/13.9 / FM1
=SUPL/10.9 / F91:2 F91:2 / +REFR/30.1
=ENGI/20.8 / Gnd_PB Gnd_PB / +REFR/32.2
=SUPL/14.7 / 31_Ar 31_Ar / =EXC/35.1
=SUPL/11.9 / 31_DCtrl 31_DCtrl / +REFR/31.1

Circuit diagrams
=SUPL/13.3 / AGND AGND / =VIB/34.1

1 1
=COM/15.9 / AGND_DC V07 V09
Only at DH-Version S1M 2 S1M 2
=SUPL/11.1 / B57:2 Nur bei DH-Version
1 1
V08 V10
S1M 2 S1M 2
X2.A 12 14 9 13 X5.A 2 16 1
B57
0,5-4,5V
sensor slope speed range selection 1 2 3
X106:1 / =VIB/34.1
Splice
Neigungssensor Stufenumschaltung Spleiss 41
- + S
X14 A X106:5 / =VIB/34.1
X14 A +REFR X104 1 2 3 4 X105:11 / =VPL/38.1

BK -
+SEAT 1 5
4+
S06 B60 3 speed
Switch, seat contact 4 2 Speed sensor, axle +DRUM
Sitzkontaktschalter Drehzahlsensor 2
BU BN
Achsgeschwindigkeit dir Only at DH-Version
X14 B C
Nur bei DH-Version
X14 B
W3 3 4
7x1
-
5
+4
B59
speed 3
X2.A 1 X2.A 4 Speed sensor, drum
2 Drehzahlsensor
dir Bandagengeschwindigkeit
11 10
BW 219 D-5 / BW 219 PD-5

X7.C X7.C
5 6 W3
X7.C-2 11 X7.C-2 10 7x1
X4.B 2
X7.C-2 11 X7.C-2 10
X5.B 10 X5.B 6 X5.B 5
X100 1 X104 5 6
X35 32 X35 15 X35 16 X35 13 X35 12 X35 35 X35 17
X35 32 X35 15 X35 16 X35 13 X35 12 X35 35 X35 17

AIN8 / 10V 25mA DIN8 / 0..32V DIN10 / 0..32V, DRZ DIN4 / 0..32V DIN2 / 0..32V, DRZ DIN3 / 0..32V, DRZ DIN12 / 0..32V
A34 A34 A34 A34 A34 A34 A34
AIN_8 DIN_8 DIN_10 DIN_4 DIN_2 DIN_3 DIN_12
Slope sensor Seat contact Proximity switch, arm rest right Direction axle Speed axle Speed drum Direction drum
Neigungssensor Sitzkontakt Näherungsinitiator Armlehne rechts Drehrichtung Achse Geschwindigkeit Achse Geschwindigkeit Bandage Drehrichtung Bandage
0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage =DRIV Blatt28 von
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Slope sensor, Speed sensors Mounting location Kind of Document
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Neigungssensor, Geschwindigkeitsaufnehmer 642 EPE /00
+ARC
+ARC
at DH Version at D Version
bei DH Version bei D Version
BTS_Brake
+REFR/32.1
switch vibration front switch vibration low high
-XS09.13
-XS35.13
-XS35.23
Schalter Vibration vorne 1 Schalter Vibration klein gross 1 1
13 13 23
low
0
high
S09 -S35
14 14 24 3
Switch, speed range selector X23
S42 Schalter Fahrstufen 1 1 1
X23.B 3
-XS09.14
-XS35.14
-XS35.24
12 Steps at DH, 5 Steps at D
12 Stufen bei DH, 5 Stufen bei D Only at BVC Not at BVC
4..20mA / 0-5V Nur bei BVC Nicht bei BVC
87
0V 9-30V 0-20mA 0,5-4,5V 0V +5V
1 2 3 6 4 5 -K189
/29.9 30
X23:5 / =EXC+EBOX/35.1 +EBOX
XS42 1 2 3 6 4 5
X26 3
X102 6 7
31_Db_2 31_Db_2 3 =SUPL+EBOX/14.6 / K189:30
=MON+EBOX/27.8 =OPT+EBOX/45.0
-XS36.13
S139 1
Potentiometer, + 13
+EBOX X102 1 2 3 4 X102 5 frequency plates -S36 =SUPL+EBOX/14.6 / K189:85
Potentiometer Splice
switch vibration 14 Spleiss 50
Frequenzverstellung - S
Schalter Vibration
Anbauplatten 1
15_Ar 1 2 85
=SUPL+EBOX/14.7 Splice
87 30
Spleiss 49 -K189
-XS36.14
X26 1 2 12V/10A 86 /29.9
relay brake
Splice Relais Bremse
Spleiss 47 5
X23
X23 11 X23 8 X23 12
X23.B 5
4 11 8 2 12
X23.B X23.B X23.B X23.B
-R40 resistor
18,2Ω/0,6W Widerstand
1
X23.A 4 X23.A 11 X23.A 8 X23.A 5 X23.A 12 X24 4 X24 1 X24 2 X23.A 3
BW 219 D-5 / BW 219 PD-5

X23 11 X23 8 X23 5 X23 12 X24 4 X24 1 X24 2 X23 3
Analog IN 1 Ground / 0V / reference to PIN 5 Output voltage supply "+5V" Analog IN 2 Digital IN 4 Digital IN 1 Digital IN 2 Signal "Brake"
S55
AK Ext 1 AGND 1 Uext 1 AK Ext 2 DK Ext 4 DK Ext 1 DK Ext 2 Brake
+ARC-S42:6 -S55:X23:5 -S36:14 +ARC-S35:14 +ARC-S35:24 -K189:86

Switch, speed range selector 2 Ground analog selectors Supply analog selectors Frequency adjustment plates Vibration plates Switch, vibration low/off (on/off) Switch, vibration off/high relay brake
Schalter Fahrstufen 2 Masse Analoge Wahlschalter Versorgung Analoge Wahlschalter Frequenzverstellung Anbauplatten Vibration Anbauplatten Schalter Vibration klein/aus (an/aus) Schalter Vibration aus/groß Relais Bremse
At dozer blade At vibratory plate

Bei Planierschild Bei Vibrationsplatte
0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage =DRIV Blatt 29 von
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Travel lever Mounting location Kind of Document
Einbauort +SEAT Dokumentenart &EFS
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Fahrhebel
961
642 EPE /00
962
+EBOX
+EBOX/28.9 / F91:2 F91:2 / =MEAS+EBOX/40.1
X2.A 10 at D Version
bei D Version
+REFR-X25 5
Circuit diagrams
+PUMP
Only at DH-Version Y16
Nur bei DH-Version Splice
Spleiss 73
Y07
X55 1 X56 1 X57 1 X58 1
A 1 B 1 C 1 D 1
B234 P B235 P B236 P B237 P

Pressure sensor, travel Pressure sensor, travel Pressure sensor, travel Pressure sensor, travel
pump axle MA 2 pump axle MB 2 pump drum MA 2 pump drum MB 2
Drucksensor Fahrpumpe Drucksensor Fahrpumpe Drucksensor Fahrpumpe Drucksensor Fahrpumpe
Achse MA Achse MB Bandage MA Bandage MB
right - front left - front right - back left - back
Y17
rechts - vorne links - vorne rechts - hinten links - hinten
Y08
X55 2 X56 2 X57 2 X58 2
at DH Version
-X25 1 2 3 4 bei DH Version
B234
B236 (X55)
+EBOX (X57)
BW 219 D-5 / BW 219 PD-5

X103 1 2 3 4
Y16
X35 6 X35 7 X35 29 X35 30 Y73

X35 6 X35 7 X35 29 X35 30
A34 A34 A34 A34 Y07
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
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Pressure sensors Mounting location Kind of Document
Einbauort +REFR Dokumentenart &EFS
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Drucksensoren 642 EPE /00
+EBOX
Travel pump axle forward Travel pump axle backward Travel pump drum forward Travel pump drum backward
Fahrpumpe Achse vorwärts Fahrpumpe Achse rückwärts Fahrpumpe Bandage vorwärts Fahrpumpe Bandage rückwarts
PWM_1 PWM_2 PWM_7 PWM_9
A34 A34 A34 A34

OUT1 / 4A curr.-measur. OUT2 / 4A curr.-measur. OUT14 / 4A curr.-measur. OUT16 / 4A curr.-measur.
X35 46 X35 47 X35 20 X35 21
X35 46 X35 47 X35 20 X35 21
X103 5 6 7 8
-X25 7 8
7 8
+PUMP
BW 219 D-5 / BW 219 PD-5

1 1 1 1
Y16 Y17 Y72 Y73
Travel pump axle 2 Travel pump axle 2 Travel pump drum 2 Travel pump drum 2
Fahrpumpe Achse C1 Fahrpumpe Achse C2 Fahrpumpe Bandage C2 Fahrpumpe Bandage C1
640...1580mA 640...1580mA 640...1580mA 640...1580mA
Splice
Spleiss 75
Only at DH-Version
Nur bei DH-Version
6
31_RFr.2
=MON+EBOX/27.0 -X25 6
BN Splice
=SUPL+EBOX/8.5 / 31_RFr 10 mm² Spleiss 31_RFr / 32.0
72
+EBOX/28.9 / 31_DCtrl 31_DCtrl / 32.0

Solenoid valve, travel direction forward Solenoid valve, travel direction forward
Magnetventil Fahrtrichtung vorwärts Magnetventil Fahrtrichtung vorwärts
Solenoid valve, travel direction backward Solenoid valve, travel direction backward
Magnetventil Fahrtrichtung rückwärts Magnetventil Fahrtrichtung rückwärts
0 1 2 3 4 5 6 7 8 9
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Travel pumps Mounting location Kind of Document
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Fahrpumpen
963
642 EPE /00
964
+EBOX
BTS brake Travel motor axle Valve brake Travel motor drum
BTS Bremse Fahrmotor Achse Ventil Bremse Fahrmotor Bandage
DO_2 PWM_5 DO_4
DIN_6
A34 A34 A34 A34
DIN6 / 0..32V OUT10 / 2,5A curr.-feedb. OUT5 / 4A curr.-measur. OUT12 / 2,5A curr.-feedb.
X35 14 X35 2 X35 64 X35 3
X35 14 X35 2 X35 64 X35 3

Circuit diagrams
X5.A 21

Relay, starting current Relais, Fahrhebel 0-Stellung K48
X5.A 14 30
Relais Startstrom 87 /32.3
87 87a 30 /32.5 Relay, travel lever 0-position
87a 30 =ENGI+EBOX/20.8 Relais, Fahrhebel 0-Stellung 87 87a
X4.A 21
X4.B 9
86 1 86 1
K05 K48
D05
D48
green
green
12V/20A 85 2 12V/20A 85 2
+ARC WH
1,5 mm²
Splice
Spleiss 61
XS01.A1
+SEAT/29.9 / BTS_Brake 1
A1
Gnd_PB Gnd_PB -S01
+EBOX/28.9 33.7
=SUPL+EBOX/9.4 A2
X103 9 switch emergency off X103 10 X104 7
1
Schalter Not Aus
WH
1,5 mm²
XS01.A2
X4.A 7
X7.C 12 X2.A 7
+DRUM
X7.C-2 12 1 W3
7x1
BW 219 D-5 / BW 219 PD-5

Splice Splice
X7.C-2 12 Spleiss 71 Spleiss 70
at DH Version a.
BW 216-219 D
bei DH Version u.
X11 3 4 BW 216-219 D
1
1 1 1 Y30
Y31 Y04 Y30 1,05A
2
1,05A 2,41A 2,41A
2 2 2
at D Version
bei D Version 2 W3
7x1
X11 5 +EBOX-X104 8
BN
1,5 mm²
31_RFr 31_RFr
31.8 33.1
31_DCtrl 31_DCtrl
31.8 =VIB+EBOX/34.1
Solenoid valve, speed range selection axle Solenoid valve, brake Solenoid valve, speed range selection drum Solenoid valve, speed range selection drum
Magnetventil Fahrstufe Achse Magnetventil Bremse Magnetventil Fahrstufe Bandage Magnetventil Fahrstufe Bandage
0 1 2 3 4 5 6 7 8 9
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Brake, Speed ranges Mounting location Kind of Document
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Bremse, Fahrstufen 642 EPE /00
+EBOX
=SUPL+EBOX/9.9 / F23:2
Back-up alarm buzzer Warning horn Relay, shut off solenoid engine
Warnsummer Rückwärtsfahrt Signalhorn Relais Hubmagnet Abschaltung Motor
30
DO_5 DO_3 DO_1
K13 A34 A34 A34
/33.8 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/51.1
X2.A 2
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 D-5 / BW 219 PD-5

BW 219-226 -5 BW 219-226 -5
1 1 2 2 1 1 + 86 1 86 1
B11.3 B11.1 V02 V03 B11.2 B11.4 H14 K13 K22
D13
D22
green
green
max. 3,5A 2 max. 3,5A 2 SF 64 1 1 SF 64 2 max. 3,5A 2 max. 3,5A 300mA - 12V/20A 85 2 12V/20A 85 2
BN BN
1,5 mm² 1,5 mm²
X30 2
BN BN
1,5 mm² 1,5 mm²
=SUPL+EBOX/14.2 / 31_Db 31_Db / =OPT+EBOX/44.0
32.9 / 31_RFr 31_RFr

=VIB+EBOX/34.1
Gnd_PB Gnd_PB
32.2 =VIB+EBOX/34.1
87 87
87a 30 /33.3 87a 30 =ENGI+EBOX/20.6
Warning horn Warning horn Warning horn Warning horn Back-up alarm buzzer Relay, warning horn Relay, shut off solenoid engine
Signalhorn Signalhorn Signalhorn Signalhorn Warnsummer Rückwärtsfahrt Relais Signalhorn Relais Hubmagnet Abschaltung Motor
0 1 2 3 4 5 6 7 8 9
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Warning horns, Back up alarm, Mounting location Kind of Document
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Warnhörner, Rückfahralarm,
965
642 EPE /00
966
=DRIV/28.9 / X106:5
=DRIV/28.9 / X106:1
=DRIV/28.9 / AGND
Speed vibration drum Vibration pump low/high Vibration pump PWM

Circuit diagrams
Drehzahl Vibration Bandage Vibrationspumpe klein/groß Vibrationspumpe PWM
DIN_1 PWM_3 PWM_4

A34 A34 A34
DIN1 / 0..32V, DRZ OUT3 / 4A curr.-measur. OUT4 / 4A curr.-measur.
X35 34 X35 48 X35 49
X35 34 X35 48 X35 49
X106 2 1 5 3
X5.B 8 X5.B 1
BW11RH - K78 30
K43
/34.4 87 87a
Relay, vibration
Relais Vibration
X5.B 9 3
not used today
wird zur Zeit nicht genutzt
X103 12 13
BW 219 D-5 / BW 219 PD-5

86 1 +PUMP 1 1
BW11RH - K78
K43 Y07 Y08
D43
green
12V/20A 2 640...1580mA 2 640...1580mA 2
85
C1 C2
X106 6
=DRIV+REFR/32.9 / 31_DCtrl 31_DCtrl / =DBL/37.1
=DRIV+REFR/33.6 / 31_RFr 31_RFr / =OPT/45.0
=DRIV+REFR/33.9 / Gnd_PB Gnd_PB / =OPT/44.0
87
87a 30 /34.5
Relay, vibration Solenoid valve, vibration front high Solenoid valve, vibration front low
Relais Vibration Magnetventil Vibration vorne gross Magnetventil Vibration vorne klein
0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage =VIB Blatt34 von
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Vibration Mounting location Kind of Document
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Vibration 642 EPE /00
+SEAT
=DRIV+SEAT/29.5 / X23:5
=DRIV/28.9 / 31_Ar 31_Ar / =OPT+CAB/50.1
=SUPL/14.7 / 15_Ar
-XS107
2
-XS439.13
XS439.A1
1 1
2+ -
123 13 A1
1 -XS107
S107 1 S439
switch amplitude adjustment 14 A2
3S
Schalter Amplitudenverstellung switch amplitude limiting
1 1
12 steps 3 Schalter Amplitudenbegrenzung
12 Stufen
4..20mA
-XS107
XS439.A2
-XS439.14
X4.B 8
X5.E 14
X5.E2 14
X5.E2 14
X5.E 14
BW 219 D-5 / BW 219 PD-5

X88 32 5 6
X24
X88 32 X24 5 X24 6
AIN8 / 10V 25mA Digital IN 5 Digital IN 6
A83 S55 S55
AIN_8 DK Ext 5 DK Ext 6
+SEAT-S107:3 +SEAT-S439:14 +SEAT-S439:A2

switch amplitude adjustment switch amplitude limiting switch amplitude limiting
Schalter Amplitudenverstellung Schalter Amplitudenbegrenzung Schalter Amplitudenbegrenzung
Only at BVC
Nur bei BVC
0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage =EXC Blatt35 von
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Variocontrol Mounting location Kind of Document
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Variocontrol
967
642 EPE /00
968
=SUPL/13.9 / FM2
X5.E 11
X5.E2 11
X5.E2 11
X5.E 11
Circuit diagrams
X107 7
+DRUM Exciter up Exciter down Exciter priority

X86:2 Erreger auf Erreger ab Erreger Priorität
=MEAS/40.1
W1
12x0,75 9 10 PWM_2 PWM_1 DO_5
A83 A83 A83
OUT2 / 4A curr.-measur. OUT1 / 4A curr.-measur. OUT6 / 4A
X86 1 X88 47 X88 46 X88 61
RD 47 46 61
B97 + X86 X88 X88
Sensor, - 2
BK
adjustable
motor
Sensor S
WH
Verstellmotor
X86 3
X107 9 10 11
W1
12x0,75 11
+DRUM
W2
X107 8
7x1 1 3
1 1
BW 219 D-5 / BW 219 PD-5

Y140 Y141
400-1200mA 2 400-1200mA 2
X88 9 b1 (v.r.) a1 (v.l.)
X88 9 -W2 2 4
AIN7 / 10V 25mA 7x1
A83
AIN_7 Splice
Y140
Spleiss 8 Y141
+DRUM-B97:S BN
1,5 mm²
Sensor, adjustable motor
Sensor Verstellmotor
X107 12
BN
=SUPL/12.9 / 31_MCtrl 1,5 mm²
Solenoid valve, exciter up Solenoid valve, exciter down

Magnetventil Erreger auf Magnetventil Erreger ab
Only at BVC
Nur bei BVC
0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage =EXC Blatt36 von
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Variocontrol Mounting location Kind of Document
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Variocontrol 642 EPE /00
Dozer blade priority Floating position dozer blade Dozer blade up Dozer blade down Adjustment left plates Adjustment right plates
Planierschild Priorität Schwimmstellung Planierschild Planierschild anheben Planierschild absenken Verschiebung links Platten Verschiebung rechts Platten
DO_6 DO_9 PWM_6 PWM_8 DO_10 DO_11

A34 A34 A34 A34 A34 A34
OUT7 / 2,5A curr.-feedb. OUT20 / 2,5A curr.-feedb. OUT13 / 4A curr.-measur. OUT15 / 4A curr.-measur. OUT21 / 5A curr.-feedb. OUT22 / 5A curr.-feedb.
X35 62 X35 11 X35 42 X35 43 X35 50 X35 51
X35 62 X35 11 X35 42 X35 43 X35 50 X35 51
X5.E 10
X105 1 2 3 4 5 6
X105:1 / =VPL+REFR/39.0
X5.A 7 X105:2 / =VPL+REFR/39.0
X105:3 / =VPL+REFR/39.0
Y379
X105:4 / =VPL+REFR/39.0
Y378 +DRUM X105:5 / =VPL+REFR/39.0
W4
X105:6 / =VPL+REFR/39.0
12x0,75 1 3 5 7
Y380
1 1 1 1
Y102 Y378 Y102 Y379 Y380
2 2 2 2
BW 219 D-5 / BW 219 PD-5

W4
12x0,75 2 4 6 8
Splice
Spleiss 2
BN
1,5 mm²
X105:7 / =VPL+REFR/39.0
X105:10 / =VPL/38.1
X105:12 / =VPL/38.1
X105 7 10 12
BN BN BN
1,5 mm² 1,5 mm² 1,5 mm²
=VIB/34.8 / 31_DCtrl
Solenoid valve, dozer blade priority Solenoid valve, lift dozer blade
Magnetventil Planierschild Priorität Magnetventil Planierschild heben
Solenoid valve, floating position Solenoid valve, lower dozer blade
Magnetventil Schwimmstellung Magnetventil Planierschild senken
0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage =DBL Blatt37 von
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Dozer blade Mounting location Kind of Document
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Planierschild
969
642 EPE /00
970
X105 11 Splice 22
=DRIV/28.9 / X105:11 Spleiss
Splice 23
=DBL/37.8 / X105:12 Spleiss
+REFR
W8 X28 2 1 W7 X29 2 1
BINDER Sensorcable M12 90° BINDER Sensorcable M12 90°
2 1 2 1
4x0,5 BU BN 4x0,5 BU BN
Circuit diagrams
- (bu) - (bu)
3 3
1 1
B312 + (bn) B313 + (bn)
Sensor Höhenverstellung Platten 4 Sensor Seitenverstellung Platten 4
4...20mA S (bk) 4...20mA S (bk)
W8 BK W7 BK
4x0,5 3
4x0,5 3
X28 3 X29 3
13 14
X105 13 X105 14
Hour meter plates Plate pump enable Vibration pump plates

Stundenzähler Platten Freigabe Plattenpumpe Vibrationspumpe Platten
8 X35 31
+PLA DO_7 X35 DIN_18 PWM_11
X35 8 X35 31
View from plate side AIN5 / 10V 25mA AIN6 / 10V 25mA
Ansicht von Plattenseite A34 A34 A34 A34 A34
OUT8 / 2,5A curr.-feedb. AIN_5 DIN18 / 0..32V AIN_6 OUT18 / 4A curr.-measur.
X35 63 X35 10 X35 22
X35 63 X35 10 X35 22

Sensor Höhenverstellung Platten Sensor Seitenverstellung Platten
X105 9 X105 15 X105 8
+REFR
BW 219 D-5 / BW 219 PD-5

X29 4 X29 5
X27 4 5
W6
1 3x0,75 BK GY
3
2
-X27 3 X27 +MOT
2
1
1
Plug, quick connect coupling plates W9
X27 = Stecker Schnellverschlußkupplung Platten Y98
2X0,75 2 1
400-1200mA 2
Solenoid valve, vibration pump plates
W6 Magnetventil Vibrationspumpe Platten
+
3x0,75 BN
P43
Operating hour meter 6
h plates
Betriebsstundenzähler X29
- 6
Platten
BN Splice
=DBL/37.8 / X105:10 1,5 mm² Spleiss
24
0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage =VPL Blatt38 von
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Vibratory plate compactor Mounting location Kind of Document
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Anbauplatten 642 EPE /00
+EBOX
Floating position plates

Schwimmstellung Anbauplatten
DO_8
A34
OUT19 / 2,5A curr.-feedb.
X35 45
X35 45
X105 16
=DBL+EBOX/37.8 / X105:2
=DBL+EBOX/37.8 / X105:1
=DBL+EBOX/37.8 / X105:6
Y145
=DBL+EBOX/37.8 / X105:5
Y143
=DBL+EBOX/37.8 / X105:4
=DBL+EBOX/37.8 / X105:3 Y142
Y122
BW 219 D-5 / BW 219 PD-5

Y123
1 1 1 1
Y122 Y142 Y145 Y144
b1 a2 a c2
2 2 2 2
1 1 1
Y123 Y143 Y60
a1 b2 c1
2 2 2
Y144
Y60
BN Splice
=DBL+EBOX/37.8 / X105:7 2,5 mm² Spleiss
25
Solenoid valve, lift plates Solenoid valve, plate displace left Solenoid valve, plate (priority) Solenoid valve, plate floating position
Magnetventil Platten heben Magnetventil Plattenverschieben links Magnetventil Platten (Priorität) Magnetventil Platten Schwimmstellung
Solenoid valve, let down plates Solenoid valve, plate displace right Solenoid valve, floating position
Magnetventil Platten senken Magnetventil Plattenverschieben rechts Magnetventil Schwimmstellung
0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage =VPL Blatt39 von
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Vibratory plate compactor Mounting location Kind of Document
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Anbauplatten
971
642 EPE /00
972
=SUPL/13.6 / AGND_MC
=DRIV+REFR/30.4 / F91:2
X5.E 7
X5.E2 7
X5.E2 7
Circuit diagrams
X5.E 7
RxD Printer TxD Printer Power supply GPS

RxD Drucker TxD Drucker Spannungsversorgung GPS
X107 1 2
RxD TxD DO_3
A83 A83 A83
RxD_1 TxD_1 OUT11 / 2,5A curr.-feedb.
+DRUM WH WH X88 4 X88 5 X88 25
1,5 mm² 1,5 mm²
Splice
Spleiss 7 X88 4 X88 5 X88 25
=EXC/36.6 / X86:2
Splice
Spleiss 6
W1
LÜTZE SUPERFLEX® N PUR
12x0,75 1 2 5 6
X5.E 5 3 8
X5.E2 5
X20 1 2 X21 1 2
BK GNYE BK GNYE
+ +
- - X5.E2 5 3 8
B62 15g
B171 15g
X5.E 5 3 8
front 20g rear 20g
vorne hinten
BN BU BN BU
X20 4 3 X21 4 3
BW 219 D-5 / BW 219 PD-5

15_GPS / =OPT+CAB/51.1
TxD / =OPT+CAB/51.1
W1
RxD / =OPT+CAB/51.1
12x0,75 4 3 8 7
X107 3 4 5 6
X88 31 X88 29 X88 7 X88 30
X88 31 X88 29 X88 7 X88 30

A83 A83 A83 A83
Transducer Acceleration front 20g Transducer Acceleration front 15g Transducer Acceleration rear 20g Transducer Acceleration rear 15g
Beschleunigungsaufn. vorne 20g Beschleunigungsaufn. vorne 15g Beschleunigungsaufn. hinten 20g Beschleunigungsaufn. hinten 15g
0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage =MEAS Blatt40 von
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Measurement equipment Mounting location Kind of Document
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Messtechnik 642 EPE /00
Splice 17
=COM/15.8 / X5.E:12 Spleiss X5.E:12 / 42.1
Splice 18
=COM/15.8 / X5.E:15 Spleiss X5.E:15 / 42.1
Splice 1
=SUPL/12.1 / X5.E:4 Spleiss X5.E:4 / 42.1
+REFR
XA103 1 XA103 2
XA103 1 XA103 2
CAN low CAN high
A103
A103 CANL CANH
module ECONOMIZER
Modul ECONOMIZER
Power supply (8...32V) Supply 5V sensors Transducer acceleration Ground Ground
A103 Versorgung 5V Sensoren Beschleunigungsaufnehmer Masse Masse
UE
5Vana_REF Analog_IN0 GND GND

Power supply A103 A103 A103 A103
Stromversorgung +5V supply Sensors 0...5V Ground Ground
Ground XA103 6 XA103 5 XA103 24 XA103 25
Masse XA103 6 XA103 5 XA103 24 XA103 25
Shielding
Schirm 9
GND
A103
Ground W18
XA103 26 3x0,75 1 2 3 SH
XA103 26
-XA103 Shielding
Plug, monitoring module Schirm 10
+EBOX X109.m 1 2 3 4
X109.f 1 2 3 4
Shielding
Schirm 7
W17
BW 219 D-5 / BW 219 PD-5

3x0,75 1 2 3 SH
+DRUM Shielding
Schirm 8
X39 1 2 3 4
=SUPL/8.5 / 31_Econ 31_Econ / 42.1 1 2 3 4

WH
0,5
1 GNYE 2 SH
3x0,5
+
-B84 OUT
sensor acceleration left
Sensor Beschleunigung links -
0 1 2 3 4 5 6 7 8 9
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Economizer Mounting location Kind of Document
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Economizer
973
642 EPE /00
974
41.8 / X5.E:12
41.8 / X5.E:15
41.8 / X5.E:4
Circuit diagrams
A161
module CAN Gateway
Modul CAN Gateway
XA161 2 XA161 4 XA161 8 XA161 7 XA161 9

2 4 8 7 9
Power supply (9-30V) Analog Input 1 Analog Input 2 Can high 1 Can low 1
-A161 -A161 -A161 -A161 -A161
30 - Vcc 15 AE H1 L1
Power supply Power supply Configuration CAN high IN CAN low IN

Stromversorgung Stromversorgung Konfiguration CAN high Eingang CAN low Eingang
Ground CAN high OUT CAN low OUT

31 - Gnd H2 L2
-A161 -A161 -A161
Ground Can high 2 Can low 2
6 1 3
XA161 6 XA161 1 XA161 3
BW 219 D-5 / BW 219 PD-5

Only at option preliminary setup VM31/VM38
Nur bei Option Vorrüstung VM31/VM38
41.2 / 31_Econ
=COM/16.9 / X5.E:1
=COM/16.9 / X5.E:2
0 1 2 3 4 5 6 7 8 9
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Economizer Mounting location Kind of Document
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Economizer 642 EPE /00
RD
=SUPL/9.9 / X7.C:1 1,5 mm²
=COM/16.9 / X5.E:2_2
=COM/16.9 / X5.E:1_2
WH
=SUPL/10.9 / X7.C:2 1,5 mm²
WH
1,5 mm²
WH
1,5 mm²
A162 -XA162 2 -XA162 4 -XA162 7 -XA162 9

module CAN Gateway 2 4 7 9
Modul CAN Gateway Power supply (9-30V) Analog Input 1 Can high 1 Can low 1
-A162 -A162 -A162 -A162
30 - Vcc 15 H1 L1
+DPL-X400:B
Ground Ground CAN high OUT CAN low OUT +DPL

Masse Masse CAN high Ausgang CAN low Ausgang
-A162:6
31 - Gnd AE H2 L2
-A162 -A162 -A162 -A162
Ground Analog Input 2 Can high 2 Can low 2
6 8 1 3
-XA162 6 -XA162 8 -XA162 1 -XA162 3
X110 X400
1 WH A
1,5 mm²
R33 + Ub pot. 30
1 2 2 WH B
1,5 mm²
+ Ub pot. 15
121Ω/0,6W
5 F
CAN low
1 D
BW 219 D-5 / BW 219 PD-5

R34 CAN high
121Ω/0,6W E
2
4 Gnd
BN BN 3 BN
1,5 mm² 1,5 mm² 1,5 mm²
BN
1,5 mm²
=SUPL/8.7 / X7.C:4
0 1 2 3 4 5 6 7 8 9
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Interface measurement Mounting location Kind of Document
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Schnittstelle Messtechnik
975
642 EPE /00
976
=SUPL/9.9 / F22:2 +ARC
S26:13 / 45.0
=SUPL/9.9 / F19:2
=SUPL/10.9 / F05:2
+CAB/51.1
X4.E:9
Circuit diagrams
13
-S26
switch working lights rear 14
Schalter Arbeitsbeleuchtung hinten
Access without StvZO
illumination.
At cabin not connected X33 5
Anschluss ohne StvZO
Beleuchtung. Bei Kabine nicht
angeschlossen X33 5
active high
A15
X4.E 16 18
DIN1
X4.A 15
Illumination
X7.C-2 6 Beleuchtung
X22
X7.C-2 6
2 X7.C 6
X6.B 2 4 1
1 X22
+DPL +ROPS
WH WH
1,5 mm² 1,5 mm²
1 1 1 1
E23 E25 E27 E28
12V 55W 2 12V 55W 2 12V 55W 2 12V 55W 2
+ 86 1
XS
BW 219 D-5 / BW 219 PD-5

K06
green
D118
12V / max. 20A 12V/30A 2

- 85
BN
2,5 mm²
X22 2
Splice
Spleiss 87
BN
2,5 mm²
=DRIV+REFR/33.5 / 31_Db 31_Db / 45.0 X4.E 3 6
=VIB/34.8 / Gnd_PB Gnd_PB / 45.0
87
87a 30 =SUPL/9.4
Socket Working headlight, front left Working headlight, rear left Relay, headlights rear
Steckdose Arbeitsscheinwerfer vorne links Arbeitsscheinwerfer hinten links Relais Scheinwerfer hinten
Working headlight, front right Working headlight, rear right
Arbeitsscheinwerfer vorne rechts Arbeitsscheinwerfer hinten rechts
0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage =OPT Blatt44 von
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Rops - Lighting, Socket Mounting location Kind of Document
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Rops - Beleuchtung, Steckdose 642 EPE /00
=SUPL/9.9 / F07:2
=SUPL/10.9 / F08:2
X4.D 6
=SUPL/9.9 / F11:2 +ARC
+ARC
=SUPL/8.9 / S15:23
=SUPL/8.9 / S15:11
30 13 23 ‎
0 ‎
13 23
K16 -S14 -S37
WH Indicator lights
1,5 mm² /45.3 87a 87 switch hazard light 14 24 switch indicator 14 24
23 Relay, headlights front Schalter Blinker Schalter Blinker
012 31 11
Relais Scheinwerfer vorne Warnblinkanlage DIN2
-S15
32 12 24
switch lighting StVZO
Schalter Beleuchtung StVZO A15
X4.D 5 2 8
Access without StvZO illumination

X4.A
Anschluss ohne StvZO Beleuchtung

11 EN_WL active high
44.9 / S26:13
WH +CAB/51.1 X33 8
1,5 mm² X1
-H06 X33 8 -A2
12V 12V Wb LE RE 30
X2
module flasher
X4.D 7 Modul Blinker LA RA 31
X4.D 10 1
1 1
V052 1 X4.A 6
Fuse, parking and tail Fuse, parking and tail
light left F09 light right F10 X4.A
2 1 4
Sicherung Park- und 10A Sicherung Park- und 10A RB Wb
2 2
Schlussleuchte links Schlussleuchte rechts V06 31
Meldeleuchte Warnblinker
indicator light hazard light
RA
LA 30
WH LE
X2.B 2 X4.D 12 X4.D 9 X2.B 3 1,5 mm²
X4.D 3 X2.B 1 X4.D 11 X2.B 4
+REFR X11 6 X11 9

+DPL Splice
Spleiss 4 X11 7 X11 10
Splice
Spleiss 5
X80 3 +DPL X81 3
X79 3 X82 3
/45.5 /45.5 X80 1 X81 1
1 1 1 1 86 1 87a 87
X79 5 X82 5 X79 2 X82 2
E13 E12 E14 E15 K16
D16
green
/45.5 /45.5 /45.5 /45.5
LED 5W 5W LED 12V/20A 1 1 1 1 1 1
BW 219 D-5 / BW 219 PD-5

2 2 2 2 85 2 30
E16 E17 E08 E09 E10 E11
/45.4
55W 2 55W 2 21W 2 21W 2 21W 2 21W 2
X80 4 X81 4
X79 6 X82 6 2 2
/45.5
X80 X81
BN /45.5 BN
1,5 mm² 1,5 mm²
44.1 / 31_Db 31_Db

+CAB/50.1
31_Db_2
+REFR
+REFR
=DRIV+SEAT/29.2 X11
31_RFr BN 11 BN Splice
=VIB/34.8 64
BN 8 BN Splice
63
44.9 / Gnd_PB Gnd_PB

46.1
Tail light, left Parking light, right Relay, headlights front Headlight, left Indicator, front left Indicator, front right
Schlussleuchte links Parkleuchte rechts Relais Scheinwerfer vorne Scheinwerfer links Blinkleuchte vorne links Blinkleuchte vorne rechts
Parking light, left Tail light, right Headlight, right Indicator, rear left Indicator, rear right
Parkleuchte links Schlussleuchte rechts Scheinwerfer rechts Blinkleuchte hinten links Blinkleuchte hinten rechts
0 1 2 3 4 5 6 7 8 9
Created M. Vogt Anlage =OPT Blatt 45 von
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 StVZO illumination Mounting location Kind of Document
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 StVZO Beleuchtung
977
642 EPE /00
978
=COM/17.8 / CAN1+ CAN1+ / +CAB/51.1
=COM/17.8 / CAN1- CAN1- / +CAB/51.1
45.9 / Gnd_PB Gnd_PB / 47.1
=COM/15.9 / F84:2
Circuit diagrams
=COM/17.8 / F148:2
X7.B 3 2 1 4 6
+DPL
A67
Keyboard
Tastatur
BW 219 D-5 / BW 219 PD-5

X16
1
0 1 2 3 4 5 6 7 8 9
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Electronical Burglary protection Mounting location Kind of Document
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Elektronische Diebstahlsicherung 642 EPE /00
A124
ECU BOMAG TELEMATIC
ECU BOMAG TELEMATIC
+ARC
T14
antenna BOMAG TELEMATIC
Antenne BOMAG TELEMATIC
GPS GSM
GPS GSM
GSM
GPS
CAN_L CAN_H Pot. 30 Pot. 15 IN0 IN1 GND
4 3 12 2 8 11 1
GSM GPS
-XA124 4 3 12 2 8 11 1
BW 219 D-5 / BW 219 PD-5

X6.D
8 8
=COM/17.8 / CAN2-_TM X6.D:8 / +MOT/48.0
7
=COM/17.8 / CAN2+_TM X6.D:7 / +MOT/48.0
4
=SUPL/10.9 / F243:2 X6.D:4 / +MOT/48.0
1
=SUPL/10.9 / F244:2
2
=MON/27.1 / D+ X6.D:2 / +MOT/48.0
D+ / +CAB/51.1
5
=ENGI/20.8 / StU_TM
6
=ENGI/19.8 / VIB_TM
3
46.9 / Gnd_PB X6.D:3 / +MOT/48.0
0 1 2 3 4 5 6 7 8 9
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 BOMAG Telematics Mounting location Kind of Document
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 BOMAG Telematik
979
642 EPE /00
980
-A175
Electronic system, Morey Telematics
Elektronik Morey Telematik
-A177
ECU ZTR telematics
Circuit diagrams
ECU ZTR Telematik
GPS Diagnostic SAT Cellular
Power
Ground
D+
Can H
Can L
8 10 16 1 2 4 11 12
-XA175 8 10 16 -XA177 1 2 4 11 12
RD WH BK
RD WH BK
-X51 1 3 2
BW 219 D-5 / BW 219 PD-5

+EBOX/47.5 / X6.D:4
fuse MD+
Sicherung MD+
F129
Splice 88 1 2 Splice 89
+EBOX/47.5 / X6.D:2 Spleiss Spleiss
3A
+EBOX/47.5 / X6.D:3
+EBOX/47.5 / X6.D:7
+EBOX/47.5 / X6.D:8
0 1 2 3 4 5 6 7 8 9
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Morey Telematics, ZTR Telematics Mounting location Kind of Document
Einbauort +MOT Dokumentenart &EFS
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Morey Telematic, ZTR Telematic 642 EPE /00
WH
=SUPL+EBOX/10.9 / F103:2 1,5 mm²
WH
=SUPL+EBOX/9.9 / F68:2 2,5 mm²
A B
F320 F321
5A 1 5A 2
Fuse, timer additional heater Fuse, timer additional heater
(potential 30) (potential 15)
Sicherung Schaltuhr Sicherung Schaltuhr
Zusatzheizung (Potential 30) Zusatzheizung (Potential 15)
Start Low Medium High

POWER
Start niedrig Medium Hoch XS28.f 10
Power consumption
Energiebedarf [W] <100 8 16 30 40
12V
E30
heating unit XS28.f XS28.m 0,35RD
Heizgerät 1 1 0,22GYBK -S28 1 Kl 30
0,22GYBK
Kl 30 2 Kl 58
1 11 11 0,35RD Timer
1 0,22BN
S+ Schaltuhr 3 Kl 31
4 6 6
4 0,22BUWH
Temp. (+) 4 Diagnose
7 9 9
7 0,22VT
DIAG 5 DAT-Leitung
8 8 8 0,22BUWH
8 0,35YE
Temp. (-) 6 S+
6 12 12 0,22BN
6 0,22BNYE
PUMP 7 ADR
5 0,22VT
5 0,22WHRD
Kl 31 8 ADR
10 0,35YE
10 0,22BNWH
0,22BNYE 9 Temp. (-)
0,22GY
0,22WHRD 10 Temp. (+)
0,22BNWH
0,22GY
WH
2,5 mm²
4
X207.m X207.f XS28.f 2
1 RD 1 1
1,5 mm²
4 YE 4 4
0,5 mm²
7 GRRD 7 7
0,5 mm²
8 BUYE 8 8
0,5 mm²
6 BNWH 6 6
0,5 mm²
5 GNRD 5 5
1 mm²
10 BN 10 10
1,5 mm²
BW 219 D-5 / BW 219 PD-5

+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
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Cabin - Additional heater Mounting location Kind of Document
Einbauort +DPL Dokumentenart &EFS
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Kabine - Zusatzheizung
981
642 EPE /00
982
+EBOX
=SUPL+EBOX/10.9 / F29:2 WWF / 51.1
=SUPL+EBOX/10.9 / F40:2 WWR / 51.1
X6.C 2 4 X4.B 3 6 X6.B 3 1
WH WH
1,5 mm² 1,5 mm²
30
Circuit diagrams
K09 Splice
Spleiss 9
=SUPL+EBOX/8.7 87 87a
Relay, air conditioning
WH
Relais Klimaanlage 2,5 mm²
+SEAT
+DPL
X1.A 5
A108 -X10 1
Heating climatic unit
Heiz-Klima-Einheit Supply
WH
RD
X87, X99
1,5 mm²
+REFR
X68.f 1
2
-X68.m 1
BK BK/GN BK
-B104 1
pressure switch air conditioning P
LP HP Out Gnd
BK/YE
WH WH
-X68.m 2 1,5 mm² 1,5 mm²
-X10 4 2
X87 1 X99 1
X68.f 2
X87 1 X99 1
WH
1,5 mm²
WH Option
1,5 mm²
3 Option 3
+MOT S29 S25
X12 1
Switch, suspension seat 4 Switch, heating operators seat 4
WH BN Schalter Luftfedersitz Schalter Fahrersitzheizung
X12 1 2 1,5 mm² 2,5 mm²
1 V04
BW 219 D-5 / BW 219 PD-5

Y15 1 + +
3,5A 1
1 1 1 1
XY15.2 X6.C
M10
M E159 M06 M07
BN
1,5 mm² 12V / < 9A 12V / 6,85A 2 2 3,5A 3,5A
Delivery equipment Sitz
Lieferumfang Sitz
31_Eng BN - -
1,5 mm² 2
=MON+EBOX/27.8
X87 2 X99 2
Only at air conditioning
Nur bei Klimaanlage X87 2 X99 2
BN BN
1,5 mm² 1,5 mm²
=EXC+EBOX/35.3 / 31_Ar
+EBOX/45.3 / 31_Db
Compressor, suspension operators seat Motor, windscreen washer front

Magnetic clutch, air conditioning compressor Kompressor Luftfedersitz Scheibenwaschermotor vorne
Magnetkupplung Klimakompressor heating operators seat Motor, windscreen washer rear
Heizung Fahrersitz Scheibenwaschermotor hinten
0 1 2 3 4 5 6 7 8 9
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Cabin - Heating, Air conditioning, Washer pumps Mounting location Kind of Document
Einbauort +CAB Dokumentenart &EFS
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Kabine - Heizung, Klimaanlage, Wascherpumpen 642 EPE /00
+EBOX
X4.E X4.E
14 14
=MEAS+EBOX/40.8 / RxD RxD / 56.6
4 4
=MEAS+EBOX/40.8 / TxD TxD / 56.6
8 8 WH
=MEAS+EBOX/40.8 / 15_GPS 1,5 mm² 15_GPS / 57.0
10 10
=COM+EBOX/16.9 / CAN3+ CAN3+ / 57.0
7 7
=COM+EBOX/16.9 / CAN3- CAN3- / 57.0
11 11
=DRIV+REFR/33.6 / Rev Rev / 58.1
X202 X202 -A178

1 1 9 9 module operator terminal cabin 1 Additional working lights left zusätzliche Arbeitsbeleuchtung links
+EBOX/46.9 / CAN1+
2 Illumination drum Bandagenbeleuchtung
2 2 10 10
+EBOX/46.9 / CAN1- Start Start
3
17 17 6 6 Stop Stop
+EBOX/47.1 / D+ 4
Print Drucken
DIG In
5
High active
5 5 4 4 Delete Löschen
+EBOX/45.4 / EN_WL 6
Reserve Reserve
DIG In
X7.C-2 X7.C-2 X7.C 7
High active
7 WH 7 7 9 9 WH 5 5 Additional working lights right zusätzliche Arbeitsbeleuchtung rechts
1,5 mm² 1,5 mm² 8
Windscreen wiper front Scheibenwischer vorne
DIG Out
+EBOX/44.2 / X4.E:9
9
10 Windscreen wiper rear Scheibenwischer hinten
15 15 WH 8 8
=SUPL+EBOX/8.9 / 15_CAB 1,5 mm² 15_PB_CAB / 52.1
11 Windscreen wascher front Scheibenwascher vorne
13 13 3 3 Rotary beacon Rundumkennleuchte
50.9 / WWF WWF_PB_CAB / 54.1 12
12 12 1 1 13 Working headlights front Arbeitsscheinwerfer vorne
50.9 / WWR WWR_PB_CAB / 54.1
14 Cabin inside light Kabineninnenbeleuchtung
15 Working headlights rear Arbeitsscheinwerfer hinten

X8.A X8.A X200 X200
BW 219 D-5 / BW 219 PD-5

30 30 RD 30 30 Rear screen heating Heckscheibenheizung
=SUPL+EBOX/8.6 / X8.A 16 mm² 30_PB_CAB / 52.1 16
RADSOK® 8mm Amphenol RADSOK® 6mm
17 Windscreen wascher rear Scheibenwascher hinten
X8.B X8.B X201 X201
31 31 BN BN 31 31
=SUPL+EBOX/8.9 / X8.B 16 mm² 10 mm² GND_PB_CAB / 52.1
RADSOK® 6mm Amphenol RADSOK® 3,6mm
1 8
Optional
Optional
2 7
3 4 5 6
not used
GND_CAB / 53.0 wird nicht genutzt
9 10
1 3 2
-U200
Ground cabin
Masse Kabine
Ground cabin
-U200 = Masse Kabine
11 12 13 14 15 16 17
0 1 2 3 4 5 6 7 8 9
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Cabin - Supply Mounting location Kind of Document
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Kabine - Versorgung
983
642 EPE /00
984
51.4 / 30_PB_CAB
51.4 / 15_PB_CAB
30
F17 F264 F271
5A 10A 10A
Circuit diagrams
K32
/52.1 87 87a
Relay, cabin
Relais Kabine
Fuse, radio
Fuse, BCM05
Fuse, BCM-Net
Sicherung Radio
Sicherung BCM05
Sicherung BCM-Net
Fuses cabin
Sicherungen Kabine
F271:2 / 57.1
F264:2 / 57.1
F17:2 / 56.1
F272 F27 F28 F143 F266 F150 F279

5A 15A 15A 20A 10A 5A 15A
BW 219 D-5 / BW 219 PD-5

86
Fuse, reserve
D2.1
K32
Sicherung Reserve
Fuse, GPS receiver
green
12V/20A 85
Relay, cabin
Sicherung GPS Receiver
Fuse, radio / tachograph
Relais Kabine
F279:2 / 54.1
Fuse, rear screen heating unit

Sicherung Radio / Tachograph
Sicherung Heckscheibenheizung F150:2 / 57.1
Fuse, controller console terminal cabin

Sicherung Wischer und Wascher vorne
Sicherung Wischer und Wascher hinten
Fuse, windscreen wiper and washer rear
Fuse, windscreen wiper and washer front

F266:2 / 56.1
Sicherung Controller Bedienkonsole Kabine

F143:2 / 55.1
F28:2 / 55.1
87
87a 30 /52.2 F27:2 / 55.1
F272:2 / 53.0
0 1 2 3 4 5 6 7 8 9
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Cabin - Fuse protection Mounting location Kind of Document
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Kabine - Absicherung 642 EPE /00
A178
/51.5
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
52.9 / F272:2 E29 E29
Inside light, cabin 2 1 2
Innenleuchte Kabine E72
Illumination, 2
switches
Beleuchtung
Bedienschalter
X206 1 6 2 4 9 X203 2 5 1 4 3 6
BW 219 D-5 / BW 219 PD-5

+ 1 1 1 1
E32 E27 E28 E23 E25
12V 70W - 12V 55W 2 12V 55W 2 12V 55W 2 12V 55W 2
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
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Cabin - Lighting Mounting location Kind of Document
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Kabine - Beleuchtung
985
642 EPE /00
986
A178
/51.5
Circuit diagrams
DIG Out DIG Out DIG Out DIG Out DIG Out DIG Out
86 86 86
D2.2 D2.3 D2.4
K141 K20 K21
green green green
12V/20A 85 12V/20A 85 12V/20A 85
Automotive Micro Relay on socket Automotive Micro Relay on socket Automotive Micro Relay on socket
Automotive Mircrorelais auf Sockel Automotive Mircrorelais auf Sockel Automotive Mircrorelais auf Sockel
51.4 / WWF_PB_CAB Relay, heating rear screen Relay, windscreen wiper front Relay, windscreen wiper rear
Relais Heckscheibenheizung Relais Wischer vorne Relais Wischer hinten
51.4 / WWR_PB_CAB
52.9 / F279:2
max. 150 mA
X206 3 7 8
BW 219 D-5 / BW 219 PD-5

87 87 87
87a 30 /55.7 87a 30 /55.3 87a 30 /55.5
0 1 2 3 4 5 6 7 8 9
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Cabin - Cabin equipment Mounting location Kind of Document
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Kabine - Kabinenausrüstung 642 EPE /00
52.9 / F143:2
52.9 / F28:2
52.9 / F27:2
87a 87 87a 87 30
K20 Relay, windscreen wiper front K21 Relay, windscreen wiper rear K141
/54.5 30 Relais Wischer vorne /54.6 30 Relais Wischer hinten /54.3 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
BW 219 D-5 / BW 219 PD-5

[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
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Cabin - Cabin equipment Mounting location Kind of Document
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Kabine - Kabinenausrüstung
987
642 EPE /00
988
52.9 / F266:2
52.9 / F17:2
54.8 / GND_PB_CAB
A178
Circuit diagrams
/51.5
PWM Out PWM Out PWM Out
X205 1 2 3 4 6 5 X202 2
X205 1 2 3 4 6 5
X202:2 / 58.1
Splice
Spleiss 58
Splice
Spleiss 57
51.4 / TxD
Splice
Spleiss 56
51.4 / RxD
XP09.A
1 A1 Splice
antenna radio Spleiss 59
XP09.A P09 -T21 Antenne Radio
2 A2
XP09.A 8 7 4
3 A3 XA12.A
XP09.A XA12.A
5 A5 -A12 8 7 4 5 Ant
31 15 30 Ctrl Ant
XP09.A 12V
BW 219 D-5 / BW 219 PD-5

6 A6 module radio
Modul Radio 1 2 5 4
XP09.C
3 C3
X94 1 2 5 4
A = white
XP09.B B = yellow RxD TxD Gnd Ub
3 B3 P11
C = red
rl+ rl- fl+ fl- fr+ fr- rr+ rr-
XP09.B 7 8 5 6 3 4 1 2
4 B4
XA12.B
Printer
Drucker
Tachograph XA12.B 7 8 1 2
Tachograph
B51.L B51.R
+ -
- +
Speaker radio Speaker radio

Lautsprecher Radio Lautsprecher Radio
AGND Only at VM29-Printer
Nur bei VM29-Drucker
X94 3
0 1 2 3 4 5 6 7 8 9
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Cabin - Radio, Tachograph, Printer measurement Mounting location Kind of Document
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Kabine - Radio, Tachograph, Drucker Messtechnik 642 EPE /00
52.9 / F271:2
52.9 / F150:2
52.9 / F264:2
X204 1 2 3 4
51.4 / 15_GPS
BN BN
1,5 mm² 1,5 mm²
X85 1 X85 2
USB-CAN Interface BCM 3 -A93
A87 USB-CAN Schnittstelle BCM GPS receiver
GPS Receiver
X85 X95.A X91
4 7 1
51.4 / CAN3+ 2
X85 3
4
5 2 2 SH
51.4 / CAN3-
12 6 7 2 11
X211 -X93 C -X97
4 B A A B C D E
Gnd2
2
RxD2
BW 219 D-5 / BW 219 PD-5

3
TxD2
P15 X96.A
BCM05 Ub 1 1 -X210 -X92
Supply
BCM05 Versorgung 1 A
AGnd 1 A
2
Gnd 2
Splice
2 2 B B
Spleiss 200
X90
Gnd1 5 5 3 3 C C
GPS receiver
GPS Receiver 2 4 D
RxD1 2 4 D
3 5 E
TxD1 3 5 E
W10
7x1,0
0 1 2 3 4 5 6 7 8 9
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 BOMAG Compaction Management BCM, GPS Mounting location Kind of Document
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 BOMAG Verdichtungsmanagement BCM, GPS
989
642 EPE /00
990
56.8 / X202:2
57.7 / GND_CAB
51.4 / Rev
Circuit diagrams
P42
display back up monitoring
Anzeige Rückraumüberwachung
Pin 1 - 12/24V DC
Pin 2 - Gnd
X50.f X50.m Pin 5 - Trigger Cam 3
P32 1 1 RD
camera back up monitoring 2 2 BK
Kamera Rückraumüberwachung 3 3 WH
4 BU
5 BN
CA1 CA1
CA2
CA3
BW 219 D-5 / BW 219 PD-5

0 1 2 3 4 5 6 7 8 9
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Back up monitoring Mounting location Kind of Document
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Rückraumüberwachung 642 EPE /00
Device tag list
Betriebsmittelliste BO_F03_001
Device tag Page Path Mounting location Higher-level characteristics

function Function text Funktionstext
BMK Blatt Pfad Einbauort Anlage Techn.-Kenngrößen
A2 45 8 +EBOX module flasher Modul Blinker 12V

A12 56 4 +CAB module radio Modul Radio 12V
A15 14 2 +ARC module monitoring Modul Überwachung ---> Pin overview
A34 11 3 +EBOX Driving Controller Fahrsteuerung ---> Pin overview
A48 21 0 +EBOX ECU engine controller ECU Motorsteuergerät
A67 46 5 +DPL Keyboard Tastatur
A83 12 3 +EBOX Measurement controller Messtechnik Steuerung ---> Pin overview
A87 57 2 +CAB USB-CAN Interface BCM USB-CAN Schnittstelle BCM
A93 57 7 +CAB GPS receiver GPS Receiver
A103 41 2 +REFR module ECONOMIZER Modul ECONOMIZER ---> Pin overview
A108 50 2 +CAB Heating climatic unit Heiz-Klima-Einheit
A124 47 3 +EBOX ECU BOMAG TELEMATIC ECU BOMAG TELEMATIC
A161 42 0 +EBOX module CAN Gateway Modul CAN Gateway ---> Pin overview
A162 43 0 +EBOX -"- -"- ---> Pin overview
A175 48 1 +MOT Electronic system, Morey Telematics Elektronik Morey Telematik
A177 48 5 +MOT ECU ZTR telematics ECU ZTR Telematik
B03 27 4 +MOT Maintenance switch, air cleaner Wartungsschalter Luftfilter
B11.1 33 1 +REFR Warning horn Signalhorn max. 3,5A
B11.2 33 4 +REFR -"- -"- max. 3,5A
B11.3 33 1 +REFR -"- -"- max. 3,5A
B11.4 33 5 +REFR -"- -"- max. 3,5A
B21 27 5 +REFR Differential pressure switch, hydraulic oil filter Differenzdruckschalter Hydraulikölfilter
BW 219 D-5 / BW 219 PD-5

B51.L 56 4 +CAB Speaker radio Lautsprecher Radio
B51.R 56 5 +CAB -"- -"-
B55 27 2 +MOT Floating switch, coolant expansion tank Schwimmerschalter Kühlmittelausgleichsbehälter
B57 28 1 +EBOX sensor slope speed range selection Neigungssensor Stufenumschaltung 0,5-4,5V
B59 28 7 +DRUM Speed sensor, drum Drehzahlsensor Bandagengeschwindigkeit
B60 28 4 +REFR Speed sensor, axle Drehzahlsensor Achsgeschwindigkeit
B84 41 5 +DRUM sensor acceleration left Sensor Beschleunigung links
B88 23 4 +MOT EMR engine oil pressure EMR Motoröldruck
B93 23 1 +MOT EMR Fuel pressure rail EMR Kraftstoffdruck Rail
B97 36 5 +DRUM Sensor, adjustable motor Sensor Verstellmotor
B104 50 1 +REFR pressure switch air conditioning Druckschalter Klimaanlage
B113 23 3 +MOT EMR Temperature sensor, coolant EMR Temperatursensor Kühlmittel
B124 21 1 +MOT Sensor, water trap fuel Sensor Wasserabscheider Kraftstoff
0 1 2 3 4 5 6 7 8 9
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Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Device tag list Kind of Document
Dokumentenart &EPB
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Betriebsmittelliste
991
642 EPE /00
992
Device tag list


Circuit diagrams
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
B208 23 8 +MOT EMR Sensor, delta p venturi EMR Sensor Delta p Venturi
B209 23 9 +MOT EMR Sensor, temperature EGR behind venturi EMR Sensor Temperatur EGR nach Venturi
B214 25 2 +MOT EMR Sensor, temperature exhaust gas before oxy EMR Temperatursensor Abgas vor Oxy Kat
cat
B215 25 3 +MOT EMR Sensor, temperature exhaust gas after oxy cat EMR Temperatursensor Abgas nach Oxy Kat
B216 25 3 +MOT EMR Sensor, differential pressure DPF EMR Sensor Differenzdruck DPF
B218 21 3 +MOT Temperature sensor, ambient temperature Temperatursensor Umgebungstemperatur
B221 25 5 +REFR Sensor, urea pressure behind pump Sensor, Ureadruck nach Pumpe
B222 24 5 +MOT Sensor, urea temperature and level Sensor Ureatemperatur und Füllstand
B223 25 2 +MOT Temperature sensor, exhaust gas before SCR kat Temperatursensor Abgas vor SCR Kat
B224 24 6 +MOT Sensor, NOx before SCR-Kat Sensor NOx vor SCR-Kat
B225 24 8 +MOT Sensor, NOx behind SCR-Kat Sensor NOx nach SCR-Kat
B234 30 2 +PUMP Pressure sensor, travel pump axle MA Drucksensor Fahrpumpe Achse MA
B235 30 3 +PUMP Pressure sensor, travel pump axle MB Drucksensor Fahrpumpe Achse MB
B236 30 4 +PUMP Pressure sensor, travel pump drum MA Drucksensor Fahrpumpe Bandage MA
B237 30 4 +PUMP Pressure sensor, travel pump drum MB Drucksensor Fahrpumpe Bandage MB
B238 23 6 +MOT Pressure sensor, exhaust gas back DPF before Drucksensor Abgasgegendruck DPF vor Turbolader
turbine
BW 219 D-5 / BW 219 PD-5

B305 25 1 +MOT EMR Pressure sensor, pressure after DPF EMR Drucksensor, Druck nach DPF
B312 38 5 +REFR Sensor, height adjustment plates Sensor Höhenverstellung Platten 4...20mA
B313 38 6 +REFR Sensor, lateral adjustment plates Sensor Seitenverstellung Platten 4...20mA
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Dokumentenart &EPB
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Betriebsmittelliste 642 EPE /00
Device tag list

Dx 9 1 +EBOX Indicator light, fuse test Meldeleuchte Sicherungstest green
E08 45 7 +DPL Indicator, front left Blinkleuchte vorne links 21W
E09 45 8 +REFR Indicator, rear left Blinkleuchte hinten links 21W
E10 45 8 +DPL Indicator, front right Blinkleuchte vorne rechts 21W
E11 45 8 +REFR Indicator, rear right Blinkleuchte hinten rechts 21W
E12 45 1 +DPL Parking light, left Parkleuchte links 5W
E13 45 1 +REFR Tail light, left Schlussleuchte links LED
E14 45 2 +DPL Parking light, right Parkleuchte rechts 5W
E15 45 2 +REFR Tail light, right Schlussleuchte rechts LED
E16 45 4 +DPL Headlight, left Scheinwerfer links 55W
E17 45 5 +DPL Headlight, right Scheinwerfer rechts 55W
E23 44 3 +ROPS Working headlight, front left Arbeitsscheinwerfer vorne links 12V 55W
E23 53 8 +CAB -"- -"- 12V 55W
E25 44 3 +ROPS Working headlight, front right Arbeitsscheinwerfer vorne rechts 12V 55W
E25 53 9 +CAB -"- -"- 12V 55W
BW 219 D-5 / BW 219 PD-5

E27 44 4 +ROPS Working headlight, rear left Arbeitsscheinwerfer hinten links 12V 55W
E27 53 7 +CAB -"- -"- 12V 55W
E28 44 4 +ROPS Working headlight, rear right Arbeitsscheinwerfer hinten rechts 12V 55W
E28 53 8 +CAB -"- -"- 12V 55W
E29 53 1 +CAB Inside light, cabin Innenleuchte Kabine
E30 49 0 +DPL heating unit Heizgerät 12V
E32 53 6 +CAB Rotary beacon Rundumkennleuchte 12V 70W
E72 53 2 +CAB Illumination, switches Beleuchtung Bedienschalter
E104 26 6 +MOT Heating, pressure line Heizung Druckleitung
E105 26 5 +MOT Heating, suction line Heizung Saugleitung
E106 26 5 +MOT Heating, return flow line Heizung Rücklaufleitung
E107 25 8 +REFR Heating, supply modul Heizung Versorgungsmodul ???W
E159 50 7 +SEAT heating operators seat Heizung Fahrersitz 12V / 6,85A
F00 8 1 +REFR Fuse, main battery Hauptsicherung Batterie 125A
F05 10 4 +EBOX Fuse, socket Sicherung Steckdose 20A
0 1 2 3 4 5 6 7 8 9
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Dokumentenart &EPB
Checked
Circuit diagrams
K. Brand
993
642 EPE /00
994
Device tag list

F07 9 8 +EBOX Fuse, hazard light Sicherung Warnblinker 10A

Circuit diagrams
F08 10 4 +EBOX Fuse, indicators Sicherung Blinker 10A

F09 45 1 +EBOX Fuse, parking and tail light left Sicherung Park- und Schlussleuchte links 10A
F10 45 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 52 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 52 4 +CAB Fuse, windscreen wiper and washer front Sicherung Wischer und Wascher vorne 15A
F28 52 4 +CAB Fuse, windscreen wiper and washer rear Sicherung Wischer und Wascher hinten 15A
F29 10 7 +EBOX Fuse, compressor suspension seat Sicherung Kompressor Luftfedersitz 15A
F39 8 6 +EBOX Fuse, main cabin Hauptsicherung Kabine 80A
F40 10 6 +EBOX Fuse, heating unit cabin Sicherung Kabinenheizung 30A
F48 18 1 +MOT Fuse, heating-flange Sicherung Heizflansch 150A
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
BW 219 D-5 / BW 219 PD-5

F122 10 2 +EBOX Fuse, engine controller Sicherung Motorsteuerung 10A
F124 10 5 +EBOX Fuse, fuel-pre-heating Sicherung Kraftstoffvorheizung 25A
F129 48 5 +MOT fuse MD+ Sicherung MD+ 3A
F143 52 5 +CAB Fuse, rear screen heating unit Sicherung Heckscheibenheizung 20A
F150 52 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
F238 26 3 +BAT Fuse, exhaust gas recirculation Sicherung Abgasrückführung 15A
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
F250 26 2 +BAT Fuse, SCR control Sicherung SCR Ansteuerung 30A
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Dokumentenart &EPB
Checked K. Brand
Device tag list

F251 26 2 +BAT Fuse, NOx sensors Sicherung NOx Sensoren 10A

F264 52 4 +CAB Fuse, BCM05 Sicherung BCM05 10A
F266 52 5 +CAB Fuse, radio / tachograph Sicherung Radio / Tachograph 10A
F268 9 8 +EBOX Fuse, fuel pump Sicherung Kraftstoffpumpe 20A
F271 52 5 +CAB Fuse, BCM-Net Sicherung BCM-Net 10A
F272 52 3 +CAB Fuse, controller console terminal cabin Sicherung Controller Bedienkonsole Kabine 5A
F279 52 6 +CAB Fuse, reserve Sicherung Reserve 15A
F310 26 3 +BAT Fuse, sensor urea quality Sicherung Sensor Ureaqualität 5A
F312 26 1 +BAT Fuse, reserve Sicherung Reserve max. 20A
F313 26 2 +BAT -"- -"- max. 20A
Fx 9 1 +EBOX Fuseholder, fuse test Sicherungshalter Sicherungstest
FM1 13 2 +EBOX Fuse, sensors Sicherung Sensoren 1A
FM2 13 5 +EBOX -"- -"- 1A
G02 8 5 +MOT Generator Generator 14V / 150A
H06 45 6 +ARC indicator light hazard light Meldeleuchte Warnblinker 12V
H07 27 7 +ARC Warning buzzer, breakdown Warnsummer Betriebsstörung 70mA
H14 33 6 +REFR Back-up alarm buzzer Warnsummer Rückwärtsfahrt 300mA
K05 32 2 +EBOX Relay, starting current Relais Startstrom 12V/20A
BW 219 D-5 / BW 219 PD-5

K06 44 5 +EBOX Relay, headlights rear Relais Scheinwerfer hinten 12V/30A
K09 8 7 +EBOX Relay, air conditioning Relais Klimaanlage 12V/20A
K11 8 8 +EBOX Relay, potential 30 on 15 Relais Potential 30 auf 15 12V
K13 33 8 +EBOX Relay, warning horn Relais Signalhorn 12V/20A
K14.1 18 1 +MOT Relay, glow plug system Relais Vorglühen
K16 45 3 +EBOX Relay, headlights front Relais Scheinwerfer vorne 12V/20A
K20 54 5 +CAB Relay, windscreen wiper front Relais Wischer vorne 12V/20A
K21 54 6 +CAB Relay, windscreen wiper rear Relais Wischer hinten 12V/20A
K22 33 9 +EBOX Relay, shut off solenoid engine Relais Hubmagnet Abschaltung Motor 12V/20A
K32 52 1 +CAB Relay, cabin Relais Kabine 12V/20A
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/20A
K43 34 4 +EBOX Relay, vibration Relais Vibration 12V/20A
K48 32 3 +EBOX Relay, travel lever 0-position Relais, Fahrhebel 0-Stellung 12V/20A
0 1 2 3 4 5 6 7 8 9
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Dokumentenart &EPB
Checked
Circuit diagrams
K. Brand
995
642 EPE /00
996
Device tag list

K61 8 6 +EBOX Relay, charge control Relais Ladekontrolle 12V/20A

Circuit diagrams
K141 54 3 +CAB Relay, heating rear screen Relais Heckscheibenheizung 12V/20A

K145 20 8 +EBOX Relay, solenoid starter Relais Hubmagnet Starter 12V/40A
K189 29 9 +SEAT relay brake Relais Bremse 12V/10A
K192 26 7 +BAT Relay, SCR control Relais, SCR Ansteuerung 12V
K193 26 8 +BAT Relay, heating urea feed-in modul Relais Heizung Urea-Einspeisemodul 12V
K194 26 8 +BAT Relay, heating urea suction hose Relais Heizung Urea-Saugleitung 12V
K195 26 9 +BAT Relay, heating urea restriction hose Relais Heizung Urea-Drosselleitung 12V
K196 26 9 +BAT Relay, heating urea pressure hose Relais Heizung Urea-Druckleitung 12V
K209 20 4 +EBOX Relay, fuel pump Relais Kraftstoffpumpe 12V/30A
K227 26 6 +BAT Relay, potential 30 on 15 Relais Potential 30 auf 15 12V
M01 8 4 +MOT Starter Starter
M04 55 3 +CAB Motor, windscreen wiper front Scheibenwischermotor vorne 4,7A
M05 55 5 +CAB Motor, windscreen wiper rear Scheibenwischermotor hinten 4,7A
M06 50 8 +DPL Motor, windscreen washer front Scheibenwaschermotor vorne 3,5A
M07 50 9 +DPL Motor, windscreen washer rear Scheibenwaschermotor hinten 3,5A
M10 50 6 +SEAT Compressor, suspension operators seat Kompressor Luftfedersitz 12V / < 9A
M41 25 7 +REFR Urea pump Urea Pumpe
M57 49 5 +MOT pump fuel heating unit Pumpe Kraftstoff Heizgerät
P09 56 3 +CAB Tachograph Tachograph
P11 56 6 +CAB Printer Drucker
P15 57 1 +CAB BCM05 BCM05
BW 219 D-5 / BW 219 PD-5

P32 58 1 +CAB camera back up monitoring Kamera Rückraumüberwachung
P42 58 5 +CAB display back up monitoring Anzeige Rückraumüberwachung
P43 38 4 +PLA Operating hour meter plates Betriebsstundenzähler Platten
R03 27 8 +REFR Sender, level gauge Geber Tankanzeige 66 Ω / 64,2 Ω
R10 8 6 +EBOX Parallel resistor Parallelwiderstand 82Ω / 22W
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
R28 17 6 +EBOX -"- -"- 120 Ω
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Dokumentenart &EPB
Checked K. Brand
Device tag list

R29 17 6 +EBOX Terminating resistor CAN Abschlußwiderstand CAN 120 Ω

R30 21 9 +EBOX -"- -"- 120 Ω
R31 24 8 +EBOX -"- -"- 120Ω
R32 24 1 +EBOX -"- -"- 120Ω
R33 43 4 +EBOX -"- -"- 121Ω/0,6W
R34 43 6 +EBOX -"- -"- 121Ω/0,6W
R40 29 3 +SEAT resistor Widerstand 18,2Ω/0,6W
R79 18 8 +MOT heating prefilter fuel Heizung Vorfilter Kraftstoff 200W
R80 55 7 +CAB Rear window heater Heizung Heckscheibe ca. 11 A
S00 8 7 +ARC switch ignition Schalter Motorstart
S01 9 4 +ARC switch emergency off Schalter Not Aus
S06 28 3 +SEAT Switch, seat contact Sitzkontaktschalter
S09 29 5 +SEAT switch vibration front Schalter Vibration vorne
S14 45 5 +ARC switch hazard light Schalter Warnblinkanlage
S15 45 2 +ARC switch lighting StVZO Schalter Beleuchtung StVZO
S25 50 7 +SEAT Switch, heating operators seat Schalter Fahrersitzheizung
S26 44 5 +ARC switch working lights rear Schalter Arbeitsbeleuchtung hinten
S28 49 7 +DPL Timer Schaltuhr
S29 50 6 +SEAT Switch, suspension seat Schalter Luftfedersitz
S30 8 3 +BAT Disconnect switch, battery Batterietrennschalter 250A
S35 29 7 +ARC switch vibration low high Schalter Vibration klein gross
S36 29 5 +SEAT switch vibration Schalter Vibration
BW 219 D-5 / BW 219 PD-5

S37 45 8 +ARC switch indicator Schalter Blinker
S42 29 0 +ARC Switch, speed range selector Schalter Fahrstufen 4..20mA / 0-5V
S55 14 8 +SEAT switch control lever travel Schalter Steuerhebel Fahren ---> Pin overview
S107 35 3 +SEAT switch amplitude adjustment Schalter Amplitudenverstellung 4..20mA
S127 19 2 +ARC switch engine speed Schalter Motordrehzahl
S139 29 4 +SEAT Potentiometer, frequency plates Potentiometer Frequenzverstellung Anbauplatten
S299 19 4 +ARC switch regeneration mode Schalter Regenerationsmodus
S439 35 6 +SEAT switch amplitude limiting Schalter Amplitudenbegrenzung
T14 47 5 +ARC antenna BOMAG TELEMATIC Antenne BOMAG TELEMATIC
T21 56 5 +CAB antenna radio Antenne Radio
V01 8 6 +EBOX diode Diode S5G-E3
V02 33 2 +REFR -"- -"- SF 64
V03 33 3 +REFR -"- -"- SF 64
V04 50 2 +MOT -"- -"- SF 64
V05 45 7 +ARC -"- -"- SF 64
0 1 2 3 4 5 6 7 8 9
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Dokumentenart &EPB
Checked
Circuit diagrams
K. Brand
997
642 EPE /00
998
Device tag list

V06 45 7 +ARC diode Diode SF 64

Circuit diagrams
V07 28 5 +EBOX -"- -"- S1M

V08 28 5 +EBOX -"- -"- S1M
V09 28 7 +EBOX -"- -"- S1M
V10 28 7 +EBOX -"- -"- S1M
Y04 32 5 +REFR Solenoid valve, brake Magnetventil Bremse 2,41A
Y07 34 5 +PUMP Solenoid valve, vibration front high Magnetventil Vibration vorne gross 640...1580mA
Y08 34 6 +PUMP Solenoid valve, vibration front low Magnetventil Vibration vorne klein 640...1580mA
Y15 50 1 +MOT Magnetic clutch, air conditioning compressor Magnetkupplung Klimakompressor 3,5A
Y30 32 7 +REFR Solenoid valve, speed range selection drum Magnetventil Fahrstufe Bandage 2,41A
Y30 32 8 +DRUM -"- -"- 1,05A
Y31 32 4 +REFR Solenoid valve, speed range selection axle Magnetventil Fahrstufe Achse 1,05A
Y60 39 5 +REFR Solenoid valve, floating position Magnetventil Schwimmstellung
Y98 38 7 +MOT Solenoid valve, vibration pump plates Magnetventil Vibrationspumpe Platten 400-1200mA
Y102 37 4 +DRUM Solenoid valve, floating position Magnetventil Schwimmstellung
Y122 39 1 +REFR Solenoid valve, lift plates Magnetventil Platten heben
Y123 39 2 +REFR Solenoid valve, let down plates Magnetventil Platten senken
Y137 23 0 +MOT EMR Actuator EMR Stellglied
BW 219 D-5 / BW 219 PD-5

Y140 36 7 +DRUM Solenoid valve, exciter up Magnetventil Erreger auf 400-1200mA
Y141 36 8 +DRUM Solenoid valve, exciter down Magnetventil Erreger ab 400-1200mA
Y142 39 3 +REFR Solenoid valve, plate displace left Magnetventil Plattenverschieben links
Y143 39 3 +REFR Solenoid valve, plate displace right Magnetventil Plattenverschieben rechts
Y144 39 5 +REFR Solenoid valve, plate floating position Magnetventil Platten Schwimmstellung
Y145 39 4 +REFR Solenoid valve, plate (priority) Magnetventil Platten (Priorität)
Y174 24 1 +MOT EMR Exhaust gas recirculation EMR Abgasrückführung
Y261 23 6 +MOT EMR Air intake throttle EMR Drosselklappe Ansaugluft
Y291 25 6 +REFR Solenoid valve, urea extraction Magnetventil Urea Absaugung
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Dokumentenart &EPB
Checked K. Brand
Device tag list

Y292 25 8 +REFR Solenoid valve, urea tank heating Magnetventil Ureatank Heizung
Y293 25 5 +MOT Solenoid valve, urea dosing Magnetventil Ureadosierung
Y378 37 3 +DRUM Solenoid valve, dozer blade priority Magnetventil Planierschild Priorität
Y379 37 5 +DRUM Solenoid valve, lift dozer blade Magnetventil Planierschild heben
Y380 37 6 +DRUM Solenoid valve, lower dozer blade Magnetventil Planierschild senken
BW 219 D-5 / BW 219 PD-5

0 1 2 3 4 5 6 7 8 9
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Dokumentenart &EPB
Checked
Circuit diagrams
K. Brand
999
642 EPE /00
1000
Plug overview
Steckerübersicht BO_F22_002
Circuit diagrams

13 1
15 9 3
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
30 8 4 1 10 8 1 20 2 1 28 4
2 20 2 2 33 6
Plug Mounting location Plug Mounting location 3 20 2 3
Stecker -X0.A Einbauort +EBOX Stecker -X1.A Einbauort +EBOX 4 20 7 4 28 5
Function text Plug, supply potential 30 Function text Plug, access harness engine 5 20 2 5
Funktionstext Stecker Versorgung Potential 30 Funktionstext Stecker Anschluß Kabelbaum Motor 6 20 3 6
Plug type Plug type 7 20 8 7 32 5
Amphenol RADSOK® 8mm AMP Junior Power Timer 9 pole blue
Steckertyp Steckertyp 8 20 3 8
Kabelbaum Kabelbaum 10 20 7 10 30 2
Page Path Page Path 11 20 6 11
Contact
Kontakt
Contact
Kontakt
1 8 5 1 9 2 13 20 7 13
2 9 2 14 20 4 14 28 5
Stecker -X0.B Einbauort +EBOX 4 20 5 16 20 5
Function text Plug supply ground 17 20 5 Plug Mounting location
5 50 1 -X2.A +EBOX
Funktionstext Stecker Versorgung Masse 18 20 8 Stecker Einbauort
6 18 6
Plug type Function text Plug, access harness rear frame
7 8 6
8 18 8 -X1.B_f +EBOX
Kabelbaum
Stecker -X1.A_f Einbauort +EBOX Plug type Kabelbaum
Contact
Kontakt
Blatt Pfad AMP Junior Power Timer 18 pole blue
31 8 6 Wire harness
Contact
Kontakt
Funktionstext Stecker Anschluß Kabelbaum Motor Blatt Pfad

EMR 16 1
Plug type Kabelbaum

Plug Mounting location AMP Junior Power Timer 9 pole blue 18 12 9 3
1 28 4
Stecker -X0.B +EBOX Steckertyp Page Path 2 33 6
Einbauort
BW 219 D-5 / BW 219 PD-5

Contact
Kontakt
Function text Plug supply ground Motor 1
7
Funktionstext Stecker Versorgung Masse Kabelbaum 1 20 2 4 28 5
9 6 3
Contact
Kontakt
Steckertyp Blatt Pfad 3 6
Kabelbaum 2 5 8
Page Path 3 6 9 28 5
7 10 30 2
Contact
Kontakt
Blatt Pfad 4
5 50 1 8 11
1 8 6 9 20 5 12 28 4
6
7 8 6 10 20 7 13 28 5
Stecker -X0.C +EBOX 8 18 8 11 14 28 5
Einbauort
9 18 8 12 20 6 15 27 8
13 20 7
14 20 4
Plug type
Steckertyp
16 20 5
Wire harness
17
Kabelbaum
18 20 8
Page Path
Contact
Kontakt
Blatt Pfad
30 10 8
0 1 2 3 4 5 6 7 8 9
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Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Plug overview Kind of Document
Dokumentenart &EMA3
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Steckerübersicht 642 EPE /00
Plug overview
Stecker -X2.B Einbauort +EBOX Stecker -X4.A Einbauort +EBOX Stecker -X4.B Einbauort +EBOX Stecker -X4.D Einbauort +EBOX
Function text Plug, access harness StvZO illumination rear Function text Plug, access harness dashboard Function text Plug, access harness console seat Function text Plug, access harness StvZO illumination front
Funktionstext Stecker Anschluß Kabelbaum StvZO Beleuchtung hinten Funktionstext Stecker Anschluß Kabelbaum Bedienpult Funktionstext Stecker Anschluß Kabelbaum Konsole Sitz Funktionstext Stecker Anschluß Kabelbaum StvZO Beleuchtung vorne
AMP Junior Power Timer 6 pole green AMP Junior Power Timer 21 pole grey AMP Junior Power Timer 9 pole grey AMP Junior Power Timer 12 pole grey
4 1 19 1 Konsole Sitz 7 1
6 3 21 12 3 9 6 3
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
1 45 8 18 14 1 5 1 45 2
2 45 1 19 9 4 6 50 7 2 45 8
3 45 2 20 8 8 7 14 6 3 45 7
4 45 8 21 32 5 8 35 3 4
5 9 32 1 5 45 8
Stecker -X4.A Einbauort +EBOX Plug Mounting location 7 45 4
Plug Mounting location Function text Plug, access harness dashboard Stecker -X4.B Einbauort +EBOX 8 45 9
Stecker -X2.B Einbauort +EBOX Funktionstext Stecker Anschluß Kabelbaum Bedienpult Function text Plug, access harness console seat 9 45 2
Function text Plug, access harness StvZO illumination rear Plug type Funktionstext Stecker Anschluß Kabelbaum Konsole Sitz 10 45 2
Funktionstext Stecker Anschluß Kabelbaum StvZO Beleuchtung hinten Steckertyp Plug type 11 45 8
Plug type Wire harness Steckertyp 12 45 1
AMP Junior Power Timer 6 pole green
Steckertyp Kabelbaum Wire harness
Wire harness Page Path Kabelbaum Plug Mounting location
Kabelbaum Stecker -X4.E Einbauort +EBOX
Contact
Kontakt
Contact
Kontakt
Page Path Blatt Pfad Function text Plug, access cabin and rops
1 10 2
Funktionstext Stecker Anschluß Kabine und Rops
Contact
Kontakt
Blatt Pfad 2 33 3 1 16 4
Plug type
1 45 8 3 8 8 2 28 3 AMP Junior Power Timer 18 pole grey
Steckertyp
2 45 1 4 45 8 3 50 7
3 45 2 5 27 8 4 16 5 Wire harness
16 1
Kabelbaum
4 45 8 6 45 8 5 18 12 9 3
5 7 32 5 6 50 7 Page Path
Contact
Kontakt
6 8 7 14 6 Blatt Pfad
9 8 7 8 35 3 1 51 2
Stecker -X4.A Einbauort +EBOX 11 45 3 3 44 3
Function text Plug, access harness dashboard 12 10 2 Plug Mounting location 4 51 2
Funktionstext Stecker Anschluß Kabelbaum Bedienpult 13 8 7 Stecker -X4.D Einbauort +EBOX 5 51 2
BW 219 D-5 / BW 219 PD-5

Plug type 14 16 2 Function text Plug, access harness StvZO illumination front 6 44 4
Steckertyp 15 44 5 Funktionstext Stecker Anschluß Kabelbaum StvZO Beleuchtung vorne 7 51 2
19 1 AMP Junior Power Timer 12 pole grey
21 12 3
Page Path 18 14 1 Wire harness 10 51 2
10 1
Kabelbaum
Contact
Kontakt
Blatt Pfad 19 9 4 11 51 2
12 9 6 3
1 10 2 20 8 8 Page Path 12 51 2
Contact
Kontakt
2 33 3 21 32 5 Blatt Pfad 13 51 2
3 8 8 1 45 2 14 51 2
4 45 8 -X4.B +EBOX 2 45 8
5 27 8 3 45 7
Function text Plug, access harness console seat 17 51 2
6 45 8 4
Funktionstext Stecker Anschluß Kabelbaum Konsole Sitz 18 44 4
7 32 5 5 45 8
Plug type
8 AMP Junior Power Timer 9 pole grey 6 45 8
Steckertyp
9 8 7 7 45 4
Konsole Sitz 7 1
Kabelbaum
11 45 3 9 6 3
9 45 2
12 10 2 Page Path 10 45 2
Contact
Kontakt
13 8 7 Blatt Pfad 11 45 8
14 16 2 1 16 4 12 45 1
15 44 5 2 28 3
16 19 5 3 50 7
17 16 2 4 16 5
0 1 2 3 4 5 6 7 8 9
Page from
107
Dokumentenart &EMA3
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Steckerübersicht
1001
642 EPE /00
1002
Plug overview
Stecker -X4.E Einbauort +EBOX Stecker -X5.A Einbauort +EBOX Stecker -X5.B Einbauort +EBOX Stecker -X5.E Einbauort +EBOX
Function text Plug, access cabin and rops Function text Plug, access harness driving controller 1 Function text Plug, access harness driving controller 2 Function text Plug, access harness measurement controller
Funktionstext Stecker Anschluß Kabine und Rops Funktionstext Stecker Anschluß Kabelbaum Fahrsteuerung 1 Funktionstext Stecker Anschluß Kabelbaum Fahrsteuerung 2 Funktionstext Stecker Anschluß Kabelbaum Messtechnik Steuerung
AMP Junior Power Timer 18 pole grey AMP Junior Power Timer 21 pole brown AMP Junior Power Timer 12 pole brown AMP Junior Power Timer 15 pole brown
Circuit diagrams

Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
1 51 1 1 28 8 1 34 6 3 40 7
2 51 1 2 28 7 2 4 12 1
3 44 3 3 11 3 3 34 6 5 40 6
4 51 1 4 13 2 4 6 12 3
5 51 1 5 33 6 5 28 5 7 40 1
6 44 4 6 15 4 6 28 4 8 40 8
7 51 1 7 37 2 7 9 13 5
8 51 1 8 8 34 4 10 37 2
9 51 1 9 15 5 9 34 5 11 36 5
10 51 1 10 27 1 10 28 3 12 15 7
11 51 1 11 11 13 12 2
12 51 1 12 15 2 12 14 35 3
13 51 1 13 13 2 15 15 6
17 51 1 17 33 9 Funktionstext Stecker Anschluß Kabelbaum Messtechnik Steuerung Function text Plug, access harness measurement controller
18 44 4 18 11 2 Plug type Funktionstext Stecker Anschluß Kabelbaum Messtechnik Steuerung
Plug Mounting location 20 33 8 Wire harness Steckertyp
-X5.A +EBOX 13 1
Stecker Einbauort 21 32 5 Kabelbaum Wire harness Verkabelung Schnittstelle
15 9 3 13 1
Function text Plug, access harness driving controller 1 Page Path Kabelbaum Messtechnik
Funktionstext Stecker Anschluß Kabelbaum Fahrsteuerung 1 15 9 3
Contact
Kontakt
Plug type Stecker -X5.B Einbauort +EBOX
Contact
Kontakt
AMP Junior Power Timer 21 pole brown 1 16 7 Blatt Pfad

Steckertyp Function text Plug, access harness driving controller 2
2 16 8 1 16 7
Wire harness Funktionstext Stecker Anschluß Kabelbaum Fahrsteuerung 2
19 1
3 40 7 2 16 8
Kabelbaum Plug type
21 12 3
AMP Junior Power Timer 12 pole brown 4 12 1 3 40 7
Page Path Steckertyp
5 40 6 4 12 1
BW 219 D-5 / BW 219 PD-5

Contact
Kontakt
Blatt Pfad Wire harness 6 12 3 5 40 6
10 1
Kabelbaum
1 28 8 12 9 6 3
7 40 1 6 12 3
2 28 7 Page Path 8 40 8 7 40 1
Contact
Kontakt
3 11 3 Blatt Pfad 9 13 5 8 40 8
4 13 2 1 34 6 10 9 13 5
5 33 6 2 11 36 5 10
6 15 4 3 34 6 12 15 7 11 36 5
7 4 13 12 2 12 15 7
8 5 28 5 14 35 3 13 12 2
9 15 5 6 28 4 15 15 6 14 35 3
10 27 1 7 15 15 6
11 8 34 4 Plug Mounting location
14 32 1 11 Funktionstext Stecker Anschluß Kabelbaum Messtechnik Steuerung Function text Plug, access harness measurement controller
15 15 3 12 Plug type Funktionstext Stecker Anschluß Kabelbaum Messtechnik Steuerung
17 33 9 Wire harness Steckertyp
18 11 2 Kabelbaum Wire harness Verkabelung Schnittstelle
1
19 11 1 Page Path Kabelbaum Messtechnik
3 9 15
Contact
Kontakt
20 33 8 Blatt Pfad Page Path

Contact
Kontakt
21 32 5 1 16 7 Blatt Pfad
2 16 8 1 16 7
0 1 2 3 4 5 6 7 8 9
Page from
107
Dokumentenart &EMA3
Checked K. Brand
Plug overview
Stecker -X5.E2 Einbauort +EBOX Stecker -X6.B Einbauort +EBOX Stecker -X6.C Einbauort +EBOX Stecker -X7.A Einbauort +EBOX
Function text Plug, access harness measurement controller Function text Plug, access sockets Function text Plug, access harness heating-climatic unit Function text Plug, access CAN Gateways
Funktionstext Stecker Anschluß Kabelbaum Messtechnik Steuerung Funktionstext Stecker Anschluß Bordsteckdosen Funktionstext Stecker Anschluß Kabelbaum Heiz-Klimamodul Funktionstext Stecker Anschluß CAN Gateways
AMP Junior Power Timer 15 pole brown AMP Junior Power Timer 2 - 4 pole black AMP Junior Power Timer 2 - 6 pole black AMP Junior Power Timer 12 pole yellow
Wire harness Verkabelung Schnittstelle Wire harness Wire harness Wire harness
2 6 1
1 10
Kabelbaum Messtechnik Kabelbaum Kabelbaum Kabelbaum
1 5 12 9 6 3
3 9 15
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
2 16 8 1 50 9 5 1
3 40 7 2 44 1 6 2
4 12 1 3 50 8 3 17 4
6 12 3 Stecker -X6.D Einbauort +EBOX 5 17 4
7 40 1 Plug Mounting location Function text Plug, access telematics 6 17 4
8 40 8 Stecker -X6.B Einbauort +EBOX Funktionstext Stecker Anschluß Telematik 7 17 6
9 13 5 Function text Plug, access sockets Plug type 8 17 5
10 Funktionstext Stecker Anschluß Bordsteckdosen Steckertyp 9 17 6
11 36 5 Plug type Wire harness 10 17 7
AMP Junior Power Timer 2 - 4 pole black 2 8
1 7
Kabelbaum
Contact
Kontakt
14 35 3 Blatt Pfad
15 15 6 Page Path Plug Mounting location
1 -X7.A +EBOX
Stecker Einbauort
Contact
Kontakt
Blatt Pfad 2 47 2
Plug Mounting location Function text Plug, access CAN Gateways
-X5.E3 +EBOX 1 50 9 3 47 2
Stecker Einbauort Funktionstext Stecker Anschluß CAN Gateways
2 44 1 4 47 2
Function text Plug, access harness measurement controller Plug type
3 50 8 5 47 2 AMP Junior Power Timer 12 pole yellow
Funktionstext Stecker Anschluß Kabelbaum Messtechnik Steuerung Steckertyp
4 44 1 6 47 2
Plug type Wire harness
Steckertyp Kabelbaum
Wire harness Stecker -X6.C Einbauort +EBOX Page Path
Economizer 13 1
Kabelbaum
Contact
Kontakt
Function text Plug, access harness heating-climatic unit Plug Mounting location Blatt Pfad
15 9 3
Page Path Funktionstext Stecker Anschluß Kabelbaum Heiz-Klimamodul Stecker -X6.D Einbauort +EBOX 1 17 2
Contact
Kontakt
Blatt Pfad Plug type Function text Plug, access telematics 2 17 2
1 16 7 Steckertyp Funktionstext Stecker Anschluß Telematik 3 17 4
2 16 8 Wire harness Plug type 4 17 4
2 6 AMP Junior Power Timer 2 - 8 pole black
3 Kabelbaum Steckertyp 5 17 4
BW 219 D-5 / BW 219 PD-5

1 5
4 12 1 Page Path Wire harness 6 17 4
Kabelbaum
Contact
Kontakt
5 Blatt Pfad 7 17 6
6 1 50 3 Page Path 8 17 5
Contact
Kontakt
7 2 50 3 Blatt Pfad 9 17 6
8 3 1 47 2 10 17 7
9 4 50 3 2 47 2 11
10 5 3 47 2 12
11 6 4 47 2
5 47 2 -X7.B +EBOX
14 Stecker -X6.C Einbauort +EBOX 7 47 2 Function text Plug, access keyboard electronical burglary protection
15 15 7 Funktionstext Stecker Anschluß Tastatur elektronische Diebstahlsicherung
Function text Plug, access harness heating-climatic unit 8 47 2
Funktionstext Stecker Anschluß Kabelbaum Heiz-Klimamodul Plug type
Steckertyp
Plug type
AMP Junior Power Timer 2 - 6 pole black Wire harness
Steckertyp 1
4
Kabelbaum
Wire harness
6 3
Kabelbaum Page Path
Contact
Kontakt
Contact
Kontakt
Blatt Pfad 1 46 3
1 50 3 2 46 3
2 50 3 3 46 3
3 4 46 3
4 50 3 5
0 1 2 3 4 5 6 7 8 9
Page from
Created M. Vogt Blatt 71 von
107
Dokumentenart &EMA3
Checked
Circuit diagrams
K. Brand
1003
642 EPE /00
1004
Plug overview
Stecker -X7.B Einbauort +EBOX Stecker -X7.C Einbauort +EBOX Stecker -X7.C-2 Einbauort +EBOX Stecker -X7.D Einbauort +EBOX
Function text Plug, access keyboard electronical burglary protection Function text Plug, additional options Function text Plug, additional options Function text Plug, access diagnosis Interface Bomag
Funktionstext Stecker Anschluß Tastatur elektronische Diebstahlsicherung Funktionstext Stecker Zusatzoptionen Funktionstext Stecker Zusatzoptionen Funktionstext Stecker Anschluß Diagnosesteckdose Bomag
AMP Junior Power Timer 6 pole yellow AMP Junior Power Timer 2 - 14 pole black AMP Junior Power Timer 2 - 14 pole black AMP Junior Power Timer 15 pole yellow
Circuit diagrams
Wire harness Wire harness Wire harness Verkabelung Schnittstelle 1 13

Wire harness
4 1
Kabelbaum Kabelbaum Kabelbaum Messtechnik Kabelbaum
2 14
6 3
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
6 1 9 2 2 10 1 2 15 1
2 10 1 3 10 1 3 15 5
Stecker -X7.B Einbauort +EBOX 4 8 7 5 8 6 5 15 2
Function text Plug, access keyboard electronical burglary protection 5 8 6 6 44 6 6 15 4
Funktionstext Stecker Anschluß Tastatur elektronische Diebstahlsicherung 6 44 6 7 51 0 7 15 3
Plug type 7 51 1 8 8 15 8
Steckertyp 8 9 9
Wire harness 9 10 28 6 10 15 2
Kabelbaum 10 28 6 11 28 5 11 15 6
Page Path 11 28 5 12 32 5 12
Contact
Kontakt
Blatt Pfad 12 32 5 13 15 2 13 15 1
1 46 3 13 15 2 14 15 4 14
2 46 3 14 15 4 15 15 1
3 46 3 -X7.D +EBOX
Plug Mounting location Stecker Einbauort Plug Mounting location
4 46 3 -X7.C-2 +EBOX -X8.A +EBOX
Stecker Einbauort Function text Plug, access diagnosis Interface Bomag Stecker Einbauort
5
Function text Plug, additional options Funktionstext Stecker Anschluß Diagnosesteckdose Bomag Function text Plug, access supply cabin potential 30
6 46 3
Funktionstext Stecker Zusatzoptionen Plug type Funktionstext Stecker Anschluß Kabine Potential 30
Plug type Steckertyp Plug type
Plug Mounting location AMP Junior Power Timer 2 - 14 pole black Amphenol RADSOK® 8mm
Stecker -X7.C +EBOX Steckertyp Wire harness Steckertyp
Einbauort 1
13
Wire harness Verkabelung Schnittstelle Kabelbaum Wire harness
Function text Plug, additional options 2 14
15 9 3
Funktionstext Stecker Zusatzoptionen Kabelbaum Messtechnik Page Path Kabelbaum
1 13
Contact
Kontakt
Plug type Page Path Blatt Pfad Page Path
Contact
Kontakt
Contact
Kontakt
Steckertyp Blatt Pfad 1 Blatt Pfad

Wire harness 2 14
1 9 2 2 15 1 30 51 2
Kabelbaum 2 10 1 3 15 5
1 13
BW 219 D-5 / BW 219 PD-5

Stecker -X8.A Einbauort +EBOX
Contact
Kontakt
Blatt Pfad 4 8 7 5 15 2
5 8 6 6 15 4 Function text Plug, access supply cabin potential 30
1 9 2
6 44 6 7 15 3 Funktionstext Stecker Anschluß Kabine Potential 30
2 10 1
7 51 1 8 15 8 Plug type
3 Amphenol RADSOK® 8mm
8 9 Steckertyp
4 8 7
10 28 6 11 15 6 Kabelbaum
6
7 11 28 5 12 Page Path
Contact
Kontakt
8 12 32 5 13 15 1 Blatt Pfad
9 13 15 2 14 30 51 1
10 14 15 4 15 15 1
Plug Mounting location Plug Mounting location Stecker -X8.B Einbauort +EBOX
12 -X7.C-2 +EBOX -X7.D +EBOX
Stecker Einbauort Stecker Einbauort
13 Function text Plug, access supply cabin potential 31
Function text Plug, additional options Function text Plug, access diagnosis Interface Bomag Funktionstext Stecker Anschluß Kabine Potential 31
14
Funktionstext Stecker Zusatzoptionen Funktionstext Stecker Anschluß Diagnosesteckdose Bomag
Plug type
Plug type Plug type Amphenol RADSOK® 6mm
AMP Junior Power Timer 2 - 14 pole black AMP Junior Power Timer 15 pole yellow Steckertyp
Wire harness
Wire harness Verkabelung Schnittstelle 1 13
Kabelbaum Messtechnik Kabelbaum
2 14 Page Path
Page Path Page Path
Contact
Kontakt
Blatt Pfad
Contact
Kontakt
Contact
Kontakt

31 51 2
1 9 2 1
0 1 2 3 4 5 6 7 8 9
Page from
107
Dokumentenart &EMA3
Checked K. Brand
Plug overview
Stecker -X8.B Einbauort +EBOX Stecker -X11 Einbauort +REFR Stecker -X14 Einbauort +SEAT Stecker -X21 Einbauort +DRUM
Function text Plug, access supply cabin potential 31 Function text Plug, connection rear frame - engine module Function text Plug, seat contact switch Function text Plug, transducer acceleration rear
Funktionstext Stecker Anschluß Kabine Potential 31 Funktionstext Stecker Verbindung Hinterrahmen - Motormodul Funktionstext Stecker Sitzkontaktschalter Funktionstext Stecker Beschleunigungsaufnehmer hinten
Amphenol RADSOK® 6mm Deutsch DT 12 pole Code A Deutsch DT 3 pole Deutsch DT 4 pole
Konsole Sitz
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
31 51 1 10 45 8 A 28 3 1 40 3
11 45 1 B 28 3 2 40 4
Plug Mounting location 12 C 3 40 4
Stecker -X10 Einbauort +CAB 4 40 3
Function text Plug, heating climatic unit Plug Mounting location Plug Mounting location
Funktionstext Stecker Heiz-Klima-Einheit Stecker -X11 Einbauort +REFR Stecker -X14 Einbauort +SEAT Plug Mounting location
Plug type Function text Plug, connection rear frame - engine module Function text Plug, seat contact switch Stecker -X22 Einbauort +EBOX
Steckertyp Funktionstext Stecker Verbindung Hinterrahmen - Motormodul Funktionstext Stecker Sitzkontaktschalter Function text Plug, access rotary beacon ROPS
Wire harness Plug type Plug type Funktionstext Stecker Anschluß Rundumkennleuchte ROPS
Deutsch DT 3 pole
Kabelbaum Steckertyp Steckertyp Plug type
FASTIN-FASTON TAB housing 2 way
Page Path Wire harness Wire harness Steckertyp
Kabelbaum Kabelbaum
Contact
Kontakt
Blatt Pfad Wire harness
Page Path Page Path Kabelbaum
1 50 3
Contact
Kontakt
Contact
Kontakt
2 50 4 Blatt Pfad Blatt Pfad Page Path
Contact
Kontakt
3 1 27 8 A 28 3 Blatt Pfad
4 50 3 2 27 8 B 28 3 1 44 2
3 C 28 3 2 44 2
Plug Mounting location 4
Stecker -X10 Einbauort +CAB 5 Plug Mounting location Plug Mounting location
Function text Plug, heating climatic unit 6 45 1 Stecker -X16 Einbauort +DPL Stecker -X23 Einbauort +SEAT
Funktionstext Stecker Heiz-Klima-Einheit 7 45 8 Function text Plug, keyboard electronical burglary protection Function text Plug, supply travel lever
Plug type 8 45 1 Funktionstext Stecker Tastatur Elektronische Diebstahlsicherung Funktionstext Stecker Vorsorgung Fahrhebel
Steckertyp 9 45 2 Plug type Plug type
Deutsch DT 4 pole Deutsch DT 12 pole Code A
Wire harness 10 45 8 Steckertyp Steckertyp
Kabelbaum 11 45 1 Wire harness Wire harness
Konsole Sitz
Page Path 12 Kabelbaum Kabelbaum
Contact
Kontakt
Blatt Pfad Page Path Page Path
Contact
Kontakt
Contact
Kontakt
1 50 3 Blatt Pfad Blatt Pfad
BW 219 D-5 / BW 219 PD-5

Stecker -X12 Einbauort +MOT
2 50 4 1 46 5 1 14 6
Function text Plug, compressor air conditioning
3 2 46 5 2 14 5
Funktionstext Stecker Kompressor Klimaanlage
4 50 3 3 46 5 3 29 9
Plug type
Circular connector 4,6mm 4 46 5 4
Steckertyp
Stecker -X11 Einbauort +REFR Wire harness
Motor Plug Mounting location 6 16 4
Function text Plug, connection rear frame - engine module Kabelbaum Stecker -X20 Einbauort +DRUM 7 16 5
Funktionstext Stecker Verbindung Hinterrahmen - Motormodul Page Path Function text Plug, transducer acceleration front 8 29 2
Contact
Kontakt
Plug type Blatt Pfad Funktionstext Stecker Beschleunigungsaufnehmer vorne 9 14 6
Steckertyp 1 50 1 Plug type 10 14 7
Deutsch DT 4 pole
Wire harness Steckertyp 11 29 1
Kabelbaum Plug Mounting location Wire harness 12 29 4
Page Path Stecker -X12 Einbauort +MOT Kabelbaum
Contact
Kontakt
Blatt Pfad Function text Plug, compressor air conditioning Page Path
Funktionstext Stecker Kompressor Klimaanlage
Contact
Kontakt
1 27 8 Blatt Pfad
Plug type
2 27 8 Circular connector 4,6mm 1 40 1
Steckertyp
3 32 6 2 40 2
Kabelbaum
5 32 6 4 40 1
6 45 1 Page Path
Contact
Kontakt
7 45 8 Blatt Pfad
8 45 1 1 50 1
9 45 2
0 1 2 3 4 5 6 7 8 9
Page from
107
Dokumentenart &EMA3
Checked
Circuit diagrams
K. Brand
1005
642 EPE /00
1006
Plug overview
Stecker -X23.A Einbauort +SEAT Stecker -X24 Einbauort +SEAT Stecker -X26 Einbauort +SEAT Stecker -X28 Einbauort +REFR
Function text Plug, supply travel lever Function text Plug, IO´s travel lever Function text Plug, potentiometer frequency plates Function text Plug, sensor height adjustment plates
Funktionstext Stecker Vorsorgung Fahrhebel Funktionstext Stecker Ein-/Ausgänge Fahrhebel Funktionstext Stecker Potentiometer Frequenzverstellung Anbauplatten Funktionstext Stecker Sensor Höhenverstellung Platten
Deutsch DTM 12 pole Code A Deutsch DT 8 pole AMP Mateń´loc 3 pole white Deutsch DTM 3 pole
Circuit diagrams

Adapter Fahrhebel Konsole Sitz Konsole Sitz
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
1 14 6 6 35 7 1 29 4 1 38 5
2 14 5 7 2 29 4 2 38 5
3 29 9 8 3 29 4 3 38 5
4 29 0
5 29 3 Plug Mounting location Plug Mounting location Plug Mounting location
6 16 4 Stecker -X25 Einbauort +REFR Stecker -X26 Einbauort +SEAT Stecker -X29 Einbauort +REFR
7 16 5 Function text Plug, access double pump Function text Plug, potentiometer frequency plates Function text Plug, access lifting unit plates
8 29 2 Funktionstext Stecker Anschluß Doppelpumpe Funktionstext Stecker Potentiometer Frequenzverstellung Anbauplatten Funktionstext Stecker Anschluß Hubwerk Platten
9 14 6 Plug type Plug type Plug type
Deutsch DTM 8 pole AMP Mateń´loc 3 pole white Deutsch DTM 6 pole
10 14 7 Steckertyp Steckertyp Steckertyp
11 29 1 Wire harness Wire harness Wire harness
12 29 4 Kabelbaum Kabelbaum Kabelbaum
Page Path Page Path Page Path
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Blatt Pfad Blatt Pfad Blatt Pfad

Stecker -X23.B Einbauort +SEAT
6 31 4 1 29 4 1 38 7
Function text Plug, supply travel lever
1 30 2 2 29 4 2 38 6
Funktionstext Stecker Vorsorgung Fahrhebel
2 30 3 3 29 4 3 38 6
Plug type
Deutsch DT 12 pole Code A 3 30 4 4 38 4
Steckertyp
4 30 4 Plug Mounting location 5 38 6
Wire harness
Adapter Fahrhebel 5 30 2 Stecker -X27 Einbauort +PLA 6 38 6
Kabelbaum Function text Plug, quick connect coupling plates
7 31 4
Page Path 8 31 5 Funktionstext Stecker Schnellverschlußkupplung Platten Plug Mounting location
-X29 +REFR
Contact
Kontakt
Blatt Pfad Plug type Stecker Einbauort
1 14 6 Plug Mounting location Steckertyp Function text Plug, access lifting unit plates
2 14 5 Stecker -X25 Einbauort +REFR Wire harness Funktionstext Stecker Anschluß Hubwerk Platten
3 29 9 Function text Plug, access double pump Kabelbaum Plug type
Deutsch DTM 6 pole
4 29 0 Funktionstext Stecker Anschluß Doppelpumpe Page Path Steckertyp
Plug type
Contact
Kontakt
5 29 3 Blatt Pfad Wire harness
Deutsch DTM 8 pole
BW 219 D-5 / BW 219 PD-5

6 16 4 Steckertyp Kabelbaum
1 38 5
7 16 5 Wire harness 2 38 5 Page Path
Kabelbaum
Contact
Kontakt
8 29 2 3 38 4 Blatt Pfad
9 14 6 Page Path 1 38 7
Contact
Kontakt
10 14 7 Blatt Pfad Plug Mounting location 2 38 6
11 29 1 1 30 2 Stecker -X28 Einbauort +REFR 3 38 6
12 29 4 2 30 3 Function text Plug, sensor height adjustment plates 4 38 4
3 30 4 Funktionstext Stecker Sensor Höhenverstellung Platten 5 38 6
-X24 +SEAT 4 30 4 Deutsch DTM 3 pole
6 38 6
Stecker Einbauort Steckertyp
5 30 2
Function text Plug, IO´s travel lever Plug
6 31 4 Wire harness Mounting location
Funktionstext Stecker Ein-/Ausgänge Fahrhebel Stecker -X30 +REFR
7 31 4 Kabelbaum Einbauort
Plug type Function text Plug, backup alarm buzzer
Deutsch DT 8 pole 8 31 5 Page Path
Steckertyp Funktionstext Stecker Rückfahrwarnsummer
Contact
Kontakt
Blatt Pfad
Wire harness Plug type
Konsole Sitz 1 38 5 Deutsch DT 2 pole
Page Path 2 38 5
3 38 5 Wire harness
Contact
Kontakt
Blatt Pfad Kabelbaum
1 29 7 Page Path
Contact
Kontakt
2 29 8 Blatt Pfad
3 1 33 6
4 29 5 2 33 6
5 35 6
0 1 2 3 4 5 6 7 8 9
Page from
107
Dokumentenart &EMA3
Checked K. Brand
Plug overview
Stecker -X30 Einbauort +REFR Stecker -X33 Einbauort +ARC Stecker -X35 Einbauort +EBOX Stecker -X35 Einbauort +EBOX
Function text Plug, backup alarm buzzer Function text Plug, module monitoring Function text Plug, ECU propulsion Function text Plug, ECU propulsion
Funktionstext Stecker Rückfahrwarnsummer Funktionstext Stecker Modul Überwachung Funktionstext Stecker ECU Fahrantrieb Funktionstext Stecker ECU Fahrantrieb
Deutsch DT 2 pole AMP Superseal 26 pole AMP 68 pole AMP 68 pole
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
1 33 6 18 2 32 4 54 11 2
2 33 6 19 3 32 7 55 11 5
20 4 56 11 3
Stecker -X31 Einbauort +REFR 22 16 2 6 30 2 58 11 5
Function text Plug, boost module SCR-System 23 7 30 3 59 11 6
Funktionstext Stecker Fördermodul SCR-System 24 8 38 5 60 11 6
Plug type 25 14 1 9 27 1 61 33 6
AMP HDSCS 12 pole
Steckertyp 26 14 1 10 38 6 62 37 3
Wire harness 11 37 4 63 38 4
Kabelbaum Plug Mounting location 12 28 5 64 32 5
Page Path Stecker -X34 Einbauort +EBOX 13 28 4 65 11 6
Contact
Kontakt
Blatt Pfad Function text Diagnosis interface BOMAG 14 32 1 66 11 7
Funktionstext Diagnosesteckdose BOMAG 15 28 3 67 11 8
2 25 6
Plug type 16 28 4 68 11 9
3 25 6 Burndy 19 pole
Steckertyp 17 28 7
4 25 5
Wire harness 18 Plug Mounting location
5 25 8 -X36 +MOT
Kabelbaum 19 Stecker Einbauort
6 25 8
Page Path 20 31 4 Function text Plug, access sensors exhaust aftertreatment
8 25 7
Funktionstext Stecker Anschluß Sensoren Abgasnachbehandlung
Contact
Kontakt
9 25 7 Blatt Pfad 21 31 5
22 38 7 Plug type
10 25 7 A 15 2 Tyco MCP 39 pole Code E
23 13 2 Steckertyp
11 25 6 B 15 3
12 25 6 C 15 4 24 33 9 Wire harness
EAT-System
25 33 8 Kabelbaum
D 15 5
Plug Mounting location E 15 6 26 15 3 Page Path
-X33 +ARC
Contact
Kontakt
Stecker Einbauort F 15 8 27 15 2 Blatt Pfad

Function text Plug, module monitoring G 28 11 1 1
Funktionstext Stecker Modul Überwachung H 29 30 4 2
BW 219 D-5 / BW 219 PD-5

Plug type J 15 2 30 30 4 3 25 2
AMP Superseal 26 pole 31 38 6
Steckertyp K 4 25 3
Wire harness L 32 28 2 5 25 4
Kabelbaum M 33 15 5 6
Page Path N 15 1 34 34 3 7
35 28 6
Contact
Kontakt
Blatt Pfad P 15 1 8 25 1
R 15 1 36 27 3 9 25 1
1 37 27 5
2 27 8 S 10 25 1
T 38 27 4 11 26 7
3 27 7 39 27 2
4 19 5 U 12
V 40 13 24 8
5 44 7 41
6 14 25 4
Plug Mounting location 42 37 5 15 25 3
7 -X35 +EBOX 43 37 6
8 45 7 44
Function text Plug, ECU propulsion 17
9 19 1 45 39 5
Funktionstext Stecker ECU Fahrantrieb 18 25 2
10 19 2 46 31 2
Plug type 19 25 2
11 19 3 AMP 68 pole 47 31 3
Steckertyp 20 26 9
12 19 4 48 34 4
13 Wire harness 21 26 9
Kabelbaum 49 34 5 22 25 5
14 50 37 7
15 Page Path 23 26 8
51 37 8
Contact
Kontakt
52 25 25 8
17 1 13 2 53 15 4
0 1 2 3 4 5 6 7 8 9
Page from
107
Dokumentenart &EMA3
Checked
Circuit diagrams
K. Brand
1007
642 EPE /00
1008
Plug overview
Stecker -X36 Einbauort +MOT Stecker -X41 Einbauort +EBOX Stecker -X44 Einbauort +EBOX Stecker -X44 Einbauort +EBOX
Function text Plug, access sensors exhaust aftertreatment Function text Plug, access external supply engine Function text Plug, engine-controller motor-part Function text Plug, engine-controller motor-part
Funktionstext Stecker Anschluß Sensoren Abgasnachbehandlung Funktionstext Stecker Anschluß externe Versorgung Motor Funktionstext Stecker Motorsteuergerät Motorseite Funktionstext Stecker Motorsteuergerät Motorseite
Tyco MCP 39 pole Code E AMP MCP 2.8 39 pole Bosch 105 pole Bosch 105 pole
Circuit diagrams

EAT-System
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
26 1 22 8 28 80 26 8
27 2 22 8 29 25 3 81
28 25 4 3 22 8 30 82 25 6
29 25 6 6 22 8 31 83
30 25 6 28 24 1 32 25 3 84
31 26 8 29 24 1 33 85 22 0
32 26 8 32 25 1 34 86 22 2
33 25 5 33 25 1 35 23 2 87 22 2
34 26 7 34 25 1 36 23 1 88 22 9
35 25 7 35 24 8 37 26 9 89 25 7
36 25 7 36 24 8 38 90
37 24 8 38 24 1 39 91
38 24 5 39 24 1 40 92 25 8
39 24 5 41 26 7 93
Plug Mounting location 42 94 22 8
Plug Mounting location Stecker -X44 Einbauort +EBOX 43 22 1 95 22 8
Stecker -X39 Einbauort +DRUM Function text Plug, engine-controller motor-part 44 22 2 96
Function text Plug, transducer Economizer Funktionstext Stecker Motorsteuergerät Motorseite 45 22 3 97
Funktionstext Stecker Aufnehmer Economizer Plug type 46 23 0 98 24 3
Bosch 105 pole
Plug type Steckertyp 47 25 4 99 22 6
Deutsch DTM 4 pole
Steckertyp Wire harness 48 25 2 100 22 6
Wire harness Kabelbaum 49 101 22 7
Aufnehmer Economizer
Kabelbaum Page Path 50 102 22 7
Contact
Kontakt
Page Path Blatt Pfad 51 23 9 103
Contact
Kontakt
Blatt Pfad 1 52 104
1 41 5 2 23 7 53 23 6 105
2 41 5 3 26 7 54 23 5 23 22 5
3 41 6 4 26 8 55 23 7 24 22 5
BW 219 D-5 / BW 219 PD-5

4 41 6 5 25 6 56 45 22 4
6 57 25 6 64 22 4
Stecker -X39 Einbauort +DRUM 8 23 9 59 25 7 85 22 4
Function text Plug, transducer Economizer 9 25 2 60
Funktionstext Stecker Aufnehmer Economizer 61 26 9 Plug Mounting location
10 -X45 +EBOX
62 26 8 Stecker Einbauort
Plug type 11 23 4
Deutsch DTM 4 pole 63 22 8 Function text Plug, engine-controller machine-part
Steckertyp 12
64 22 1 Funktionstext Stecker Motorsteuergerät Maschinenseite
Wire harness 13 23 3
Kabelbaum 65 22 1 Plug type
14 Tyco MQS 94 pole
66 22 2 Steckertyp
Page Path 15 25 2
67 23 7 Wire harness
Contact
Kontakt
Blatt Pfad 16
68 Kabelbaum
1 41 5 17 23 2
18 23 8 69 Page Path
2 41 5
Contact
Kontakt
19 25 6 70 25 5 Blatt Pfad
3 41 6 71
4 41 6 20 25 4 1 21 0
21 23 4 72 23 4 2 21 9
22 22 1 73 23 4 3 21 0
23 22 2 74 23 3 4 21 9
24 22 3 75 22 6 5 21 0
25 23 1 76 23 8 6 21 9
26 25 5 77 24 3 7
27 25 4 78 23 1 8
79
0 1 2 3 4 5 6 7 8 9
Page from
107
Dokumentenart &EMA3
Checked K. Brand
Plug overview
Stecker -X45 Einbauort +EBOX Stecker -X45 Einbauort +EBOX Stecker -X46.1 Einbauort +MOT Stecker -X46.2 Einbauort +MOT
Function text Plug, engine-controller machine-part Function text Plug, engine-controller machine-part Function text Plug, engine EMR 1 Function text Plug, engine EMR 2
Funktionstext Stecker Motorsteuergerät Maschinenseite Funktionstext Stecker Motorsteuergerät Maschinenseite Funktionstext Stecker Motor EMR 1 Funktionstext Stecker Motor EMR 2
Tyco MQS 94 pole Tyco MQS 94 pole AMP MCP 39 pole AMP MCP 62 pole
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
9 61 9 22 6 37 23 8
10 21 3 62 13 22 6 41 23 9
11 63 14 22 6 46 23 6
12 64 21 5 15 22 7 57 24 1
13 21 5 65 17 23 5 59 24 1
14 66 19 23 0
15 67 21 5 20 23 1 Plug Mounting location
16 68 21 22 7 Stecker -X47.1 Einbauort +MOT
17 69 22 23 4 Function text Plug, injectors 1
18 21 5 70 21 1 23 23 4 Funktionstext Stecker Injektoren 1
19 71 24 23 3 Plug type
20 72 25 23 1 Steckertyp
22 74 21 4 27 23 2 Kabelbaum
23 21 4 75 28 23 3 Page Path
Contact
Kontakt
24 76 29 23 4 Blatt Pfad
25 77 30 23 1 1 22 0
26 21 1 78 31 23 2 1 22 4
27 79 32 22 2 2 22 1
28 80 32 22 5 2 22 4
29 81 33 22 3 3 22 1
30 82 21 8 33 22 5 3 22 5
31 21 5 83 21 8 34 22 0 4 22 2
32 84 34 22 4 4 22 5
33 85 21 8 35 22 1 5 22 4
34 86 21 8 35 22 4
35 87 36 22 1 Plug Mounting location
36 88 21 4 37 22 2 Stecker -X47.2 Einbauort +MOT
BW 219 D-5 / BW 219 PD-5

37 89 37 22 4 Function text Plug, injectors 2
38 90 38 22 1 Funktionstext Stecker Injektoren 2
39 91 21 2 39 22 3 Plug type
40 92 Steckertyp
41 93 Plug Mounting location
-X46.2 +MOT Wire harness
42 94 Stecker Einbauort Kabelbaum
43 21 3 Function text Plug, engine EMR 2
Page Path
44 Plug Mounting location Funktionstext Stecker Motor EMR 2
Contact
Kontakt
-X46.1 +MOT Blatt Pfad

45 Stecker Einbauort Plug type
AMP MCP 62 pole 1 22 3
46 Function text Plug, engine EMR 1 Steckertyp
47 Funktionstext Stecker Motor EMR 1 Wire harness 2 22 1
48 Plug type Kabelbaum 3 22 2
AMP MCP 39 pole 4 22 3
49 Steckertyp Page Path
Wire harness
Contact
Kontakt
50 21 3 Blatt Pfad
51 Kabelbaum
13 23 7
52 Page Path 18 23 7
Contact
Kontakt
54 1 22 7 22 24 2
55 2 22 8 23 24 2
56 3 22 8 24 23 8
57 6 22 8 28 24 1
58 21 2 7 22 9 29 24 1
59 8 22 9 30 23 9
60
0 1 2 3 4 5 6 7 8 9
Page from
107
Dokumentenart &EMA3
Checked
Circuit diagrams
K. Brand
1009
642 EPE /00
1010
Plug overview
Stecker -X50.f Einbauort +CAB Stecker -X51 Einbauort +MOT Stecker -X58 Einbauort +PUMP Stecker -X67.m Einbauort +MOT
Function text Plug, access display back up monitoring Function text Plug, electronic system ZTR telematics Function text Plug, pressure sensor travel pump drum MB Function text Plug access heating prefilter fuel
Funktionstext Stecker Anschluß Monitor Rückraumüberwachung Funktionstext Stecker Elektronik System ZTR Telematic Funktionstext Stecker Drucksensor Fahrpumpe Bandage MB Funktionstext Stecker Anschluß Heizung Vorfilter Kraftstoff
Deutsch DT 6 pole Deutsch DT 8 pole Code A AMP Superseal 3pol Deutsch DT 2 pole
Circuit diagrams

Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
1 58 5 1 48 2 1 30 4 1 18 8
2 58 5 2 48 2 2 30 4 2 18 8
3 58 5 3 48 2 3
4 4 Plug Mounting location
5 5 Plug Mounting location Stecker -X68.f Einbauort +REFR
6 6 Stecker -X65 Einbauort +CAB Function text Plug, pressure switch air conditioning
7 Function text Plug, windscreen wiper motor rear Funktionstext Stecker Druckschalter Klimaanlage
Plug Mounting location 8 Funktionstext Stecker Scheibenwischermotor hinten Plug type
-X50.m +CAB Deutsch DT 4 pole
Stecker Einbauort Plug type Steckertyp
P4NAT
Function text Plug, access display back up monitoring Plug Mounting location Steckertyp Wire harness
-X55 +PUMP Motor
Funktionstext Stecker Anschluß Monitor Rückraumüberwachung Stecker Einbauort Wire harness Kabelbaum
Plug type Function text Plug, pressure sensor travel pump axle MA Kabelbaum Page Path
Deutsch DT 6 pole
Steckertyp Funktionstext Stecker Drucksensor Fahrpumpe Achse MA
Contact
Kontakt

Contact
Kontakt
AMP Superseal 3pol
Blatt Pfad 1 50 1
1 55 5 2 50 1
Page Path Wire harness 2 55 5 3
Kabelbaum
Contact
Kontakt
Blatt Pfad 3 55 5 4
1 58 5 Page Path 4 55 5
Contact
Kontakt
2 58 5 Blatt Pfad Plug Mounting location
3 58 5 1 30 2 Plug Mounting location Stecker -X68.m Einbauort +REFR
4 58 5 2 30 2 Stecker -X66 Einbauort +CAB Function text Plug, pressure switch air conditioning
5 58 5 3 Function text Plug windscreen wiper motor front Funktionstext Stecker Druckschalter Klimaanlage
6 Funktionstext Stecker Scheibenwischermotor vorne Plug type
Deutsch DT 4 pole
Plug Mounting location Plug type Steckertyp
-X56 +PUMP P6SNAT
Plug Mounting location Stecker Einbauort Steckertyp Wire harness
Stecker -X51 Einbauort +MOT Function text Plug, pressure sensor travel pump axle MB Wire harness Kabelbaum
Function text Plug, electronic system ZTR telematics Funktionstext Stecker Drucksensor Fahrpumpe Achse MB Kabelbaum Page Path
Funktionstext Stecker Elektronik System ZTR Telematic Plug type
Contact
Kontakt
AMP Superseal 3pol

BW 219 D-5 / BW 219 PD-5

Contact
Kontakt
Blatt Pfad 1 50 1
Steckertyp Wire harness 1 55 3 2 50 1
2 55 3 3
Kabelbaum Page Path 3 55 3 4
Contact
Kontakt
Page Path Blatt Pfad 4
Contact
Kontakt
Blatt Pfad 1 30 3 5 55 3 Plug Mounting location
1 48 2 2 30 3 6 Stecker -X69 Einbauort +REFR
2 48 2 3 Function text Plug, sender level gauge
3 48 2 Plug Mounting location Funktionstext Stecker Tauchrohrgeber
4 Plug Mounting location Stecker -X67.f Einbauort +MOT Plug type
-X57 +PUMP AMP Superseal 3pol
5 Stecker Einbauort Function text Plug access heating prefilter fuel Steckertyp
6 Function text Plug, pressure sensor travel pump drum MA Funktionstext Stecker Anschluß Heizung Vorfilter Kraftstoff Wire harness
7 Funktionstext Stecker Drucksensor Fahrpumpe Bandage MA Plug type Kabelbaum
Deutsch DT 2 pole
8 Plug type Steckertyp Page Path
AMP Superseal 3pol
Contact
Kontakt
Motor
Blatt Pfad
1
Kabelbaum Page Path 2 27 8
Contact
Kontakt
Contact
Kontakt
Blatt Pfad 1 18 8
1 30 4 2 18 8
2 30 4
3
0 1 2 3 4 5 6 7 8 9
Page from
107
Dokumentenart &EMA3
Checked K. Brand
Plug overview
Stecker -X72.f Einbauort +MOT Stecker -X76 Einbauort +MOT Stecker -X80 Einbauort +REFR Stecker -X82 Einbauort +DPL
Function text Plug, floating switch coolant expansion tank Function text Plug, access fuel pump additional heater Function text Plug, tail light rear left Function text Plug, headlight front right
Funktionstext Stecker Schwimmerschalter Kühlmittelausgleichsbehälter Funktionstext Stecker Anschluss Kraftstoffpumpe Zusatzheizung Funktionstext Stecker Rückleuchte links Funktionstext Stecker Scheinwerfer vorne rechts
PKC 2 way Deutsch DTM 2 pole Deutsch DT 4 pole Deutsch DT 6 pole
Motor
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
1 27 2 1 49 5 1 45 8 2 45 8
2 27 2 2 49 5 2 45 8 3 45 2
3 45 1 5 45 5
Plug Mounting location Plug Mounting location 4 45 1 6 45 2
Stecker -X72.m Einbauort +MOT Stecker -X76 Einbauort +MOT
Function text Plug, floating switch coolant expansion tank Function text Plug, access fuel pump additional heater Plug Mounting location Plug Mounting location
Funktionstext Stecker Schwimmerschalter Kühlmittelausgleichsbehälter Funktionstext Stecker Anschluss Kraftstoffpumpe Zusatzheizung Stecker -X80 Einbauort +REFR Stecker -X85 Einbauort +CAB
Plug type Plug type Function text Plug, tail light rear left Function text Plug, access BCM-system
Deutsch DTM 2 pole
Steckertyp Steckertyp Funktionstext Stecker Rückleuchte links Funktionstext Stecker Anschluß BCM-System
Wire harness Wire harness Plug type Plug type
Deutsch DT 4 pole
Kabelbaum Kabelbaum Steckertyp Steckertyp
Page Path Page Path Wire harness Wire harness
Kabelbaum Kabelbaum
Contact
Kontakt
Contact
Kontakt
1 27 2 1 49 5 Page Path Page Path
Contact
Kontakt
Contact
Kontakt
2 27 2 2 49 5 Blatt Pfad Blatt Pfad

1 45 8 1 57 5
Plug Mounting location Plug Mounting location 2 45 8 2 57 5
Stecker -X73 Einbauort +MOT Stecker -X78.m Einbauort +MOT 3 45 1 3 57 6
Function text Plug, WaterInFuel Sensor Function text Plug, access potential 15 Powerboard SCR-System 4 45 1 4 57 1
Funktionstext Stecker Sensor Wasser im Kraftstoff Funktionstext Stecker Anschluß Potential 15 Powerboard SCR-System 5 57 1
Plug type Plug type Plug Mounting location 6
Tyco Junior Power Timer 2 pole Deutsch DT 2 pole -X81 +REFR
Steckertyp Steckertyp Stecker Einbauort
Wire harness Wire harness Function text Plug, tail light rear right Plug Mounting location
Motor EAT-System -X85 +CAB
Kabelbaum Kabelbaum Funktionstext Stecker Rückleuchte rechts Stecker Einbauort
Page Path Page Path Plug type Function text Plug, access BCM-system
Deutsch DT 4 pole
Steckertyp Funktionstext Stecker Anschluß BCM-System
Contact
Kontakt
Contact
Kontakt
1 21 1 1 18 8 Deutsch DT 6 pole
2 21 1 2
BW 219 D-5 / BW 219 PD-5

Page Path Wire harness
Kabelbaum
Contact
Kontakt
Plug Mounting location Plug Mounting location Blatt Pfad
Stecker -X73 Einbauort +MOT Stecker -X79 Einbauort +DPL 1 45 8 Page Path
Contact
Kontakt
Function text Plug, WaterInFuel Sensor Function text Plug, headlight front left 2 45 8 Blatt Pfad
Funktionstext Stecker Sensor Wasser im Kraftstoff Funktionstext Stecker Scheinwerfer vorne links 3 45 2 1
Plug type Plug type 4 45 2 2 57 5
Tyco Junior Power Timer 2 pole Deutsch DT 6 pole
Steckertyp Steckertyp 3 57 6
Wire harness Wire harness Plug Mounting location 4 57 1
Kabelbaum Kabelbaum Stecker -X81 Einbauort +REFR 5 57 1
Page Path Page Path Function text Plug, tail light rear right 6
Funktionstext Stecker Rückleuchte rechts
Contact
Kontakt
Contact
Kontakt
Plug type Plug Mounting location
1 21 1 2 45 7 Deutsch DT 4 pole -X86 +DRUM
Steckertyp Stecker Einbauort
2 21 1 3 45 1
5 45 4 Wire harness Function text Plug, sensor adjustable motor
Kabelbaum Funktionstext Stecker Sensor Verstellmotor
6 45 1
Page Path Plug type
Deutsch DTM 3 pole
Steckertyp
Contact
Kontakt
Blatt Pfad
1 45 8 Wire harness
Kabelbaum
2 45 8
3 45 2 Page Path
Contact
Kontakt
4 45 2 Blatt Pfad
1 36 5
2 36 5
0 1 2 3 4 5 6 7 8 9
Page from
107
Dokumentenart &EMA3
Checked
Circuit diagrams
K. Brand
1011
642 EPE /00
1012
Plug overview
Stecker -X86 Einbauort +DRUM Stecker -X88 Einbauort +EBOX Stecker -X88 Einbauort +EBOX Stecker -X91 Einbauort +CAB
Function text Plug, sensor adjustable motor Function text Plug, measurement controller Function text Plug, measurement controller Function text Plug, USB BCM Dongle
Funktionstext Stecker Sensor Verstellmotor Funktionstext Stecker Messtechniksteuerung Funktionstext Stecker Messtechniksteuerung Funktionstext Stecker USB BCM Dongle
Deutsch DTM 3 pole AMP 68 pole AMP 68 pole USB
Circuit diagrams

Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
3 36 5 14 66 12 7 1 57 4
15 67 12 8 2 57 4
Stecker -X87 Einbauort +SEAT 17 4 57 4
Function text Plug, suspension seat 18 Plug Mounting location SH 57 4
Funktionstext Stecker Luftfedersitz 19 Stecker -X90 Einbauort +CAB
Plug type 20 Function text Plug, access GPS - BCM Plug Mounting location
FASTIN-FASTON TAB housing 2 way -X92 +CAB
Steckertyp 21 Funktionstext Stecker Anschluß GPS - BCM Stecker Einbauort
Wire harness 22 Plug type Function text Plug, access GPS-Receiver
Konsole Sitz SUB-D 9 pole
Kabelbaum 23 13 5 Steckertyp Funktionstext Stecker Anschluß GPS-Antenne
Page Path 24 Wire harness Plug type
Burndy 12 pole
Contact
Kontakt
Blatt Pfad 25 40 8
1 50 6 26 15 7 Page Path Wire harness
Kabelbaum
Contact
Kontakt
2 50 6 27 15 6 Blatt Pfad
28 12 1 1 Page Path
Contact
Kontakt
Plug Mounting location 29 40 2 2 57 5 Blatt Pfad

Stecker -X87 Einbauort +SEAT 30 40 4 3 57 5 A 57 7
Function text Plug, suspension seat 31 40 1 4 B 57 7
Funktionstext Stecker Luftfedersitz 32 35 3 5 57 5 C 57 7
Plug type 33 16 8 6 D 57 7
FASTIN-FASTON TAB housing 2 way 34
Steckertyp 7 E 57 7
Wire harness 35 8 F
Kabelbaum 36 9 G
Page Path 37 H
38 Plug
Contact
Kontakt
Blatt Pfad Mounting location J
39 Stecker -X90 Einbauort +CAB T
1 50 6 40 Function text Plug, access GPS - BCM L
2 50 6 41 Funktionstext Stecker Anschluß GPS - BCM M
BW 219 D-5 / BW 219 PD-5

42 Plug type
Plug Mounting location SUB-D 9 pole
Stecker -X88 +EBOX 43 Steckertyp Plug Mounting location
Einbauort
44 Wire harness Stecker -X92 Einbauort +CAB
Function text Plug, measurement controller
Funktionstext Stecker Messtechniksteuerung
45 Kabelbaum Function text Plug, access GPS-Receiver
46 36 8 Page Path Funktionstext Stecker Anschluß GPS-Antenne
Plug type
AMP 68 pole 47 36 7 Plug type
Contact
Kontakt
Steckertyp Blatt Pfad Burndy 12 pole
48 Steckertyp
Wire harness 1
49 Wire harness
Kabelbaum 2 57 5
50 Kabelbaum
Page Path 51 3 57 5
Page Path
Contact
Kontakt
Blatt Pfad 52 4
Contact
Kontakt
5 57 5 Blatt Pfad
1 13 6 53 16 7
2 54 12 2 6 A 57 8
3 55 12 5 7 B 57 8
4 40 6 56 12 3 8 C 57 8
5 40 7 57 12 4 9 D 57 8
6 58 12 5 E 57 8
7 40 3 59 12 6 F
8 60 12 6 G
9 36 5 61 36 9 H
10 62 J
11 63 K
12 64 L
13 65 12 6
0 1 2 3 4 5 6 7 8 9
Page from
107
Dokumentenart &EMA3
Checked K. Brand
Plug overview
Stecker -X92 Einbauort +CAB Stecker -X95.A Einbauort +CAB Stecker -X96.A Einbauort +CAB Stecker -X100 Einbauort +EBOX
Function text Plug, access GPS-Receiver Function text Plug, CAN BCM Dongle Function text Plug, supply BCM Function text Plug, connection Driving controller - Console seat
Funktionstext Stecker Anschluß GPS-Antenne Funktionstext Stecker CAN BCM Dongle Funktionstext Stecker Versorgung BCM Funktionstext Stecker Verbindung Fahrsteuerung - Konsole Sitz
Burndy 12 pole SUB-D 9 pole Deutsch DT 2 pole AMP Junior Power Timer 6 pole grey
4 1
6 3
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
M 1 1 57 5 1
2 57 2 2 57 5 2
Plug Mounting location 3 3
Stecker -X93 Einbauort +CAB 4 Plug Mounting location 4
Function text Plug, supply GPS System 5 Stecker -X97 Einbauort +CAB 5
Funktionstext Stecker Spannungsversorgung GPS System 6 Function text Plug, GPS-Receiver StarFire 6
Plug type 7 57 2 Funktionstext Stecker GPS-Antenne StarFire
Deutsch DT 3 pole
Steckertyp 8 Plug type Plug Mounting location
Deutsch DT 12 pole -X100 +EBOX
Wire harness 9 Steckertyp Stecker Einbauort
Kabelbaum Wire harness Function text Plug, connection Driving controller - Console seat
Page Path Plug Mounting location Kabelbaum Funktionstext Stecker Verbindung Fahrsteuerung - Konsole Sitz
Stecker -X95.A Einbauort +CAB Plug type
Contact
Kontakt
Blatt Pfad Page Path AMP Junior Power Timer 6 pole grey
Function text Plug, CAN BCM Dongle Steckertyp
Contact
Kontakt
A 57 6 Blatt Pfad
Funktionstext Stecker CAN BCM Dongle Wire harness
B 57 6 2 57 9 1
Plug type Kabelbaum
C 57 6 SUB-D 9 pole 6 57 9 3 6
7 57 9
Wire harness
Contact
Kontakt
Plug Mounting location 11 57 9 Blatt Pfad

Stecker -X94 Einbauort +CAB Kabelbaum
12 57 8 1 28 4
Function text Plug, printer Page Path 2
Contact
Kontakt
Funktionstext Stecker Drucker Blatt Pfad Plug Mounting location 3
Plug type 1 Stecker -X99 Einbauort +SEAT 4
AMP Mateń´loc 6 pole white
Steckertyp 2 57 2 Function text Plug, heating operators seat 5
Wire harness 3 Funktionstext Stecker Sitzheizung 6
Kabelbaum 4 Plug type
FASTIN-FASTON TAB housing 2 way
Page Path 5 Steckertyp Plug Mounting location
Stecker -X101.f Einbauort +EBOX
Contact
Kontakt
Blatt Pfad 6 Wire harness
Konsole Sitz
7 57 2 Kabelbaum Function text Plug, connection Driving controller - Engine
1 56 6
8 Page Path Funktionstext Stecker Verbindung Fahrsteuerung - Motor
2 56 7
BW 219 D-5 / BW 219 PD-5

Plug type
Contact
Kontakt
3 9 Blatt Pfad AMP Junior Power Timer 12 pole blue
Steckertyp
4 56 8 1 50 7
Plug Mounting location Wire harness
5 56 7 -X96.A +CAB 2 50 7 Motor 10 1
Stecker Einbauort Kabelbaum
6 12 9 6 3
Function text Plug, supply BCM Plug Page Path
Mounting location
Funktionstext Stecker Versorgung BCM -X99 +SEAT
Contact
Kontakt
Plug Mounting location Stecker Einbauort Blatt Pfad

Stecker -X94 Einbauort +CAB Plug type Function text Plug, heating operators seat
Deutsch DT 2 pole 1 27 2
Steckertyp Funktionstext Stecker Sitzheizung
Function text Plug, printer 2
Funktionstext Stecker Drucker Wire harness Plug type 3 27 4
Kabelbaum FASTIN-FASTON TAB housing 2 way
Plug type Steckertyp 4
AMP Mateń´loc 6 pole white Page Path
Steckertyp Wire harness 5
Contact
Kontakt
Wire harness Blatt Pfad Kabelbaum 6
Kabelbaum 1 57 5 Page Path 7
Contact
Kontakt
Page Path 2 57 5 Blatt Pfad 8
Contact
Kontakt
Blatt Pfad 1 50 7 9
1 56 6 2 50 7 10
2 56 7 11
3 56 7 12
4 56 8
5 56 7
6
0 1 2 3 4 5 6 7 8 9
Page from
Created M. Vogt Blatt81 von 107
Dokumentenart &EMA3
Checked
Circuit diagrams
K. Brand
1013
642 EPE /00
1014
Plug overview
Stecker -X101.m Einbauort +EBOX Stecker -X102 Einbauort +EBOX Stecker -X103 Einbauort +EBOX Stecker -X104 Einbauort +EBOX
Function text Plug, connection Driving controller - Engine Function text Plug, connection Armatures - Console seat Function text Plug, connection Driving controller - Rear frame Function text Plug, connection Driving controller - Front frame
Funktionstext Stecker Verbindung Fahrsteuerung - Motor Funktionstext Stecker Verbindung Armaturen - Konsole Sitz Funktionstext Stecker Verbindung Fahrsteuerung - Hinterrahmen Funktionstext Stecker Verbindung Fahrsteuerung - Vorderrahmen
AMP Junior Power Timer 12 pole blue AMP Junior Power Timer 15 pole grey AMP Junior Power Timer 18 pole green AMP Junior Power Timer 9 pole purple
Circuit diagrams

Fahrsteuerung 1 1 1 1
3 6 9 12 3 9 15 3 9 12 18 3 6 9
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
1 27 2 3 29 1 1 30 2 3 28 7
2 27 3 4 29 1 2 30 3 4 28 8
3 27 4 5 29 3 3 30 4 5 28 6
4 6 29 7 4 30 4 6 28 7
5 7 29 7 5 31 2 7 32 8
6 8 6 31 3 8 32 8
7 9 7 31 4 9
8 10 8 31 5
9 11 9 32 4 Plug Mounting location
10 12 10 32 7 Stecker -X105 Einbauort +EBOX
11 13 11 27 5 Function text Plug, connection Driving controller - Front frame dozer blade
12 14 12 34 5 Funktionstext Stecker Verbindung Fahrsteuerung - Vorderrahmen Planierschild
15 13 34 6 Plug type
Plug Mounting location 14 Steckertyp
Stecker -X102 Einbauort +EBOX Plug Mounting location 15 Wire harness
-X103 +EBOX 16 1
Function text Plug, connection Armatures - Console seat Stecker Einbauort 16 Kabelbaum
Funktionstext Stecker Verbindung Armaturen - Konsole Sitz 18 12 9 3
Function text Plug, connection Driving controller - Rear frame 17 Page Path
Plug type Funktionstext Stecker Verbindung Fahrsteuerung - Hinterrahmen
Contact
Kontakt

18 Blatt Pfad
Steckertyp Plug type
AMP Junior Power Timer 18 pole green 1 37 3
Wire harness Steckertyp Plug Mounting location
Konsole Sitz 13 1 -X104 +EBOX 2 37 4
Kabelbaum Wire harness Stecker Einbauort
15 9 3 16 1
3 37 5
Page Path Kabelbaum Function text Plug, connection Driving controller - Front frame
18 12 9 3
4 37 6
Funktionstext Stecker Verbindung Fahrsteuerung - Vorderrahmen
Contact
Kontakt
Blatt Pfad Page Path 5 37 7
Plug type
Contact
Kontakt
1 29 1 Blatt Pfad AMP Junior Power Timer 9 pole purple 6 37 8
Steckertyp
2 1 30 2 7 37 3
3 29 1 2 30 3 Wire harness 8 38 7
7 1
Kabelbaum
4 29 1 3 30 4 9 6 3
9 38 4
5 29 3 4 30 4 Page Path 10 37 4
BW 219 D-5 / BW 219 PD-5

Contact
Kontakt
6 29 7 5 31 2 Blatt Pfad 11 38 1
7 29 7 6 31 3 1 28 7 12 37 4
8 7 31 4 2 13 38 5
9 8 31 5 3 28 7 14 38 6
10 9 32 4 4 15 38 6
11 10 32 7 5 28 6 16 39 5
12 11 27 5 6 28 7 17
13 12 34 5 7 32 8 18
14 13 34 6 8 32 8
15 Stecker -X105 Einbauort +EBOX
Plug Mounting location 16 Plug Mounting location Function text Plug, connection Driving controller - Front frame dozer blade
Stecker -X102 Einbauort +EBOX 17 Stecker -X104 Einbauort +EBOX Funktionstext Stecker Verbindung Fahrsteuerung - Vorderrahmen Planierschild
Function text Plug, connection Armatures - Console seat 18 Function text Plug, connection Driving controller - Front frame Plug type
Funktionstext Stecker Verbindung Armaturen - Konsole Sitz Funktionstext Stecker Verbindung Fahrsteuerung - Vorderrahmen Steckertyp
Plug type Plug type Wire harness
AMP Junior Power Timer 15 pole grey AMP Junior Power Timer 9 pole purple 1
Steckertyp Steckertyp Kabelbaum
3 9 12 18
Wire harness Wire harness Page Path
1 1
Kabelbaum Kabelbaum
Contact
Kontakt
Blatt Pfad
3 9 15 3 6 9
Page Path Page Path 1 37 3
Contact
Kontakt
Contact
Kontakt
Blatt Pfad Blatt Pfad 2 37 4

1 29 1 1 28 7 3 37 5
2 29 1 2 28 7 4 37 6
0 1 2 3 4 5 6 7 8 9
Page from
Dokumentenart &EMA3
Checked K. Brand
Plug overview
Stecker -X105 Einbauort +EBOX Stecker -X107 Einbauort +EBOX Stecker -X108.f Einbauort +EBOX Stecker -X109.m Einbauort +EBOX
Function text Plug, connection Driving controller - Front frame dozer blade Function text Plug, connection Measurement controller - Front frame Function text Plug, connection Engine - Engine Controller Function text Plug, access transducer acceleration Economizer
Funktionstext Stecker Verbindung Fahrsteuerung - Vorderrahmen PlanierschildFunktionstext Stecker Verbindung Messrechner - Vorderrahmen Funktionstext Stecker Verbindung Motor - Motorsteuergerät Funktionstext Stecker Anschluss Beschleunigungsaufnehmer Economizer
AMP Junior Power Timer 18 pole purple AMP Junior Power Timer 12 pole purple AMP Junior Power Timer 15 pole blue AMP Junior Power Timer 12 pole purple
1 1 Motor 13 1 Aufnehmer Economizer 1
10
3 9 12 18 12 9 6 3 15 9 3 3 6 9 12
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
5 37 7 10 36 8 15 1 41 5
6 37 8 11 2 41 5
8 38 7 Stecker -X108.m Einbauort +EBOX 4 41 6
9 38 4 Plug Mounting location Function text Plug, connection Engine - Engine Controller 5
10 37 4 Stecker -X107 Einbauort +EBOX Funktionstext Stecker Verbindung Motor - Motorsteuergerät 6
11 38 1 Function text Plug, connection Measurement controller - Front frame Plug type 7
12 37 4 Funktionstext Stecker Verbindung Messrechner - Vorderrahmen Steckertyp 8
13 38 5 Plug type Wire harness 9
AMP Junior Power Timer 12 pole purple EMR 1
3 9 15
1
Kabelbaum
Contact
Kontakt
16 39 5 Blatt Pfad 12
3 6 9 12
17 Page Path 1 21 1
Plug
Contact
Kontakt
18 Blatt Pfad 2 21 1 Mounting location
Stecker -X110 Einbauort +EBOX
1 40 1 3 21 3
Plug Mounting location Function text Plug, access interface meassurement
-X106 +EBOX 2 40 2 4 21 3
Stecker Einbauort Funktionstext Stecker Anschluß Schnittstelle Messtechnik
3 40 1 5 21 4
Function text Plug, connection Driving controller - Front frame sensor speed vibration Plug type
4 40 2 6 AMP Junior Power Timer 6 pole brown
Funktionstext Stecker Verbindung Fahrsteuerung - Vorderrahmen Drehzahlaufnehmer Vibration Steckertyp
5 40 3 7
Plug type Wire harness Kabelbaum Schnittstelle
AMP Junior Power Timer 6 pole purple 6 40 4 8 4 1
Steckertyp Kabelbaum Messtechnik
7 36 5 9 6 3
Wire harness 8 36 5 10 Page Path
1
Kabelbaum
Contact
Kontakt
9 36 7 11 Blatt Pfad
3 6
Page Path 10 36 8 12 1 43 7
Contact
Kontakt
Blatt Pfad 11 36 9 13 2 43 7
1 34 2 12 36 7 14 3 43 7
2 34 1 15 4 43 7
3 34 3 Plug Mounting location 5 43 7
BW 219 D-5 / BW 219 PD-5

4 Stecker -X108.f Einbauort +EBOX Plug Mounting location 6
5 34 2 Function text Plug, connection Engine - Engine Controller Stecker -X109.f Einbauort +EBOX
6 34 2 Funktionstext Stecker Verbindung Motor - Motorsteuergerät Function text Plug, access transducer acceleration Economizer Plug Mounting location
Plug type Funktionstext Stecker Anschluss Beschleunigungsaufnehmer Economizer Stecker -X110 Einbauort +EBOX
Plug Mounting location Steckertyp Plug type Function text Plug, access interface meassurement
-X107 +EBOX AMP Junior Power Timer 12 pole purple
Stecker Einbauort Wire harness Steckertyp Funktionstext Stecker Anschluß Schnittstelle Messtechnik
Motor 13 1
Function text Plug, connection Measurement controller - Front frame Kabelbaum Wire harness Plug type
15 9 3
Economizer 10 1 AMP Junior Power Timer 6 pole brown
Funktionstext Stecker Verbindung Messrechner - Vorderrahmen Page Path Kabelbaum Steckertyp
12 9 6 3
Plug type
Contact
Kontakt
Blatt Pfad Page Path Wire harness Verkabelung Schnittstelle
AMP Junior Power Timer 12 pole purple 1
Steckertyp Kabelbaum Messtechnik
Contact
Kontakt
1 21 1 Blatt Pfad
3 6
Wire harness 2 21 1 1 41 5 Page Path
10 1
Kabelbaum
Contact
Kontakt
3 21 3 2 41 5 Blatt Pfad
12 9 6 3
Page Path 4 21 3 3 41 6 1 43 7
Contact
Kontakt
Blatt Pfad 5 4 41 6 2 43 7
1 40 1 6 5 3 43 7
2 40 2 7 6 4 43 7
3 40 1 8 7 5 43 7
4 40 2 9 8 6
5 40 3 10 9
6 40 4 11 10
7 36 5 12 11
8 36 5 13 12
9 36 7 14
0 1 2 3 4 5 6 7 8 9
Page from
Dokumentenart &EMA3
Checked
Circuit diagrams
K. Brand
1015
642 EPE /00
1016
Plug overview
Stecker -X200 Einbauort +CAB Stecker -X202 Einbauort +CAB Stecker -X203 Einbauort +CAB Stecker -X204 Einbauort +CAB
Function text Plug, supply potential 30 Function text Plug, signals from/to central electric Function text Plug access cabin equipment Function text Plug supply BCM System, printer
Funktionstext Stecker Versorgung Potential 30 Funktionstext Stecker, Signale von/zur Zentralelektrik Funktionstext Stecker Anschluß Kabinenausrüstung Funktionstext Stecker Versorgung BCM System, Drucker
Amphenol RADSOK® 6mm AMP Junior Power Timer 2 - 10 pole black AMP Junior Power Timer 2 - 14 pole black AMP Junior Power Timer 2 - 4 pole black
Circuit diagrams
Wire harness Wire harness Wire harness 2 14

Wire harness
2 10
1 9 1 13
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
30 51 3 3 51 3 12 55 5 1 57 5
4 51 3 13 55 7 2 57 6
Stecker -X200 Einbauort +CAB 6 51 3 4 57 7
Function text Plug, supply potential 30 7 Plug Mounting location
Funktionstext Stecker Versorgung Potential 30 8 51 3 Stecker -X203 Einbauort +CAB Plug Mounting location
Plug type 9 51 3 Function text Plug access cabin equipment Stecker -X205 Einbauort +CAB
Steckertyp 10 51 3 Funktionstext Stecker Anschluß Kabinenausrüstung Function text Plug access radio and tachograph
Wire harness Plug type Funktionstext Stecker Anschluß Radio und Tachograph
Kabelbaum Plug Mounting location Steckertyp Plug type
-X202 +CAB AMP Junior Power Timer 2 - 6 pole black
Page Path Stecker Einbauort Wire harness Steckertyp
Kabelbaum
Contact
Kontakt
Blatt Pfad Function text Plug, signals from/to central electric Wire harness
2 6
Funktionstext Stecker, Signale von/zur Zentralelektrik Page Path Kabelbaum
30 51 3 1 5
Plug type
Contact
Kontakt
Steckertyp
Contact
Kontakt
Plug Mounting location 1 53 7 Blatt Pfad

Stecker -X201 Einbauort +CAB Wire harness 2 53 6 1 56 0
Function text Plug supply ground Kabelbaum
3 53 8 2 56 1
Funktionstext Stecker Versorgung Masse Page Path 4 53 8 3 56 1
Contact
Kontakt
Plug type Blatt Pfad 5 53 7 4 56 2
Amphenol RADSOK® 3,6mm
Steckertyp 1 51 3 6 53 9 5 56 2
Wire harness 2 56 8 7 55 3 6 56 2
Kabelbaum 3 51 3 8 55 3
Page Path 4 51 3 9 55 3 Plug Mounting location
Stecker -X205 Einbauort +CAB
Contact
Kontakt
Blatt Pfad 5 51 3 10 55 5
6 51 3 11 55 5 Function text Plug access radio and tachograph
31 51 3
7 12 55 5 Funktionstext Stecker Anschluß Radio und Tachograph
Plug 8 51 3 13 55 7 Plug type
Mounting location AMP Junior Power Timer 2 - 6 pole black
Stecker -X201 +CAB 9 51 3 14 55 7 Steckertyp
Einbauort
BW 219 D-5 / BW 219 PD-5

Function text Plug supply ground 10 51 3 Wire harness
Funktionstext Stecker Versorgung Masse Plug Mounting location Kabelbaum
Plug Mounting location Stecker -X204 Einbauort +CAB Page Path
Plug type -X203 +CAB
Amphenol RADSOK® 3,6mm Stecker Einbauort Function text Plug supply BCM System, printer
Contact
Kontakt
Steckertyp Blatt Pfad

Function text Plug access cabin equipment Funktionstext Stecker Versorgung BCM System, Drucker
Wire harness 1 56 0
Funktionstext Stecker Anschluß Kabinenausrüstung Plug type
Kabelbaum AMP Junior Power Timer 2 - 4 pole black 2 56 1
Page Path AMP Junior Power Timer 2 - 14 pole black 3 56 1
Contact
Kontakt
2 14 5 5 56 2
31 51 3 1
Kabelbaum Page Path
1 13 6 56 2
Contact
Kontakt

Contact
Kontakt
-X202 +CAB Blatt Pfad 1 57 5 Plug Mounting location
Stecker Einbauort
1 53 7 2 57 6 Stecker -X206 Einbauort +CAB
Function text Plug, signals from/to central electric
Funktionstext Stecker, Signale von/zur Zentralelektrik 2 53 6 3 57 6 Function text Plug, access additional headlights, reserve funktions
3 53 8 4 Funktionstext Stecker Anschluß Zusatzscheinwerfer, Reservefunktionen
Plug type
AMP Junior Power Timer 2 - 10 pole black 4 53 8 Plug type
Steckertyp AMP Junior Power Timer 9 pole grey
5 Steckertyp
Wire harness
2 10
Kabelbaum 6 53 9 Wire harness
1 9 Kabelbaum
Page Path 7 55 3
8 55 3 Page Path
Contact
Kontakt
Blatt Pfad
Contact
Kontakt
9 55 3 Blatt Pfad
1 51 3 10 55 5
2 56 8 1 53 3
11 55 5 2 53 4
0 1 2 3 4 5 6 7 8 9
Page from
107
Dokumentenart &EMA3
Checked K. Brand
Plug overview
Stecker -X206 Einbauort +CAB Stecker -X207.m Einbauort +DPL Stecker -X301 Einbauort +BAT Stecker -X303 Einbauort +BAT
Function text Plug, access additional headlights, reserve funktions Function text Plug, heating unit additional heater Function text Plug, distribution box SCR-heating 1 Function text Plug, supply EAT-System
Funktionstext Stecker Anschluß Zusatzscheinwerfer, Reservefunktionen Funktionstext Stecker Heizgerät Zusatzheizung Funktionstext Stecker Verteiler SCR-Heizung 1 Funktionstext Stecker Versorgung Abgasnachbehandlung
AMP Junior Power Timer 9 pole grey AMP Junior Power Timer 16 pole AMP Junior Power Timer 15 pole blue Tyco MCP 21 pole Code A
EAT-System
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
3 54 7 10 49 2 1 26 4 9 26 5
4 53 5 2 26 6 10 26 5
5 Plug Mounting location 3 26 5 11 26 6
6 53 4 Stecker -X210 Einbauort +CAB 4 26 3 12 26 6
7 54 7 Function text Plug, access GPS-Receiver 5 26 4 13 26 6
8 54 7 Funktionstext Stecker Anschluß GPS-Antenne 6 26 5 14 26 7
9 53 5 Plug type 7 26 4 15 26 7
Deutsch DTM 6 pole
Steckertyp 8 26 4 16 26 7
Plug Mounting location Wire harness 9 26 6 17 26 8
Stecker -X207.f Einbauort +DPL Kabelbaum 10 26 6 18 26 8
Function text Plug, heating unit additional heater Page Path 12 26 2 19 26 8
Funktionstext Stecker Heizgerät Zusatzheizung
Contact
Kontakt
Blatt Pfad 13 26 7 20 26 9
Plug type 14 26 3 21 26 9
AMP Junior Power Timer 16 pole 1 57 7
Steckertyp 15 26 3
2 57 7
Wire harness Plug Mounting location
3 57 7 -X303 +BAT
Kabelbaum Plug Mounting location Stecker Einbauort
4 57 7 -X302 +BAT
Page Path Stecker Einbauort Function text Plug, supply EAT-System
5 57 7
Funktionstext Stecker Versorgung Abgasnachbehandlung
Contact
Kontakt
Blatt Pfad Function text Plug, distribution box SCR-heating 2
6
Funktionstext Stecker Verteiler SCR-Heizung 2 Plug type
1 49 3 Tyco MCP 21 pole Code A
2 Plug Mounting location AMP Junior Power Timer 9 pole blue
Stecker -X211 +CAB Steckertyp Wire harness
3 Einbauort Supply EAT-System
Function text Plug, access temperature sensor asphalt Wire harness Kabelbaum
4 49 3
Funktionstext Stecker Anschluß Asphalttemperatursensor Kabelbaum Page Path
5 49 3
Contact
Kontakt
6 49 3 Plug type Page Path Blatt Pfad

DTM 4 pole
Contact
Kontakt
7 49 3 Steckertyp Blatt Pfad 1 26 0
8 49 3 Wire harness 1 26 7 2 26 2
9 Kabelbaum 2 26 7 3 26 3
10 49 3 Page Path 3 26 8 4 26 3
BW 219 D-5 / BW 219 PD-5

Contact
Kontakt
11 Blatt Pfad 4 26 8 5 26 4
12 1 5 26 8 6 26 4
13 2 57 5 6 26 9 7 26 4
14 3 57 5 7 26 9 8 26 4
15 4 57 5 9 26 5
Stecker -X303 Einbauort +BAT 11 26 6
Plug Mounting location Stecker -X300 Einbauort +BAT Function text Plug, supply EAT-System 12 26 6
Stecker -X207.m Einbauort +DPL Funktionstext Stecker Versorgung Abgasnachbehandlung 13 26 6
Function text Plug, supply distribution box SCR-heating
Function text Plug, heating unit additional heater Funktionstext Stecker Versorgung Verteiler SCR-Heizung Plug type 14 26 7
Tyco MCP 21 pole Code A
Funktionstext Stecker Heizgerät Zusatzheizung Steckertyp 15 26 7
Plug type
Plug type Amphenol RADSOK® 6mm Wire harness 16 26 7
AMP Junior Power Timer 16 pole Steckertyp EAT-System
Steckertyp Kabelbaum 17 26 8
Wire harness
Wire harness Kabelbaum Page Path 18 26 8
Kabelbaum
Contact
Kontakt

Page Path 20 26 9
Contact
Kontakt
Blatt Pfad 1 26 0
Contact
Kontakt
Blatt Pfad 2 26 2 21 26 9
30 26 1
1 49 2 3 26 3
4 49 2 4 26 3
5 49 2 5 26 4
6 49 2 6 26 4
7 49 2 7 26 4
8 49 2 8 26 4
0 1 2 3 4 5 6 7 8 9
Page from
107
Dokumentenart &EMA3
Checked
Circuit diagrams
K. Brand
1017
642 EPE /00
1018
Plug overview
Stecker -X400 Einbauort +DPL Stecker -XA12.B Einbauort +CAB Stecker -XA124 Einbauort +EBOX Stecker -XA162 Einbauort +EBOX
Function text Interface measurement Function text Plug, B radio speaker Function text Plug ECU BOMAG TELEMATIC Function text Relay socket A162
Funktionstext Schnittstelle Messtechnik Funktionstext Stecker B Radio Lautsprecher Funktionstext Stecker ECU BOMAG TELEMATIC Funktionstext Relaissockel A162
Burndy 12 pole ISO-speaker 8 pole Deutsch DTM 12 pole Code A socket minirelay 9 pole
Circuit diagrams
Wire harness Kabelbaum Schnittstelle Wire harness Wire harness Wire harness Verkabelung Schnittstelle
Kabelbaum Messtechnik Kabelbaum Kabelbaum Kabelbaum Messtechnik
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
A 43 8 1 56 5 1 47 4 9 43 5
B 43 8 2 56 5 2 47 3
C 3 3 47 3 Plug Mounting location
D 43 8 4 4 47 3 Stecker -XA175 Einbauort +MOT
E 43 8 5 5 Function text Plug, electronic system Morey telematics
F 43 8 6 6 Funktionstext Stecker Elektronik System Morey Telematic
G 7 56 4 7 Plug type
16 pole Morey
H 8 56 5 8 47 4 Steckertyp
J 9 Wire harness
T Plug Mounting location 10 Kabelbaum
L Stecker -XA103 Einbauort +REFR 11 47 4 Page Path
Function text Plug, monitoring module
Contact
Kontakt
M 12 47 3 Blatt Pfad
Funktionstext Stecker Überwachungsmodul
8 48 2
Plug Mounting location Plug type Plug Mounting location
-XGnd +SEAT AMP Superseal 26 pole -XA161 +EBOX 10 48 2
Stecker Einbauort Steckertyp Stecker Einbauort
16 48 2
Function text Plug ground control lever travel Wire harness Function text Relay socket, gateway economizer
Economizer
Funktionstext Stecker Masse Steuerhebel fahren Kabelbaum Funktionstext Relaissockel Gateway Economizer
Plug type Page Path Plug type Stecker -XA177 Einbauort +MOT
FASTON 6,3mm Car minirelay socket
Contact
Kontakt
Blatt Pfad Function text Plug, ECU ZTR telematics
Wire harness 1 41 4 Wire harness Funktionstext Stecker ECU ZTR Telematik
Adapter Fahrhebel Economizer
Kabelbaum Kabelbaum Plug type
2 41 5 Deutsch DT 12 pole Code A
Page Path 3 Page Path Steckertyp
Contact
Kontakt
Contact
Kontakt
Blatt Pfad 4 Blatt Pfad Wire harness
1 14 9 5 41 5 1 42 6 Kabelbaum
6 41 4 2 42 2 Page Path
Contact
Kontakt
7 3 42 6 Blatt Pfad
Stecker -XA12.A Einbauort +CAB 8 4 42 3 1 48 5
Function text Plug, A radio supply 9 5 2 48 6
BW 219 D-5 / BW 219 PD-5

Funktionstext Stecker A Radio Versorgung 10 6 42 2 3
Plug type 11 7 42 6
ISO-Current 8 pole 4 48 6
Steckertyp 12 8 42 4 5
Wire harness 13 41 1 9 42 6 6
Kabelbaum 14 7
Page Path 15 Plug Mounting location
-XA162 +EBOX 8
Stecker Einbauort
Contact
Kontakt
Blatt Pfad 16 9
17 Function text Relay socket A162
1 10
18 Funktionstext Relaissockel A162
2 11 48 6
19 Plug type
3 socket minirelay 9 pole 12 48 6
20 Steckertyp
4 56 5
5 21 Wire harness Verkabelung Schnittstelle Plug Mounting location
22 Kabelbaum Messtechnik Stecker -XB03 Einbauort +MOT
6
7 56 5 23 Page Path Function text Plug, maintenance switch air cleaner
Contact
Kontakt
8 56 4 24 41 6 Blatt Pfad Funktionstext Stecker Wartungsschalter Luftfilter

25 41 7 1 43 4 Plug type
26 41 1 Tyco Junior Power Timer 2 pole
2 43 2 Steckertyp
3 43 5 Wire harness
Motor
4 43 3 Kabelbaum
5 Page Path
Contact
Kontakt
6 43 2 Blatt Pfad
7 43 4 1 27 4
8 43 3
0 1 2 3 4 5 6 7 8 9
Page from
107
Dokumentenart &EMA3
Checked K. Brand
Plug overview
Stecker -XB03 Einbauort +MOT Stecker -XK189 Einbauort +SEAT Stecker -XP09.C Einbauort +CAB Stecker -XS01.11 Einbauort +ARC
Function text Plug, maintenance switch air cleaner Function text Relay socket K189 Function text Plug, C tachograph Function text Plug, switch S127 pin 11
Funktionstext Stecker Wartungsschalter Luftfilter Funktionstext Relaissockel K189 Funktionstext Stecker C Tachograph Funktionstext Stecker Schalter S127 Pin 11
Tyco Junior Power Timer 2 pole socket microrelay 5 pole Tyco JPT 8 pole red FASTON 6,3mm
Motor Adapter Fahrhebel Radio_Tachograph Armaturen
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
2 27 4 1 1 1 9 4
2 2
Plug Mounting location 3 3 56 3 Plug Mounting location
Stecker -XB218 Einbauort +MOT 4 4 Stecker -XS01.12 Einbauort +ARC
Function text Plug, sensor ambient temperature 5 5 Function text Plug, switch S127 pin 12
Funktionstext Stecker Sensor Umgebungstemperatur 6 Funktionstext Stecker Schalter S127 Pin 12
Plug type Plug Mounting location 7 Plug type
Bosch Kompakt 1.1a 2 pole black Code 1 -XP09.A +CAB FASTON 6,3mm
Steckertyp Stecker Einbauort 8 Steckertyp
Wire harness Function text Plug, A tachograph Wire harness
Motor Armaturen
Kabelbaum Funktionstext Stecker A Tachograph Plug Mounting location Kabelbaum
Page Path Plug type Stecker -XR79 Einbauort +MOT Page Path
Tyco JPT 8 pole white
Steckertyp
Contact
Kontakt
Function text Plug heating prefilter fuel
Contact
Kontakt

Wire harness Funktionstext Stecker Heizung Vorfilter Kraftstoff
1 21 3 Radio_Tachograph 1 9 4
Kabelbaum Plug type
2 21 3 AMP 2,5mm 4 way black Code 1
Page Path Steckertyp
+ARC
Contact
Kontakt
Plug Mounting location Blatt Pfad Wire harness Stecker -XS01.21 Einbauort
Stecker -XG01.+_2 Einbauort +BAT Kabelbaum Function text Plug, switch S127 pin 21
1 56 3
Function text Cable lug, battery plus 2 56 3 Page Path Funktionstext Stecker Schalter S127 Pin 21
Contact
Kontakt
Funktionstext Kabelschuh Batterie plus 3 56 3 Blatt Pfad Plug type
FASTON 6,3mm
Plug type 4 1 18 8 Steckertyp
Tubular cable lug M12
Steckertyp 5 56 3 2 18 8 Wire harness
Armaturen
Wire harness 6 56 3 3 Kabelbaum
Supply EAT-System
Kabelbaum 7 4 Page Path
Contact
Kontakt
Page Path 8 Blatt Pfad

Plug
Contact
Kontakt
Blatt Pfad Mounting location 1 10 2
Plug Mounting location Stecker -XR79 Einbauort +MOT
1 8 2 -XP09.B +CAB
Stecker Einbauort Function text Plug heating prefilter fuel Plug Mounting location
Function text Plug, B tachograph Funktionstext Stecker Heizung Vorfilter Kraftstoff Stecker -XS01.22 Einbauort +ARC
BW 219 D-5 / BW 219 PD-5

Stecker -XG01.-_2 Einbauort +BAT Funktionstext Stecker B Tachograph Plug type
AMP 2,5mm 4 way black Code 1 Function text Plug, switch S127 pin 22
Plug type Steckertyp Funktionstext Stecker Schalter S127 Pin 22
Function text Cable lug, ground battery Tyco JPT 8 pole yellow
Funktionstext Kabelschuh Masse Batterie Steckertyp Wire harness Plug type
Wire harness Kabelbaum FASTON 6,3mm
Plug type Radio_Tachograph Steckertyp
Tubular cable lug M10 Kabelbaum Page Path
Armaturen
Contact
Kontakt
Wire harness Page Path Blatt Pfad Kabelbaum
Supply EAT-System
Contact
Kontakt
Kabelbaum Blatt Pfad 1 18 8 Page Path
Contact
Kontakt
Page Path 1 2 18 8 Blatt Pfad
Contact
Kontakt
1 8 2 3 56 3 4
Plug 5 Plug Mounting location Stecker -XS01.A1 Einbauort +ARC
Mounting location -XS +DPL
Stecker -XG02.D+ Einbauort +MOT 6 Stecker Einbauort Function text Plug, switch S127 pin A1
Function text Plug, D+ generator 7 Function text Socket Funktionstext Stecker Schalter S127 Pin A1
Funktionstext Stecker D+ Generator 8 Funktionstext Steckdose
Plug type
Plug type FASTON 6,3mm
Cable lug ring form A5 Steckertyp
Wire harness Armaturen
Motor Kabelbaum
Kabelbaum Page Path
Page Path
Contact
Kontakt

Contact
Kontakt
Blatt Pfad
Contact
Kontakt
Blatt Pfad 1 32 5
1 8 6 44 1
0 1 2 3 4 5 6 7 8 9
Page from
107
Dokumentenart &EMA3
Checked
Circuit diagrams
K. Brand
1019
642 EPE /00
1020
Plug overview
Stecker -XS01.A2 Einbauort +ARC Stecker -XS28.m Einbauort +DPL Stecker -XS35.24 Einbauort +ARC Stecker -XS55.Gnd Einbauort +SEAT
Function text Plug, switch S127 pin A2 Function text Plug, heating unit additional heater Function text Plug, switch S35 pin 24 Function text Plug ground control lever travel
Funktionstext Stecker Schalter S127 Pin A2 Funktionstext Stecker Heizgerät Zusatzheizung Funktionstext Stecker Schalter S35 Pin 24 Funktionstext Stecker Masse Steuerhebel fahren
FASTON 6,3mm AMP Junior Power Timer 12 pole grey FASTON 6,3mm FASTON 6,3mm
Circuit diagrams

Armaturen 1 Armaturen Konsole Sitz
3 6 9 12
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
1 32 5 1 49 6 1 29 7 1 14 9
2
Plug Mounting location 3 Plug Mounting location Plug Mounting location
Stecker -XS09.13 Einbauort +SEAT 4 Stecker -XS36.13 Einbauort +SEAT Stecker -XS107 Einbauort +SEAT
Function text Plug, switch S09 pin 13 5 Function text Plug, switch S36 pin 13 Function text Plug switch amplitude adjustment
Funktionstext Stecker Schalter S09 Pin 13 6 49 6 Funktionstext Stecker Schalter S36 Pin 13 Funktionstext Stecker Schalter Amplitudenverstellung
Plug type 7 Plug type Plug type
FASTON 6,3mm FASTON 6,3mm Tyco Superseal 3 pole
Steckertyp 8 49 6 Steckertyp Steckertyp
Wire harness 9 49 6 Wire harness Wire harness
Konsole Sitz Konsole Sitz Konsole Sitz
Kabelbaum 10 Kabelbaum Kabelbaum
Page Path 11 49 6 Page Path Page Path
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Blatt Pfad 12 49 6 Blatt Pfad Blatt Pfad

1 29 5 1 29 5 1 35 3
+ARC 2 35 3
Stecker -XS35.13 Einbauort
Plug Mounting location Plug Mounting location 3 35 3
Stecker -XS09.14 Einbauort +SEAT Function text Plug, switch S35 pin 13 Stecker -XS36.14 Einbauort +SEAT
Funktionstext Stecker Schalter S35 Pin 13
Function text Plug, switch S09 pin 14 Function text Plug, switch S36 pin 14 Plug Mounting location
Funktionstext Stecker Schalter S09 Pin 14 Plug type Funktionstext Stecker Schalter S36 Pin 14 Stecker -XS127.13 Einbauort +ARC
FASTON 6,3mm
Steckertyp
Plug type Plug type Function text Plug, switch S127 pin 13
FASTON 6,3mm Wire harness FASTON 6,3mm
Steckertyp Armaturen Steckertyp Funktionstext Stecker Schalter S127 Pin 13
Kabelbaum Plug type
Konsole Sitz Page Path Konsole Sitz FASTON 6,3mm
Kabelbaum Kabelbaum Steckertyp
Contact
Kontakt
Page Path Blatt Pfad Page Path Wire harness
Armaturen
Kabelbaum
Contact
Kontakt
Contact
Kontakt
Blatt Pfad 1 29 7 Blatt Pfad
1 29 5 1 29 5 Page Path
Contact
Kontakt
Blatt Pfad
Stecker -XS35.14 Einbauort +ARC
Plug Mounting location Plug Mounting location 1 19 2
Stecker -XS28.f Einbauort +DPL Function text Plug, switch S35 pin 14 Stecker -XS42 Einbauort +ARC
BW 219 D-5 / BW 219 PD-5

Function text Plug, timer additional heater Function text Plug, switch speed range selector Plug Mounting location
Funktionstext Stecker Schaltuhr Zusatzheizung Plug type Funktionstext Stecker Schalter Fahrstufen Stecker -XS127.14 Einbauort +ARC
FASTON 6,3mm
Steckertyp
Plug type Plug type Function text Plug, switch S127 pin 14
AMP Junior Power Timer 12 pole grey Wire harness AMP GET 6 way
Steckertyp Armaturen Steckertyp Funktionstext Stecker Schalter S127 Pin 14
Kabelbaum Plug type
10 1
Page Path Armaturen FASTON 6,3mm
Kabelbaum Kabelbaum Steckertyp
12 9 6 3
Contact
Kontakt
Page Path Blatt Pfad Page Path Wire harness
Armaturen
Kabelbaum
Contact
Kontakt
Contact
Kontakt
Blatt Pfad 1 29 7 Blatt Pfad
1 49 6 1 29 0 Page Path
Contact
Kontakt
2 49 4 2 29 1 Blatt Pfad
Stecker -XS35.23 Einbauort +ARC
3 3 29 1 1 19 2
Function text Plug, switch S35 pin 23
4 49 5 4 29 1
5 5 29 1
Plug type
6 49 6 FASTON 6,3mm 6 29 1
Steckertyp
7
8 49 6 Wire harness
Armaturen
Kabelbaum
9 49 6
10 49 6 Page Path
Contact
Kontakt
11 49 6 Blatt Pfad
12 49 6 1 29 7
0 1 2 3 4 5 6 7 8 9
Page from
107
Dokumentenart &EMA3
Checked K. Brand
Plug overview
Stecker -XS127.23 Einbauort +ARC Stecker -XS299.24 Einbauort +ARC Stecker -XU600.2 Einbauort +EBOX Stecker -XY15.2 Einbauort +MOT
Function text Plug, switch S127 pin 23 Function text Plug, switch S299 pin 24 Function text Plug, ground harness ground powerboard Function text Plug, ground compressor air conditioning(Kopie)
Funktionstext Stecker Schalter S127 Pin 23 Funktionstext Stecker Schalter S299 Pin 24 Funktionstext Stecker Masse Kabelbaum Masse Powerboard Funktionstext Stecker Masse Kompressor Klimaanlage
FASTON 6,3mm FASTON 6,3mm Tubular cable lug M10 Cable lug ring form A4
Armaturen Armaturen Economizer Motor
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
1 19 2 1 19 4 1 8 4 1 50 1

Stecker -XS127.24 Einbauort +ARC Stecker -XS439.13 Einbauort +SEAT Stecker -XU600.3 Einbauort +EBOX
Function text Plug, switch S127 pin 24 Function text Plug, switch S439 pin 13 Function text Plug, ground harness engine
Funktionstext Stecker Schalter S127 Pin 24 Funktionstext Stecker Schalter S439 Pin 13 Funktionstext Stecker Masse Kabelbaum Motor
Plug type Plug type Plug type
FASTON 6,3mm FASTON 6,3mm Cable lug ring form A10
Steckertyp Steckertyp Steckertyp
Wire harness Wire harness Wire harness
Armaturen Konsole Sitz Motor
Kabelbaum Kabelbaum Kabelbaum
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
1 19 2 1 35 6 1 8 4

Stecker -XS299.13 Einbauort +ARC Stecker -XS439.14 Einbauort +SEAT Stecker -XU600.4 Einbauort +EBOX
Function text Plug, switch S299 pin 13 Function text Plug, switch S439 pin 14 Function text Plug, ground harness engine controller
Funktionstext Stecker Schalter S299 Pin 13 Funktionstext Stecker Schalter S439 Pin 14 Funktionstext Stecker Masse Kabelbaum Motorsteuergerät
Armaturen Konsole Sitz EMR
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
1 19 3 1 35 6 1 8 4

Stecker -XS299.14 Einbauort +ARC Stecker -XS439.A1 Einbauort +SEAT Stecker -XU600.8 Einbauort +EBOX
BW 219 D-5 / BW 219 PD-5

Function text Plug, switch S299 pin 14 Function text Plug, switch S439 pin A1 Function text Plug ground harness console seat
Funktionstext Stecker Schalter S299 Pin 14 Funktionstext Stecker Schalter S439 Pin A1 Funktionstext Stecker Masse Kabelbaum Konsole Sitz
Armaturen Konsole Sitz Konsole Sitz
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt
1 19 3 1 35 7 1 8 4

Stecker -XS299.23 Einbauort +ARC Stecker -XS439.A2 Einbauort +SEAT Stecker -XU600.10 Einbauort +EBOX
Function text Plug, switch S299 pin 23 Function text Plug, switch S439 pin A2 Function text Plug ground harness economizer
Funktionstext Stecker Schalter S299 Pin 23 Funktionstext Stecker Schalter S439 Pin A2 Funktionstext Stecker Masse Kabelbaum Economizer
Armaturen Konsole Sitz Economizer
Contact
Kontakt
Contact
Kontakt
Contact
Kontakt

1 19 4 1 35 7 1 8 4
0 1 2 3 4 5 6 7 8 9
Page from
107
Dokumentenart &EMA3
Checked
Circuit diagrams
K. Brand
1021
642 EPE /00
1022
BO_F09_002
Cable name
Kabelname W1
Cable type
Kabeltyp LÜTZE SUPERFLEX® N PUR 12x0,75 mm²
Free conductors W1
Freie Adern 1
Mounting location Page Path Source Quelle Target Ziel Page Path Mounting location
Name Contact Connection Name Contact Connection
Einbauort Blatt Pfad Name Kontakt Anschluß Name Kontakt Anschluß Blatt Pfad Einbauort
Drum
40 1 SP6 2 1 1 X20 1 40 1 DRUM Bandage
Circuit diagrams
Drum
40 2 SP7 2 2 2 X20 2 40 2 DRUM Bandage
Central electric Drum
Zentralelektrik EBOX 40 2 X107 4 3 3 X20 3 40 2 DRUM Bandage
Drum
40 3 SP6 2 5 5 X21 1 40 3 DRUM Bandage
Drum
40 4 SP7 2 6 6 X21 2 40 4 DRUM Bandage
Drum
36 5 SP7 2 10 10 X86 2 36 5 DRUM Bandage
GNYE GNYE
Cable name
Kabelname W2
Cable type
Kabeltyp LÜTZE-SILFLEX® N PUR 7x1 mm²
Free conductors W2
Freie Adern 3
Zentralelektrik EBOX 36 7 X107 9 1 1 Y140 1 36 7 DRUM Bandage
Drum
36 7 SP8 2 2 2 Y140 2 36 7 DRUM Bandage
Drum
36 8 SP8 2 4 4 Y141 2 36 8 DRUM Bandage
5 5
6 6
BW 219 D-5 / BW 219 PD-5

GNYE GNYE
Cable name
Kabelname W3
Cable type
Kabeltyp LÜTZE-SILFLEX® N PUR 7x1 mm²
Free conductors W3
Freie Adern 1
Zentralelektrik EBOX 28 7 X104 1 3 3 B59 4 28 7 DRUM Bandage
GNYE GNYE
0 1 2 3 4 5 6 7 8 9
Page from
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Cable diagram W1, W2, W3 Kind of Document
Dokumentenart &EMB2
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Kabelplan W1, W2, W3 642 EPE /00
BO_F09_002
Cable name
Kabelname W4
Cable type
Free conductors W4
Freie Adern 4
Drum
37 3 SP2 1 2 2 Y378 2 37 3 DRUM Bandage
Drum
37 4 SP2 1 4 4 Y102 2 37 4 DRUM Bandage
Drum
37 5 SP2 1 6 6 Y379 2 37 5 DRUM Bandage
Drum
37 6 SP2 1 8 8 Y380 2 37 6 DRUM Bandage
9 9
10 10
11 11
GNYE GNYE
Cable name
Kabelname W6
Cable type
Kabeltyp LÜTZE-SILFLEX® B 3x0,75 mm²
Free conductors W6
Freie Adern 0
Rear frame Vibratory plate compactor
Hinterrahmen REFR 38 5 X29 6 BN BN X27 1 38 5 PLA Anbauplatten
Hinterrahmen REFR 38 4 X29 4 BK BK X27 3 38 4 PLA Anbauplatten
Hinterrahmen REFR 38 5 X29 5 GY GY X27 2 38 5 PLA Anbauplatten
Cable name
Kabelname W7
BW 219 D-5 / BW 219 PD-5

Cable type
Kabeltyp BINDER Sensorcable M12 90° 4x0,5 mm²
Free conductors W7
Freie Adern 1
Rear frame Rear frame
Hinterrahmen REFR 38 6 X29 1 BN BN B313 1 38 6 REFR Hinterrahmen
WH WH
Hinterrahmen REFR 38 6 X29 2 BU BU B313 3 38 6 REFR Hinterrahmen
Hinterrahmen REFR 38 6 X29 3 BK BK B313 4 38 6 REFR Hinterrahmen
Cable name
Kabelname W8
Cable type
Free conductors W8
Freie Adern 1
Hinterrahmen REFR 38 5 X28 1 BN BN B312 1 38 5 REFR Hinterrahmen
0 1 2 3 4 5 6 7 8 9
Page from
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Cable diagram W4, W6, W7, W8 Kind of Document
Dokumentenart &EMB2
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Kabelplan W4, W6, W7, W8
1023
642 EPE /00
1024
BO_F09_002
Cable name
Kabelname W8
Cable type
Free conductors W8
Freie Adern 1
WH WH
Circuit diagrams

Hinterrahmen REFR 38 5 X28 2 BU BU B312 3 38 5 REFR Hinterrahmen
Hinterrahmen REFR 38 5 X28 3 BK BK B312 4 38 5 REFR Hinterrahmen
Cable name
Kabelname W9
Cable type
Kabeltyp ÖLFLEX® FD CLASSIC 810 P 2X0,75 mm²
Free conductors W9
Freie Adern 0
Vibratory plate compactor Vibratory plate compactor
Anbauplatten PLA 38 4 X27 1 1 1 P43 - 38 4 PLA Anbauplatten
Vibratory plate compactor Vibratory plate compactor
Anbauplatten PLA 38 4 X27 3 2 2 P43 + 38 4 PLA Anbauplatten
Cable name
Kabelname W10
Cable type
Free conductors W10
Freie Adern 2
Cabin Cabin
Kabine CAB 57 7 X92 A 1 1 X210 1 57 7 CAB Kabine
Cabin Cabin
Kabine CAB 57 7 X92 B 2 2 X210 2 57 7 CAB Kabine
Cabin Cabin
Kabine CAB 57 7 X92 C 3 3 X210 3 57 7 CAB Kabine
Cabin Cabin
Kabine CAB 57 7 X92 D 4 4 X210 4 57 7 CAB Kabine
Cabin Cabin
Kabine CAB 57 7 X92 E 5 5 X210 5 57 7 CAB Kabine
BW 219 D-5 / BW 219 PD-5

6 6
GNYE GNYE
Cable name
Kabelname W17
Cable type
Kabeltyp LÜTZE-SILFLEX® N (C) Y 3x0,75 mm²
Free conductors W17
Freie Adern 0
Zentralelektrik EBOX 41 5 X109.f 1 1 1 X39 1 41 5 DRUM Bandage
41 6 SP-SH7 1 SH SH SP-SH8 1 41 6
0 1 2 3 4 5 6 7 8 9
Page from
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Cable diagram W8, W9, W10, W17 Kind of Document
Dokumentenart &EMB2
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Kabelplan W8, W9, W10, W17 642 EPE /00
BO_F09_002
Cable name
Kabelname W18
Cable type
Kabeltyp LÜTZE-SILFLEX® N (C) Y 3x0,75 mm²
Free conductors W18
Freie Adern 0
Central electric Rear frame
Zentralelektrik EBOX 41 4 X109.m 1 1 1 XA103 6 41 4 REFR Hinterrahmen
41 7 SP-SH10 1 SH SH SP-SH9 1 41 7
BW 219 D-5 / BW 219 PD-5

0 1 2 3 4 5 6 7 8 9
Page from
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Cable diagram W18 Kind of Document
Dokumentenart &EMB2
Checked
Circuit diagrams
K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Kabelplan W18
1025
642 EPE /00
1026
Pin overview
Pin Übersicht BO_F19_001
module monitoring
A15 Modul Überwachung
Circuit diagrams
X33 1 0...1500 Ω
X33 2 27 8 0...140Ω Fuel level Tankfüllstand
X33 3 27 7 +UB, max 1,5A Warning buzzer, breakdown Warnsummer Betriebsstörung
X33 4 19 5 +UB, max 1,5A Vibration Telematics Vibration Telematik
X33 5 44 7 active high Illumination Beleuchtung
X33 6 configuration Pin RXD
X33 7 configuration Pin TXD
X33 8 45 7 active high Indicator lights Blinker
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 high
X33 22 16 2 CAN low CAN low CAN low
BW 219 D-5 / BW 219 PD-5

X33 23 active low
X33 24 active high
0 1 2 3 4 5 6 7 8 9
Page from
107
Erstellt 16.07.2019 BW 213-226 D, DH, BVC-5 Pin overview A15 Kind of Document
Dokumentenart &EFA1
Checked K. Brand
Geprüft 16.07.2019 Deutz TCD 4.1_6.1 Pin Übersicht A15 642 EPE /00
Pin overview
Pin Übersicht BO_F19_001
Driving Controller
A34 Fahrsteuerung
Stecker Kontakt Blatt Pfad Beschreibung Signa

Service Manual BW 219 - D5

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Service Manual BW 219 - D5

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Service Manual

BW 219 D-5 / BW 219 PD-5

Single drum roller

008 401 20 EN © 02/2020

BW 219 D-5 / BW 219 PD-5 3

3.1.4 Economizer.............................................................................................................................. 103

4 BW 219 D-5 / BW 219 PD-5

5.1.2 Swash plate principle, pump.................................................................................................... 341

BW 219 D-5 / BW 219 PD-5 5

6.3.1 Attaching the padfoot shells..................................................................................................... 562

6 BW 219 D-5 / BW 219 PD-5

7.2.3 Disconnecting the battery......................................................................................................... 662

BW 219 D-5 / BW 219 PD-5 7

8 BW 219 D-5 / BW 219 PD-5

BW 219 D-5 / BW 219 PD-5 9

10 BW 219 D-5 / BW 219 PD-5

Copyright Information and illustrations in this manual must not be reproduced

BW 219 D-5 / BW 219 PD-5 11

1.2 Concerning your safety

1.2.1.2 Explanation of signal words used:

12 BW 219 D-5 / BW 219 PD-5

Sections marked accordingly indicate technical

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

BW 219 D-5 / BW 219 PD-5 13

Safety goggles To protect the eyes against airborne particles and

Face protection To protect the face against airborne particles and

Hearing protection To protect hearing against excessive noise.

Respiratory protection To protect respiratory tracts against substances or parti-

1.2.1.4 Intended use

1.2.1.5 Improper use

14 BW 219 D-5 / BW 219 PD-5

Examples of improper use are:

1.2.1.6 Estimated service life of the machine

1.2.2 Definition of responsible persons

BW 219 D-5 / BW 219 PD-5 15

1.2.2.2 Expert / qualified person

1.2.2.3 Driver / operator

1.2.3 Fundamentals for safe operation

16 BW 219 D-5 / BW 219 PD-5

All persons remaining in the area of the machine must be informed

1.2.3.2 Regular safety inspections

1.2.3.3 Modifications and alterations to the machine

1.2.3.4 Damage, defects, misuse of safety devices

1.2.3.5 Roll Over Protective Structure (ROPS)

On machines with cab the ROPS is an integral part

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

BW 219 D-5 / BW 219 PD-5 17

A defect ROPS must generally be replaced with an original spare

1.2.4 Handling fuels and lubricants

18 BW 219 D-5 / BW 219 PD-5

AdBlue®/DEF has not been classified as environ-

BW 219 D-5 / BW 219 PD-5 19

20 BW 219 D-5 / BW 219 PD-5

Should pressure fluid penetrate the skin, imme-

BW 219 D-5 / BW 219 PD-5 21

22 BW 219 D-5 / BW 219 PD-5

1.2.5 Load/transport the machine

BW 219 D-5 / BW 219 PD-5 23

1.2.6 Starting up the machine

24 BW 219 D-5 / BW 219 PD-5

1.2.6.2 Starting the engine