BW177 213 226 Series 4 Service Training
BW177 213 226 Series 4 Service Training
BW177 213 226 Series 4 Service Training
Variocontrol
General B1
Peculiarities B3
Electric steering C1
Steering circuit C2
Steering pump C4
Steering wheel C5
Steering valve C6
Steering angle sensor C12
Trouble shooting C15
BVC - System E1
Exciter system E4
Gear pump E5
Valve block E7
Swashing motor E9
Acceleration transducer E 10
MESX-control E 11
BOP E 12
Trouble shooting H1
Electrics I1
Service Training
MESX - Service Training
Wiring diagram
Hydraulic diagrams
• for the customer/user it is a basis for an exact calculation of utilization periods and the completion of
projects as scheduled.
• in the rental business it means that the equipment can be reliably used and planned without having
to stock a large number of stand-by machines.
• for the manufacturer it means that customers are satisfied, provides him with a good image and gives
him a feeling of confidence.
It is BOMAG’s philosophy to design and produce the machines with highest possible reliability. This
aspect of simple and easy maintenance was one of the key issues when developing and designing the
machine:
• the high quality standard of BOMAG is the basis for the considerable extension of the service and
maintenance intervals.
• the After Sales Service of BOMAG, including excellent operating and maintenance instruction
manuals, high quality training courses and on-site machine demonstrations helps the customer to
maintain their machines in good condition over a long period of time.
Permanent training of BOMAG’s own service personnel as well as the service personnel of BOMAG
Profit Centres and dealers is therefore a general prerequisite for BOMAG’s excellent world-wide service.
This program of permanent training is only possible with appropriate and up-to-date training material for
trainers as well as persons attending the training courses.
This training manual has not only been written as a support for the professional work of the trainer, but
also for the trainees attending these training courses.
The different levels of product training demand, that the training performed by BOMAG, its Profit Centres
or its dealers reflects the high quality of the training conducted at the Training Centre at BOMAG in
Boppard. For this reason we invested a lot of time in the preparation of these materials .
The structure of this training manual enables us to change or up-date individual chapters in case of
alterations to the machine.
For the BOMAG machines described in this training manual the following documentation is additionally
available:
Attention!
The currently valid part numbers for the documents can be taken from the Doclist or the
Customer Service page in the BOMAG (BOMAG Secured Area) in accordance with the serial
number of the machine.
The increased demands concerning quantity and quality in the application and compaction of soils and
rolled asphalt inevitably requires a permanent further development of vibratory rollers.
From the contractor's point of view a vibratory roller must fulfil three major requirements:
1. efficient operation
3.flexible in use
Due to the inflexible parameterization, standard compaction systems are not able to adapt to the
permanently changing construction conditions in an optimal way.
However, this problem can be solved by the introduction of intelligent compaction systems. The control
values required for an automatic optimization of the compaction parameters are directly gained from the
interaction between drum and material to be compacted.
BOMAG VARIOCONTROL is a compaction system, which improves the quality and reproducibility of
compaction and enhances the efficiency of the roller, independently from the roller operator.
1.Automatic adaptation of the emitted compaction energy to the actual compaction status
4. The resulting direction of force is automatically adapted to the travel direction. This improves the
surface quality of the material and the gradability of the roller.
The further development of the VARIOCONTROL system for earthwork was founded on experiences
gained with the VARIOMATIC system used for asphalt compaction . The basic difference between
VARIOCONTROL and VARIOMATIC is the new exciter system.
It meets the demands of many users for an "intelligent" roller with automatic adaptation
of compaction.
Besides the display of the entire operation of the measuring technology the BOP also enables a simple
self diagnose of the overall system.
The operation of the BOP is described in detail in the operating and maintenance instructions.
Error and input codes can be found on the electrics page (MESX Service Training).
All BVC single drum rollers of series 4 are equipped with an electric steering
system as standard.
The electronically controlled circuit consists of a small electric steering wheel (in the left hand seat
armrest), the ESX-control (located in the electric junction box), which converts the signal from the
steering wheel into electric signals for the proportional solenoids of the steering valve and the
steering angle sensor (located on the articulated joint), which feeds the steering angle back to the
control.
The hydraulic steering circuit consists of steering pump, high pressure filter, steering valve and
steering cylinders.
06
to charging
to emergency steering
and Vario control valve
MG
from
hydr.
tank
Emergency steering:
The emergency steering valve is only an option and can only be operated via a special
input code. The valve is supplied by the additional Variocontrol gear pump.
Steering pump
Filter outlet
Filter inlet
VCC 8,5 V
to the
Steerin
cylinder
from the
pump
to the charge
system
7 8
6 1 4 2
9
10
3 2
5 3
The steering angle potentiometer is located inside the articulated joint BW 226
A detailed description of how to read out the error codes and on the display
can be found in chapter "Electrics" (Service Training "Electrics")
The following trouble shooting chart contains a small selection of possible faults, which may occur
during operation of the machine. The fault list is by no means complete, however, the fault table is based
on the experience of the central service department, i.e. the list covers almost all faults that have
occurred in the past.
The following trouble shooting chart mainly lists mechanical and hydraulic faults.
The number specified in the table indicate the probability of the fault cause and thereby the
recommended trouble shooting sequence, based on our latest field experience.
FEHLERSUCHE elektr.LENKUNG
BVC-4 Maschinen
Endanschläge werden nicht erreicht
Lenkung schwergängig
Keine Lenkfunktion
SYMPTOME
MÖGLICHE URSACHEN
Lenkventil 2 2 1
Lenk- Speisepumpe 1 1 2
Lenkzylinder 3 3 3
Knickgelenk 3 3 2
FEHLERSUCHE
Variocontrol Single Drum Rollers Series 4 - C 18 -
Service Training
Compaction measuring system for single drum rollers:
BEM
CAN Bus I
BMFSA
E vib
150
50 200
!
0 E VIB 250
MN/mm²
Signale
Beschleunigung
VV / VL 15g
MESX Befehle
Neutral
Pos.
D+ Signal
Bedienfunktionen
Beschleunigung
VH / VL 15g
Vibrationspumpe
Stromsignal
CAN Bus I
Drucker
RS 232
BOP
!
Signale
Beschleunigung
VV / VL 15g
Drehzahlsensor
hinten
MESX
Neutral
Pos.
D+ Signal
Bedienfunktionen
Beschleunigung
VH / VL 15g
Vibrationspumpe
Stromsignal
CAN Bus I
BOP
!
Signale
Beschleunigung
VV / VL 15g
Drehzahlsensor
hinten
MESX
Neutral
Pos.
D+ Signal
Bedienfunktionen
Beschleunigung
VH / VL 15g
Vibrationspumpe
Stromsignal
CAN Bus I
Drucker
RS 232
BOP
!
Signale
Beschleunigung
VV / VL 15g
Vibrationspumpe
Stromsignal
Erreger
Position vorn
BOMAG VARIOCONTROL is able to control the compaction power, independently from the driver. For
this purpose the size and direction of the effective amplitude is automatically adjusted in dependence
on compaction status and travel direction of the roller. This optimal adaptation of compaction ensures
that the roller emits the max. compaction power to the soil at any time. Apart from this, jumping of the
drum with the related over-compaction of the material is automatically prevented.
1. Exciter unit
2. Additional gear pump with line filter
3. Valve block with pressure relief valve and shock valves and (accumulator on
BW 213 and BW 226)
4. Variable displacement motor with integrated potentiometer based distance
measuring system
5. 2 acceleration transducers
6. Programmable logic control = MESX
7. Display and control unit = BOP
8. ) Optional printer
Y141 Y140
to the
20 tank
from
tank
to filter
to steering system
Y141 Y140
to
Emergency
steering
to the
tank
from
tank
to filter
Steering valve
BVC uses a new type of exciter system with two counter-rotating, concentrically arranged
shafts, generating directed vibrations (see Fig. below).
One common shaft carries three eccentrics, the two smaller weights near the ends and the
larger eccentric weight in the middle of the exciter shaft. The middle eccentric weight rotates in
opposite direction to the outer weights. The resulting centrifugal forces add up to a directed
vibration. The effective direction of this directed vibration can be adjusted by turning the
complete vibrator unit. Any desired angle position between horizontal and vertical oscillating
direction is possible.
The adjustment of the exciter unit is accommodated by a hydraulic swashing motor with
integrated displacement measuring system (potentiometer). The vibrator system is driven by a
hydraulic motor, the eccentrics are synchronized by gears.
additional
gear pump
for Variocontrol system
BW 177 BVC
Filter
Input
High pressure
Line filter
Filter
Output
The pressure retaining valve with accumulator is located between Vario pump and valve block.
It helps to keep any losses through the pressure relief valve as low as possible.
7 1
2
8
3
9 4
On BW 213 and BW 226 the valve is equipped with an upstream pressure retaining valve.
8 1
9 2
3
4
10 5
6
8
7
11
Pos. Designation Pos. in wiring diagram Pos. in hydraulic Measuring values
diagram
1 Test port BW 177 18 80 bar
1 Test port BW 213 and 226 18 120 bar
2 P2 18
3 A 18
4 T1 18
5 P1 18
6 B 18
7 T2 18
8 Shock valves 18 120 bar
9 Prop. solenoid Y 141 Page 008 18 0,4 - 1,2 A
10 Prop. solenoid Y 140 Page 008 18 0,4 - 1,2 A
11 Pressure relief valve BW 177 18 80 bar
Valve block installation front left and protection housing for electric connections
Potentiometer
As with the VARIOMATIC system, the resulting force may occur at any angle position
between horizontal and vertical direction of vibration. The adjusting motor is equipped
with an integrated displacement measuring system. This displacement measuring
system is based on a potentiometer mounted on the motor output shaft. Each position
of the motor has a resistance or voltage value assigned.
Potentiometer voltage:
Acceleration transducer
MESX
The operation of the BOP is described in detail in the operating and maintenance instructions!
Die Messung der Bodenkontaktkraft zwischen der Bandage und dem Einbaumaterial
erfolgt durch die beiden Beschleunigungsaufnehmer an der Bandage, die das
dynamische Verhalten kontinuierlich überwachen. Die Beschleunigungssignale, die
aus der dynamischen Wechselwirkung zwischen dem Walzenkörper und der
Unterlage resultieren, werden an die MESX-Steuerung weitergeleitet.
Werden bestimmte Grenzzustände bzw. Sollzustände erreicht, wird von der MESX ein
Signal auf die Verstelleinheit gegeben und dadurch die Verdichtungsenergie an den
neuen Einbauzustand angepaßt.
Signalisieren die Beschleunigungsaufnehmer eine geringe Bodensteifigkeit, schwenkt
das Erregersystem so weit in Richtung der vertikalen Arbeitsrichtung, bis die maximal
mögliche Verdichtungsenergie abgegeben wird. Nimmt die Bodensteifigkeit zu und
werden bestimmte Grenzwerte bzw. Sollwerte erreicht, schwenkt das Erregersystem
in Richtung der horizontalen Arbeitsrichtung, bis die Sollwerte unterschritten werden.
Das Ergebnis dieser Regelung ist, daß das VARIOCONTROL-System die maximal
mögliche Verdichtungsenergie automatisch an den jeweiligen Einbauzustand anpaßt.
Das System muß dabei sehr schnell auf die Steifigkeitsänderungen reagieren. Die
Verstellzeiten von vertikaler zu horizontaler Arbeitsrichtung liegen unter einer Sekunde.
Damit kann das System
Für den Verdichtungserfolg ist schon die erste dynamische Überfahrt von entscheidender
Bedeutung.
Die VARIOCONTROL Walzenzüge sind daher auf besonders hohe Zentrifugalkräfte bzw.
Amplituden ausgelegt. Hierdurch wird eine sehr hohe Verdichtung und eine gute
Tiefenwirkung erzeugt.
Durch die große Amplitude würde die VARIOCONTROL Walzenzüge früher springen als
Standardwalzenzüge gleichen Betriebsgewicht. Durch die Automatik wird aber der
Vertikalanteil der Amplitude dann automatisch zurückgenommen und so ein Springen der
Walze verhindert.
Dichte
Hochleistungswalze
große Amplitude
Standardwalze
0 1 2 3 4 5 6 7 Übergänge
Amplitude mm 2,5 1,8 / 1,0 2,4 1,8 / 0,9 2,1 / 1,2 2,3 2,0 / 1,1
Frequenz Hz 28 30 / 36 28 30 / 36 26 / 30 26 26 / 26
Swashing motor
Potentiometer
Fastening
screws
Potentiometer
Locking screw
vertical reverse
Locking screw
horizontal
2. Unscrew the bottom plug (Pos.26, P/N 076 320 16) from the gearbox
3. Disconnect the hydraulic hoses and the electric connections from the potentiometer on the swashing
motor
4. Connect the hand pump to the front port (in travel direction) of the swashing motor (Pos.5) and pump
to the right, until the locking recess in the gear is in line with the bore in the gearbox.
5. Turn the locking screw (P/N 955 822 11) into the gearbox, the exciter is thus blocked in position
vertical reverse.
8. Connect the manual pump again zo the front port of the new swashing motor and pump to the right
to the same position as with the removed swashing motor (position vertical forward)
9. Install the swashing motor, grease the splined shaft (with Optimol White P/N 009 960 01) and connect
hydraulically and electrically.
10. Remove the bottom locking screw (P/N 955 822 11) again and turn in the plug (Pos.26, P/N
076 320 16) with seal ring.
1. Unscrew the top plug (Pos.16, P/N 076 320 16) from the gearbox
2. Connect the hand pump to the rear port (in travel direction) of the swashing motor (Pos.4) and pump
to the left (middle position of swashing motor), until the locking recess in the upper gear is in line with
the bore in the gearbox.
3. Turn the locking screw (P/N 955 821 69) into the upper bore in the gearbox, the exciter is thus blocked
in position horizontal.
4. Loosen the fastening screws for the potentiometer so that it can be adjusted in the slots.
6. Measure the signal voltage between X2:69 (white cable) and X2:68 (AGND).
The terminal bar X2 for the volatge measurement is located inside the electrics junction box.
7. Nominal value = 1/2 supply voltage (e.g. 8,42/2 = 4,21V) in case of deviations turn the potentiometer,
until the nominal value is reached.
9. Remove the blocking screw and insert the plug with a new seal ring.
10. Check the swashing motor by pumping it to both end positions with the hand pump and measure the
voltage values. Nominal values: left hand stop vertical forward approx. 2V and right hand stop vertical
reverse approx. 6,5V
Show the fault code by pressing button „?“ followed by button „F5“
Red fault light
Button „F5“
Button „?“
For detail info on reading out fault codes please refer to the chapter "Electrics, Training MESX".
Version 3.00
Status:06.12.2004 Page 2 of 48
Author: T.Löw / TE
Service Training MESX
Status:06.12.2004 Page 3 of 48
Author: T.Löw / TE
Service Training MESX
Status:06.12.2004 Page 4 of 48
Author: T.Löw / TE
Service Training MESX
3 Known faults
Despite the fault monitoring of inputs and outputs on the ESX control, the ESX control is not able to
detect all faults. The following list contains a selection of known fault reactions of the control, which
mostly have a different cause to the one described in this documentation.
During initial start-up the display shows "ct0" Bit rate on bmfsa not set to 125 kBit
=> see "Change bit rate"
Status:06.12.2004 Page 5 of 48
Author: T.Löw / TE
Service Training MESX
The following describes the generally required adjustment measures on the control, if individual
components of the measuring system have to be changed.
You should therefore set the machine type as the first step! see
"4.4 List of machine types", or. "6.1 Setting the machine type (BOP)")
• Check the direction signal and invert it if necessary, see 5.4, or 6.2.
• Set the machine serial number (only machines with BOP) see: 6.5
• Set the printer language (only machines with printer), see: 6.4
Check the direction signal and invert it if necessary, see 5.4, or 5.4.
Status:06.12.2004 Page 6 of 48
Author: T.Löw / TE
Service Training MESX
Status:06.12.2004 Page 7 of 48
Author: T.Löw / TE
Service Training MESX
Note: The display module described next is only used in machines without the Bomag
Operation Panel (BOP). On machines with BOP all settings are made via the BOP!
(see item 6 "Adjustment/display possibilities on machines with BOP")
The display module consists of a 4-digit display and two keys, F1 and F2.
It is used for the output of fault codes and display values as well as for the input of code numbers.
Faults and warnings are displayed by flashing. If several faults are detected, the displayed fault codes
will change in a 3 second cycle.
Display values are permanently displayed, whereby values from 0 0 0 0 ...9 9 9 9 are possible. Higher
values lead to the display „- - - - “, negative values are indicated by the „prefix“ lighting up (see
illustration).
Vorzeichen
057 667 72
15/54
1. Press both keys (F1 and F2) on the instrument cluster for 2 seconds.
" The value 0 0 0 0 is displayed with the 1st digit flashing.
2. The value of the flashing digit can be increased by pressing the left hand key (F1). When the figure
9 is displayed and the left hand key (F1) is pressed again, the display will return to the value 0 .
3. When pressing the right hand key (F2) the flashing digit will move one digit to the right. When the
4th digit is flashing, the right hand key (F2) is pressed once again to confirm the input. The desired
function is then executed or the desired value is displayed respectively.
In order to terminate a display function you must either enter code number 0 0 0 0 or switch the
ignition off.
Note: Parameter adjustments can only be performed when the engine is not running.
• Enter code number 7 0 1 0 . This code number activates the function "Adjusting machine type“.
The display module now permanently shows the entered code. (e.g. 7 5 3 3 )
• Enter code number 7 0 1 1 . This code number confirms the entered machine type.
After confirming the machine type the control is restarted, the display module shows the new machine
type for approx. 3 seconds.
After this the newly adjusted machine type will be displayed for approx. 3 seconds.
Attention: A machine must not be operated with a wrong type adjustment, because in such
a case the correct function of the control cannot be assured!
In order to make sure that exciter position (only BVC machines) and printout correspond with the actual
travel direction, it may be necessary to invert the direction signal.
Note: Parameter adjustments can only be performed when the engine is not running.
• Enter code number 7 6 0 0 . This code number activates the function "Invert direction signal“.
• Enter code number 7 6 0 1 . This code number is used to invert the direction signal.
The display module now permanently shows the code 0 0 0 1 (signal inverted), or the code 0 0 0 0
(signal not inverted).
After this the code number 1 0 0 1 can be used to check whether the direction signal is correctly
interpreted (see item 11 "Input codes for ESX control").
• Hold both keys (F1 and F2) of the multi-function display depressed and switch on the ignition.
" The currently set bit rate is displayed, e.g. 0 1 0 0 .
• By pressing the right hand key (F2) the bit rate can be changed in fixed steps. Keep pressing the
key, until the display shows 0 1 2 5 .
• Press the left hand key (F1) to accept the bit rate and the display will change to the normal display
mode.
Note: Parameter adjustments can only be performed when the engine is not running.
• Press key "?" to call up the screen page "MENU". The following screen appears:
• Press key "F2" to call up the screen page "Set machine type". The following screen appears:
• The required machine type can be selected by pressing keys "F11" and "F12". (see list of machine
types under item 4.4 "List of machine types").
• After selecting the required machine type keep pressing key "F14", until the symbol (F14) lights
green for confirmation (approx. 4s).
When releasing the key the screen will automatically change to the start screen and the control will
reboot.
BOP and MESX are now set to the new machine type.
6.2 Inverting the direction signal via the BOP control terminal
In dependence on the mounting position the axle sensor used delivers a 12 V output signal during
forward or reverse travel.
In order to make sure that exciter position (only BVC machines) and printout correspond with the actual
travel direction, it may be necessary to invert the direction signal.
Note: Parameter adjustments can only be performed when the engine is not running.
• Press key "?" to call up the screen page "MENU". The following screen appears:
• Press key "F1" to call up the screen page "Invert direction signal". The following screen appears:
• The direction signal can now be inverted or not inverted by pressing key "F5" ("Invert = 1" or "Invert
= 0").
• After this change press key "F14" to save the setting. The symbol lights green for a moment as
confirmation.
After this check on the printout or in the diagnostics menu whether the travel direction is now correctly
recognized.
• Press key "F5" to call up the screen page "Diagnose1". The following screen appears:
In case of a actually existing code the corresponding error code is displayed in the field "Actual Errors".
• Pressing key "A" brings you to a machine related, extended diagnostics menu (see below).
98% Small Ampl: Control of solenoid valve for low amplitude in percent
MD+ Status MESX input MD+ (sensing of engine operation) (LED on = 12V)
+01234 Distance pulses (10 cm steps) detected by MESX. The actually detected travel
direction can be seen by the roller symbol above.
MD+ Status MESX input MD+ (sensing of engine operation) (LED on = 12V)
+01234 Distance pulses (10 cm steps) detected by MESX. The actually detected travel
direction can be seen by the roller symbol above.
• Press key "F6" to call up the screen page "Printer language". The following screen appears:
• The required printer language can be selected by pressing keys "F11" and "F12".
• After selecting the required language press key "F14" to save the setting. The symbol (F14) lights
green for a moment as confirmation.
• Press key "F7" to call up the screen page "Serial number". The following screen appears:
• The required serial number can be set by pressing keys "F11" and "F12".
• After completing the setting press key "F14" to save the setting. The symbol (F14) lights green for
a moment as confirmation.
Note: The distance impulses can only be adapted within the range of +/- 10% of the
previously adjusted value.
• Press key "?" to call up the screen page "MENU". The following screen appears:
• Press key "F8" to call up the screen page "Distance impulses". The following screen appears:
• Press key "F5" to start the Teach-mode. The following symbol is displayed:
• Travel a distance of 10 m forward and press key "F6" at the end. The following symbol is
displayed:
• After completing the measuring pass press key "F14" to save the setting. The following symbol is
displayed:
Note: If the following symbol is displayed after completing the measuring pass, the
measured distance pulses are outside the range of +/- 10% of the preset value. The
setting cannot be saved! The measurement must be repeated!
X0:3 Output Evib display PWM signal (100Hz): " approx. 0..6 V
PWM (max. 2.5 A)
X0:4 Interface RS 232 RxD, is used for printer control. Measurement not possible!
X0:5 Interface RS 232 TxD, is used for printer control. Measurement not possible!
X0:6
X0:7 Input acceleration transducer VH20g/HR15g Acceleration signal (measured against AGND)
X0:9 Input exciter position front Position exciter front (measured against AGND)
Analogue input / voltage input 0..8.5 V Bottom stop " approx. 2,2 V
Neutral position " approx. 4,25 V
Top stop " approx. 6,6 V
X0:11
X0:12
X0:13
X0:14
X0:21
X0:22
X0:26 Interface CAN-Bus1 Wire -, is used to communicate with the BOP- Measurement not possible!
operating panel.
X0:27 Interface CAN-Bus1 Wire +, is used to communicate with the BOP- Measurement not possible!
operating panel.
X0:33 Interface CAN-Bus2 Wire -, is used to communicate with the BCM05. Measurement not possible!
X0:34
X0:35 Input distance transducer Transducer delivers square-wave pulses. Frequency machine type
dependent.
Digital input active high
X0:40
X0:41
X0:42
X0:43
X0:44
X0:45
X0:49
X0:50
X0:51
X0:52
X0:61
X0:62
X0:63
X0:64
10.1 Overview
Note: Faults with fault reaction 1 are only warnings and are NOT stored in the error log!
452 Output proportional solenoid front " Current path is interrupted X0:46 2
3 Valve exciter up " Current path has unpermitted connection to another current
Fault when calibrating the valve path / ground
452 Output proportional solenoid front " Current path has short circuit to voltage supply X0:47 2
6 Valve exciter down " Current path has non-permitted connection to another current
Output current too low. path
" Current path is interrupted
452 Output proportional solenoid front " Current path has short circuit to ground X0:47 2
7 Valve exciter down " Current path has non-permitted connection to another current
Output current too high. path
452 Output proportional solenoid front " Current path is interrupted X0:47 2
8 Valve exciter down " Current path has impermissible connection to another current
Fault when calibrating the valve path / ground
453 Position controller has reached negative limit " Supply and ground terminals on exciter potentiometer mixed X0:09 5000 2
2 The exciter does not move to the desired up+ X0:37
direction or does not move at all. " Valves "exciter up" and "exciter down" mixed up
" MD+ input has 12 V potential, even though the engine is not
running
460 Input acceleration transducer 1 " Current path has no connection to +12 V / +8,5 V X0:29, 4601 2
1 The voltage applied to the input is below the " Current path connected to ground or
specified range (see signal description). " Transducer defective X0:31
460 Input acceleration transducer 1 " Current path connected to +12 V / +8,5 V X0:29, 4601 2
2 The voltage applied to the input is above the " Current path not connected to ground or
specified range (see signal description). " Transducer defective X0:31
460 Input acceleration transducer 2 " Current path has no connection to +12 V / +8,5 V X0:30, 4606 2
6 The voltage applied to the input is below the " Current path connected to ground or
specified range (see signal description). " Transducer defective X0:07
460 Input acceleration transducer 2 " Current path connected to +12 V / +8,5 V X0:30, 4606 2
7 The voltage applied to the input is above the " Current path not connected to ground or
specified range (see signal description). " Transducer defective X0:07
Ct0 Display module has no connection to ESX- " Wire breakage in CAN Bus lines X0:26 - -
control. " Short circuit between CAN Bus lines X0:27
" One or both CAN Bus line(s) has (have) connection to +12V or
ground
" Bit rate in display module not correct (nominal value: 125 kBit)
11 Input codes for ESX control (only via BEM display module)
11.2 Vibration
11.3 Light
Wire breakage
This generally means that a connection is interrupted. Possible reasons may be:
Line:
• torn (not necessarily visible from outside)
• chafed
• chafed mostly in connection with a short circuit to ground
Digital
There are only two permissible states, e.g. switched on or off; lamp on / off; current flows /
does not flow; valve open / closed (black-white valve)
Analogue
In contrast to Digital many conditions are permitted within a certain range. For instance room
temperature 0° to 40°; current 4mA to 20mA; voltage 0V to 8,5V; resistance 100 Ω to 300 Ω;
valve 0% to 100% opened (proportional valve)
Control
Controlling describes the process during which an input value influences a distance (the
value to be controlled), following a fixed command. For this purpose all possible interfering
factors (e.g. temperature, humidity ...) must be known.
Ohm’s law:
U = Voltage
R = Resistance
I = Current
Plausibility check
The control (ESX) runs a plausibility check on all inputs. This means the control checks
permanently whether certain state combinations are permitted; e.g. travel lever position
forward and reverse will cause an fault message, because this condition is normally not
possible.
GND - AGND
Besides the "normal" battery ground (terminal 31) in the vehicle there is an additional
analogue ground, which is only to be used for sensors. (see description of the signals on the
ESX-control)
Version 1.03
Table of contents
3.4 Changing the steering unit on BVC-4 machines (from version 1.09).................................................. 10
3.8 Teaching the electronic end stops of the steering angle sensor (BVC) ............................................... 14
4.2 How to proceed when replacing a travel pump / axle drive motor / drum drive motor?.................. 16
4.5 How to proceed when replacing an front / rear axle sensor? .............................................................. 16
4.6 Which components can be replaced without a subsequent adjustment procedure? ......................... 17
10.3 Detailed description of fault codes and their possible causes ............................................................. 31
11.1 General..................................................................................................................................................... 38
11.6 Engine....................................................................................................................................................... 42
11.7 Hydraulics................................................................................................................................................ 42
1 List of changes
Pre-heating of engine
Brake
ASC
Different fault causes and reaction times.
See fault codes
Hydraulic oil filter
5502 5503
after 5s after 2min
Water separator on fuel
filter 5028 5029
after 5s after 2min
Theft warning system
(Option)
Seat contact
(Option)
1) 3)
After reaching the warning limit! Shut-down currently deactivated by parameter
2)
After reaching the shut-down limit!
Known faults
Despite the fault monitoring of inputs and outputs on the ESX control, the ESX control is not able to
detect all faults. The following list contains a selection of known fault reactions of the control, which
mostly have a different cause to the one described in this documentation.
Effect: Cause:
Display stay dark, no voltage PIN in display plug X 28 bent
Existing faults and warnings are displayed by flashing. If several faults are detected, the displayed fault
codes will change in a 3 second cycle.
Display values are permanently displayed, whereby values from 0 0 0 0 ...9 9 9 9 are possible.
Negative values are marked with a "minus sign".
The following description deals with the operation of the LC-Display via the travel lever buttons.
INFO 2 Taste
(gelb) Werte ändern
(grün)
Navigieren
(blau)
To activate the input mode the travel lever must be engaged in the brake lock! Input mode is
activated by simultaneous pressing of both INFO – buttons over a period of approx. 3 seconds.
The input mode starts with flashing of the left hand digit. At this point you have the possibility to change
into service mode by entering 9 9 9 9 . The green buttons are used to increase or reduce the values of
the individual digits. Pressing one of the blue buttons brings you to the next digit (left or right). When
pressing the right hand blue navigation key again after entering the last digit, the code will be
transferred to the control.
If the access code has been entered correctly, the "Spanner" symbol will be displayed and the first
input digit flashes again. By transferring input codes to the control (as described above) individual
operating states of the machine can be interrogated.
When pressing bothINFO buttons over a period of approx. 3 seconds a new input code can be
entered. The service mode can be terminated by entering the code "0 0 0 0 ", or by switching off the
ignition.
If the travel lever is shifted out of brake lock position in service mode, all machine function will become
active again, except the reading in the LC.Display, which remains in service mode and shows the
previously requested operation values.
„Eingabe“ - Modus:
Umschaltung Displayfunktion
Einstellungen Display
Betätigen INFO 1
+ INFO 2 ca. 3s
Plattenverstellung inaktiv!
Bet. INFO 1 +
Eingabe
INFO 2 ca. 3s
Zugangangscode
oder Fahrhebel
9999
aus Bremsr.
„Service“- Modus:
CODE - Eingabe „0000" oder Eingabe Diagnosecodes
Zündung aus
Fehlerspeicher abrufen / löschen
Maschinentypen umstellen
Plattenverstellung inaktiv!
For simple checking the currently set machine type is displayed for approx. 3 seconds on the display
module of the central electrics when switching the ignition on. The machine type can also be checked
by entering code 0720 .
0 1 2 3 4 5 6 7 8 9
72XX
0 Default BW 177 BW 177 BW 179 BW 179 BW 213 BW 213 BW 213 BW 213 BW 216 DH
DH-4 PDH-4 DH-4 PDH-4 DH-4 PDH-4 DH-4 PDH-4 DH-4
(Dozer USA USA
blade)
1 BW 216 BW 219 BW 219 BW 226 BW 226 BW 226 BW 226 DH
PDH-4 DH-4 PDH-4 DH-4 PDH-4 DH-4 PDH-4
147kW 147kW 174kW 174kW
2 DH
3 DH
4 DH
7 BVC
8 BVC
9 BVC
Note: Parameter adjustments can only be performed when the engine is not running.
Note: This function can only be activated / deactivated when the travel lever is in brake lock
! Input mode)
position. (!
The following method must be used for initial start-up of a control:
• After approx. 7 seconds the set machine type code, e.g. 7 2 1 2 is displayed for approx. 3
seconds. The new parameters are loaded according to the newly set machine type. Do not switch
the ignition off during this time!
• Then switch the ignition off and on again to accept the configuration.
• This is followed by the normal display reading.
The following applies for correcting the machine type code is a code is already set.
• Select the machine code from the table above and confirm with the arrow to right key. Pressing the
arrow to right key automatically switches the control off and on again.
• After approx. 7 seconds the set machine type code, e.g. 7 2 1 2 is displayed for approx. 3
seconds. The new parameters are loaded according to the newly set machine type. Do not switch
the ignition off during this time!
• Then switch the ignition off and on again to accept the configuration.
• This is followed by the normal display reading.
Attention: A machine must not be operated with a wrong type adjustment, because in such
a case the correct function of the control cannot be assured!
New controls are delivered with a default machine type setting 7 2 0 0 . This does
not allow driving or steering the machine. It solely serves the purpose of
commissioning.
Attention: The steering unit can only be changed when the engine is not running!
For a sensitive and exact travel function the surge currents in the travel system must be determined for
both travel directions. The surge currents are automatically determined after entering a code number,
so that no electric meter is required.
The surge currents must only be determined during initial commissioning in the factory, after a service
during which the control on a steering valve or the complete steering valve has been replaced and after
the replacement of the ESX-control.
The measurement is identical for both travel directions: After entering the respective code number the
current is increased by the control solenoid on the travel pump in steps of 5 mA, starting from 250 mA..
After each current increase the system waits for 3 seconds. If a considerable drum movement is
measured during the waiting time, the surge current is reached. In order to enhance the measuring
result this measurement is performed three times. The final surge current is the mean value of these
three measurements. This surge current is automatically stored and is valid from the next start of the
machine.
Before the measurement you should strictly make sure that the machine is parked on level ground and
has a sufficient distance for movement to front and back, because the machine will move to the
respective direction when performing the measurement.
Attention! Set the machine to input mode first (code 9 9 9 9 ). It must be strictly assured that the speed
sensor (in front right hand hydraulic motor) is working correctly. For a function test enter code number
1 1 0 6 at the display module. This code can be used to display the number path pulses from the speed
sensor. The displayed value must change when the machine is driven.
If this value does not change even though the machine is moving, the measurement must not
be performed!
The state of the speed sensor must first be corrected, as otherwise the movement of the drum will not
be detected. (See also: „Resetting the surge currents in the travel system”)
Attention!
During the measurement the machine will move when the surge current is reached!
Do not leave the machine while the measurement is progressing!
During the measurement keep an eye on your environment!
To stop the machine reset the travel lever to neutral position!
The automatic measurement of the travel system surge currents is performed as follows:
• The switch for rotary speed preselection must be set to ECO
• If necessary enter code number 9 9 9 9 to enter into service mode.
• Then enter 1 0 9 0 . This code number activates the function "Automatic detection of surge
currents"; the display now shows the value 0 0 0 0 with the first zero flashing. This code number
must be entered before the following steps can be performed. From this point the machine can
no longer be operated with the travel lever! The travel lever will only be in function again
after the steering function has been ended or the engine has been restarted.
• The measurement (forward/reverse) must be started by entering a code number. The code number
for teaching the travel direction is as follows:
• After entering the above code number the display will show " F O R E". The travel lever must now
be actuated forward, this will also start the measurement for the surge current in forward.
• During the measurement the actual current is displayed (display value = current in mA).
• Once the measurement of the surge current in forward is finished, the display will show O K for 5
seconds.
• After this wait time the display will show the reading "B A C K". The travel lever is now moved
backward, this will start the surge current measurement in reverse.
• During the measurement the actual current is displayed (display value = current in mA).
• Once this measurement is finished the display will show O K again.
• The travel lever must now be returned to brake position.
• Once both jump currents have been learned correctly and the travel lever is back in "brake
position", the display will show the message "D O N E", the values are saved and the function is
finished. Now the machine can be operated again by the travel lever. The new surge current values
for the travel system are valid from the next start.
• The teach function can at any point be aborted by simply pressing the emergency stop button or via
the ignition switch.
With software versions 1.07 and 1.08 use the following procedure:
The automatic measurement of the travel system surge currents is performed as follows:
• The seat must be adjusted for travel direction forward!
• The switch for rotary speed preselection must be set to ECO
• If necessary enter code number 9 9 9 9 to enter into service mode.
• Then enter 1 0 9 0 . This code number activates the function "Automatic detection of surge
currents"; the display now shows the value 0 0 0 0 with the first zero flashing. This code number
must be entered before the next steps are possible. From this point the machine can no longer
be operated with the travel lever! The travel lever will only be in function again after the
steering function has been ended or the engine has been restarted.
• Both measurements (forward/reverse) must be started by entering a code number. The code
numbers for both travel directions are:
• After entering one of the above code numbers the measurement of the surge current will only start
after moving the travel lever to the respective travel direction.
ATTENTION: During the teach process the ASC-lamp will come on. In this case this is without
any meaning. Restarting the machine eliminates the warning.
• During the measurement the actual current is displayed (display value = current in mA).
• Teaching must be performed for both travel directions.
• When returning the travel lever to neutral after the two measurements, O K is displayed for 3
seconds and the determined values will be memorized.
• After both surge currents have been measured the machine can again be driven with the travel
lever. The new surge current values for the travel system are valid from the next start.
• The teach function can at any point be aborted by simply pressing the emergency stop button or via
the ignition switch.
Attention: Does not apply for BVC machines with the optional hydraulic steering
To enable a sensitive and exact function of the steering the surge currents of the two control solenoids
and both steering valves must be measured. The surge currents are automatically adjusted after
entering a code number, so that no electric meter is required.
The surge currents must only be adjusted during initial commissioning in the factory, after a service
during which the control on a steering valve or the complete steering valve has been replaced and after
the replacement of the ESX-control.
The measuring procedure is identical for both solenoids:
The automatic measurement of the steering valve surge currents is performed as follows:
• The engine must be operated in ECO mode!
• Enter code number 9 9 9 9 to enter into service mode.
• Travel lever in neutral position (brake must be relieved!)
• Enter code number 2 0 0 0 . This code number activates the function "Automatic detection of surge
currents on steering valves"; the display now shows the value 0 0 0 0 with the first zero flashing.
• Now you must enter code number 2 0 0 1 .
• After entering o0ne of the above mentioned code numbers the measurement of the surge current
will start immediately.
• The drum is thereby first steered to the right and then to the left.
• During the measurement the actual current is displayed (display value in mA).
• Attention! During the measurement the drum cannot be used for steering ! The steering
wheel has no effect.
• During the measurement the machine should not be driven !
• Once the measurement is completed the display value OK will appear for 3 seconds, after this the
code number 0000 is displayed again with the first digit flashing and the next measurement can be
started.
• The new surge current values are valid from the next start.
Note: During the measurement the machine should be parked on level ground.
Before the measurement both drums should be steered to straight ahead position.
3.8 Teaching the electronic end stops of the steering angle sensor (BVC)
Attention: Does not apply for BVC machines with the optional hydraulic steering!
Do prevent the steering from running against the mechanical end stops of the steering cylinder, a
clearly defined safety distance to the end stops must be determined.
• Enter code number 9 9 9 9 to enter into service mode.
• Enter code number 2 0 1 0 to activate the mode for "teaching the steering stops".
• Shift the travel lever to neutral position (no brake function, to relieve the machine). The display now
shows the standardized steering position (0..1000 → right ... left).
• Now turn the electronic steering wheel clockwise, until the mechanical end stop is reached. The
displayed value should be in the range of 100..300. Then shift the travel lever to brake position
and enter code number 2 0 1 2 . Upon acceptance the value 2 2 2 2 is displayed for a moment. In
case of a fault the reading is 9 9 9 9 (see below).
• Shift the travel lever to neutral position (no brake function, to relieve the machine). The display now
shows the standardized steering position (0..1000 → right ... left).
• Now turn the electronic steering wheel anti-clockwise, until the mechanical end stop is reached.
The displayed value should be in the range of 700..900. Then shift the travel lever to brake
position and enter code number 2 0 1 3 . Upon acceptance the value 3 3 3 3 is displayed for a
moment. In case of a fault the reading is 9 9 9 9 (see below).
• To exit this mode shut down the machine or enter code 2 0 1 1 .
In order to terminate this function and release the brake you must either enter code number 0 5 0 1 or
switch the ignition off. After entering the code number 0 5 0 1 the function is terminated and the
confirmation OK appears for 5 seconds. After this a new code number can be entered.
Note: This function can only be activated / deactivated when the travel lever is in brake lock
! Input mode)
position. (!
The faults stored in the ESX are displayed in flashing mode. If several faults are stored, these are
successively displayed in cycles of 3 second. After the last fault has been displayed, the first fault will
appear again. If no faults are stored in the ESX the display will show "- - - - - "
Note: Apart from the stored faults the current faults are also displayed.
Note: This function can only be activated / deactivated when the travel lever is in brake lock
position. (! Input mode)
Note: The stored faults can only be deleted when the engine is not running.
Note: This function can only be activated / deactivated when the travel lever is in brake lock
! Input mode)
position. (!
Since the control stores all teach values of the machine, each teaching procedure must be performed
with the new control after a replacement.
Attention: Before performing one of the following steps you must first adjust the respective
machine type (see chapt 3.6 Fehler! Es wurde kein Textmarkenname vergeben.)!
When changing the machine type all previously made adjustments will be lost!
4.2 How to proceed when replacing a travel pump / axle drive motor / drum
drive motor?
• Automatic detection of surge currents in the travel system (see chapter 3.6 Fehler! Es wurde kein
Textmarkenname vergeben.)
• Automatic detection of surge currents of the steering valve (BVC) (see chapter 3.7 Fehler! Es
wurde kein Textmarkenname vergeben.)
• Teaching electric end positions of the steering angle sensors (see chapter 3.8)
9 Description of signals on the DIOS module (only with optional extension plates)
10.1 Overview
2 Warning.
Fault code is displayed.
Audible signal
4 Partial function faulty, the partial function cannot be overridden by an emergency function.
The machine is stopped if this fault occurs.
The machine can still be driven to a limited extent, but must be repaired by the service department as soon as possible.
Fault code is displayed.
Audible signal
5 Partial function faulty, the partial function cannot be overridden by an emergency function.
The machine is no longer able to drive, e.g. because parts of the travel system are defective " the diesel engine is shut
down.
Fault code is displayed.
Audible signal
Note: Faults with fault reaction 1 and 2 are only warnings and are NOT stored in the error log!
502 Warning "Simulated engine run" A corresponding input code was entered X
The function "sumulated engine run" is active
504 Warning "Anti-Slip Control (ASC) deactivated" A corresponding input code was entered X
The function "Anti-Slup Control (ASC)" is deactivated
507 Warning "Drum drive deactivated" A corresponding input code was entered X
The test mode "drum drive deactivated" was activated.
508 Warning "Axle drive deactivated" A corresponding input code was entered X
The test mode "axle drive deactivated" was activated.
560 Fault "Overvoltage 8,5V" Connection of the voltage level to operating voltage, another X
The voltage level of 8,5V range is exceeded in an voltage potential or control defective
unacceptable way
(see signal description)
561 Fault "Undervoltage 8,5V" Connection of the voltage level to ground, another voltage X
The voltage level of 8,5V range is fallen short of in an potential or control defective
unacceptable way
(see signal description)
562 Fault "Voltage override relay" X
The voltage level of the 8,5V range is...
1001 Fault brake valve The connecting line from the output of the control to the control X X
The required control power cannot be transmitted to the solenoid is interrupted, or
control solenoid. the proportional solenoid is defective
1002 Fault brake valve Cable breakage in ground line, or X X
Signal outside the valid range (see signal description) the connecting cable valve / ground connection has come loose
1003 Fault brake valve Cable breakage in supply line, or X X
Signal outside the valid range (see signal description) the connecting cable valve / supply has come loose
1004 Fault BTS brake / travel lever Hardware defect on travel lever X X
Overheating of the BTS has the effect that the travel lever
brake position is not recognized correctly
1040 Fault travel range switch "ground connection" Cable breakage in ground line, or X X
Signal outside the valid range (see signal description) the connecting cable switch / ground connection has come
loose
1041 Fault travel range switch "supply connection" Cable breakage in supply line, or X X
Signal outside the valid range (see signal description) the connecting cable switch / supply has come loose
1042 Fault travel range switch Increased transition resistance values on contacts may have led X X
Signal outside the valid range (see signal description) to a falsification of the signal.
The switch needs to be replaced
1070 Fault output "travel pump forward" The connecting line from the output of the control to the X X
The required control power cannot be transmitted to the
proportional solenoid is interrupted, or the proportional
proportional solenoid.
solenoid is defective
1071 Fault of current regulator forward X X
1072 Fault of current regulator forward X X
1073 Fault output "travel pump forward" Short circuit in the connecting line (control to prop valve) to X X
Supply voltage UB applied at the output to the proportional supply voltage
valve.
1074 Fault when teaching surge current forward Machine is mechanically blocked
Bypass valves in travel system are deadjusted
1080 Fault output "travel pump reverse" The connecting line from the output of the control to the X X
The required control power cannot be transmitted to the proportional solenoid is interrupted, or the proportional solenoid
proportional solenoid. is defective
1081 Fault of current regulator reverse X X
1082 Fault of current regulator reverse X X
1083 Fault output "travel pump reverse" Short circuit in the connecting line (control to prop valve) to X X
Supply voltage UB applied at the output to the proportional supply voltage
valve.
1084 Fault when teaching surge current reverse Machine is mechanically blocked
Bypass valves in travel system are deadjusted
1088 Informative message! Surge currents of travel pump Function "Learning of pump surge currents" for travel pump not X X Note
NOT YET learned. See 3.6 yet executed.
-> New machine/control change
1100 Fault output "front travel motor" The connecting line from the output of the control to the X X
The required control power cannot be transmitted to the proportional solenoid is interrupted, or the proportional
proportional solenoid. solenoid is defective
1106 Fault front travel motor "speed sensor" Check connecting lines and plugs to the wheel speed sensor or X X
Faulty or non-existent signal "direction" replace the speed sensor, if necessary
1107 Fault output "front travel motor" Short circuit in the connecting line (control to prop valve) to X X
Supply voltage UB applied at the output to the proportional supply voltage
valve.
1110 Fault output "rear travel motor" The connecting line from the output of the control to the X X
The required control power cannot be transmitted to the proportional solenoid is interrupted, or the proportional solenoid
proportional solenoid. is defective
1115 Fault rear travel motor "speed sensor" Check connecting lines and plugs to the wheel speed sensor or X X
Faulty or non-existent signal "frequency" replace the speed sensor, if necessary
1116 Fault rear travel motor "speed sensor" Check connecting lines and plugs to the wheel speed sensor or X X
Faulty or non-existent signal "direction" replace the speed sensor, if necessary
1117 Fault output "rear travel motor" Short circuit in the connecting line (control to prop valve) to X X
Supply voltage UB applied at the output to the proportional supply voltage
valve.
1140 Fault pressure switch travel system "signal" The connecting line from the output of the control to the X X
The current signal is not transmitted (see signal pressure sensor is interrupted, or
specification) The pressure sensor is defective
1141 Fault pressure switch travel system "signal range" The pressure sensor is defective X X
The current signal is outside the permissible range (see
signal specification)
1142 Fault pressure switch travel system "no pressure" No pressure connection on sensor, of X X
The current signal indicates that no permanent travel supply line clogged or
pressure is built up. no travel pressure is built up
1145 Fault inclination sensor "supply connection" Cable breakage in supply line, or X X
Signal outside the valid range (see signal description) the connecting cable sensor / voltage supply has come loose
1146 Fault inclination sensor "ground connection" Cable breakage in ground line, or X X
Signal outside the valid range (see signal description) the connecting cable sensor / ground connection has come
loose
2060 Fault output "steering valve right" The connecting line from the output of the control to the X
The required control power cannot be transmitted to the proportional solenoid is interrupted, or
proportional solenoid. the proportional solenoid is defective
2061 Fault output "steering valve left" The connecting line from the output of the control to the X
The required control power cannot be transmitted to the proportional solenoid is interrupted, or
proportional solenoid. the proportional solenoid is defective
2065 Fault learning the surge current right hand valve Drum was not moved, maximum current reached, steering is
blocked (e.g. articulation lock applied)
2066 Fault learning the surge current left hand valve Drum was not moved, maximum current reached, steering is
blocked (e.g. articulation lock applied)
2068 Informative message! Surge currents of steering pump Function "Learning of pump surge currents" for steering pump (X) Note
NOT YET learned. See 3.7 not yet executed.
(Only machines with electric steering) -> New machine/control change
2170 Fault steering wheel "change of direction" Wiring fault or steering sensor in left hand arm rest defective X
2171 Fault steering wheel "impulse coverage" Steering sensor in left hand arm rest defective. X
Measuring value of sensor 1 and 2 difference too strong
2172 Fault steering wheel "sensor 1 pulse range" Check connecting line to steering sensor – sensor 1, X
The detected steering pulses on steering sensor 1 are if necessary change the steering sensor in the left hand arm rest
outside the valid range (see signal description)
2173 Fault steering sensor "sensor 2 pulse range" Check the connecting lines to the steering sensor – sensor 2, or X
The detected steering pulses on steering sensor 2 are replace the steering sensor in the left hand arm rest.
outside the valid range (see signal description)
2174 Fault steering wheel "sensor 1" Steering sensor in left hand arm rest defective. X
2175 Fault steering wheel "sensor 2" Steering sensor in left hand arm rest defective. X
2176 Fault steering wheel "sensor 1 cable damage" Check the connecting lines to the steering sensor – sensor 1, or X
replace the steering sensor in the left hand arm rest.
2177 Fault steering wheel "sensor 2 cable damage" Check the connecting lines to the steering sensor – sensor 2, or X
replace the steering sensor in the left hand arm rest.
2190 Fault steering "steering angle sensor... initialization" Steering angle sensor on articulated joint defective X
Fault when initializing the steering angle sensor
2191 Fault steering "steering angle sensor—ADC" Steering angle sensor on articulated joint defective X
2192 Fault steering "steering angle sensor—cable damage Voltage supply line to steering angle sensor interrupted or X
supply" Steering angle sensor on articulated joint defective
2193 Fault steering "steering angle sensor—cable damage Ground supply line to steering angle sensor interrupted or X
2300 Fault "driver's seat armrest lifted" Arm rest is raised or magnetic switch under left hand arm rest X
defective
2301 Fault "driver's seat armrest" Cable breakage in signal line, or X
Signal outside the valid range (see signal description) magnetic switch under left hand arm rest defective
2302 Fault "driver's seat armrest cable damage supply" Voltage supply line to magnetic switch interrupted or X
magnetic switch under left hand arm rest defective
2303 Fault "driver's seat armrest cable damage ground" Ground supply line to magnet switch interrupted or X
magnetic switch under left hand arm rest defective
3000 Fault vibration sensor "no signal" Check connecting lines and plugs to the vibration sensor X X
The sensor in the vibration motor does not detect any
or replace the sensor in the vibration motor, if
pulses.
necessary
3001 Fault vibration pump "valve for low amplitude" The connecting line from the output of the control to the X X
The required control power cannot be transmitted to the
proportional solenoid is interrupted, or the
proportional solenoid.
proportional solenoid is defective, or the changeover
relay / bridge is missing
3002 Fault vib. pump valve low amplitude "hysteresis" X X
The...
3003 Fault vib. pump valve low amplitude "current range" Fault in connecting line or connection to another potential (e.g.: X X
The current signal is outside the permissible range (see operating voltage)
signal specification)
3004 Fault vibration pump "valve for high amplitude" The connecting line from the output of the control to the X
The required control power cannot be transmitted to the proportional solenoid is interrupted, or
proportional solenoid. the proportional solenoid is defective, or
the change-over relay / bridge is missing
3005 Fault vib. pump valve high amplitude "hysteresis" X
The...
3006 Fault vib. pump valve high amplitude "current range" Fault in connecting line or connection to another potential (e.g.: X
The current signal is outside the permissible range (see operating voltage)
signal specification)
5024 Fault diesel engine warning "coolant filling level" Coolant level too low or sensor defective X X
5110 Fault diesel engine EMR "nominal speed value" " CAN connection between ESX and EMR interrupted X X
" CAN connection has short circuit to ground, to +12 V or
connection between CAN+ and CAN-.
" ESX without voltage supply
" Voltage of on-board battery too low
5112 Fault diesel engine EMR "oil pressure" " Engine oil pressure too low X X
5113 Fault diesel engine EMR "charge air pressure" " Charge air pressure too low X X
5114 Fault diesel engine EMR "temperature intake pipe" " Charge air temperature too high X X
5116 Fault diesel engine EMR "coolant temperature" " Coolant temperature too high X X
5117 Fault diesel engine EMR "fuel temperature" " Fuel temperature too high X X
5118 Fault diesel engine EMR "engine speed" " Speed sensor 1 or 2 defective X X
" Connection between EMR and speed sensor 1 or 2
interrupted
5122 Fault diesel engine EMR "nominal speed value" " CAN connection between ESX and EMR interrupted
" CAN connection has short circuit to ground, to +12 V or
connection between CAN+ and CAN-.
" ESX without voltage supply
" Voltage of on-board battery too low
5123 Fault CAN communication " CAN communication between EMR and ESX X X
5124 Fault CAN communication " CAN communication between EMR and ESX X X
5125 Fault CAN communication " CAN communication between EMR and ESX X X
5130 Fault diesel engine EMR "oil pressure sensor" " sensor defective X X
" Wire breakage in current path
" Current path has short circuit to ground
5131 Fault diesel engine EMR "charge air pressure sensor" " sensor defective X X
" Wire breakage in current path
" Current path has short circuit to ground
5132 Fault diesel engine EMR "charge air temperature" " sensor defective X X
" Wire breakage in current path
" Current path has short circuit to ground
5140 Fault diesel engine EMR "unknown fault" Fault diagnose only with DEUTZ diagnose tool (SERDIA) X X
5502 Fault warning "hydraulic oil filter" Hydraulic oil filter soiled or sensor defective X X
5503 Fault shut down "hydraulic oil filter" Hydraulic oil filter soiled or sensor defective X X
5504 Fault warning "oil temperature" Hydraulic oil temperature too high or sensor defective X X
5005 Fault shut down "oil temperature" Hydraulic oil temperature too high or sensor defective X X
7011 Fault warning "change of machine type" Only change the machine type after appropriate measures have X X
This warning appears when the machine type has been been applied; e.g. conversion from D to PD (different rolling
changed. circumference of drum)
7012 Fault "conflict machine type" The machine type was changed in a way that the type X X
This fault message is displayed if the set machines do not parameters no longer comply with the basic parameters → enter
comply with the basic parameters of the machine. the correct machine code or a basic parameter of the machine
was changed (e.g. a different axle)
11.1 General
0700 Activation of function "Show stored faults" Fault codes are successively displayed
0701 Deactivation of function "Show stored faults" 0000
0710 Delete stored faults once the error log is deleted the display will return to 0000
0720 Display of "machine code" The machine code is displayed (72xx) (see chapter 3.6)
11.2 Brake
1040 Display "speed range / gear" The display shows the travel range switch position from 1...24
1041 Display "voltage value for speed range / gear" Stages 0...4 = 4
Stages 5...9 = 3
Stages 10...14 = 2
Stages 15...19 = 1
Stages 20...24 = 0
1042 Display "voltage value for speed range / gear standardized" Stage 1 ≈ 956 Stage 2 ≈ 916 Stage 3 ≈ 875
Stage 4 ≈ 835 Stage 5 ≈ 795 Stage 6 ≈ 756
Stage 7 ≈ 716 Stage 8 ≈ 675 Stage 9 ≈ 637
Stage 10 ≈ 597 Stage 11 ≈ 557 Stage 12 ≈ 517
Stage 13 ≈ 478 Stage 14 ≈ 436 Stage 15 ≈ 396
Stage 16 ≈ 357 Stage 17 ≈ 318 Stage 18 ≈ 279
Stage 19 ≈ 238 Stage 20 ≈ 200 Stage 21 ≈ 160
Stage 22 ≈ 120 Stage 23 ≈ 80 Stage 24 ≈ 40
1044 Display "speed range / gear" end value Stage 1 = 417 Stage 2 = 833 Stage 3 = 1'250
Stage 4 = 1'667 Stage 5 = 2'089 Stage 6 = 2'500
Stage 7 = 2'917 Stage 8 = 3'333 Stage 9 = 3'750
Stage 10 = 4'167 Stage 11 = 4'583 Stage 12 = 5'000
Stage 13 = 5'417 Stage 14 = 5'833 Stage 15 = 6'250
Stage 16 = 6'667 Stage 17 = 7'500 Stage 18 = 8'333
Stage 19 = 9'167 Stage 20 = 10'000 Stage 21 = 13'334
Stage 22 = 16'667 Stage 23 = 20'000 Stage 24 = 23'333
1090 Activates Function "detect surge currents in travel system see chapter "Teach travel system surge currents"
automatically"
1091 Function "Determine surge current forward" (only vers.1.07 and 1.08) see chapter "Teach travel system surge currents"
1092 Function "Determine surge current reverse" (only vers.1.07 and 1.08) see chapter "Teach travel system surge currents"
1106 Display "speed sensor travel motor front / pulses" Counts the pulses up to 99'999 and then starts at 0 again
1107 Display "speed sensor travel motor front / direction signal" 2 = forward
1 = standstill and reverse
1108 Display "sense of rotation front drive" 1 = forward
0 = standstill
2 = reverse
1116 Display "speed sensor travel motor rear / pulses" Counts the pulses up to 99'999 and then starts at 0 again
1117 Display "speed sensor travel motor rear / direction signal" 2 = forward
1 = standstill and reverse
1118 display "sense of rotation rear drive" 1 = forward
0 = standstill
2 = reverse
1145 Display "inclination sensor" standardized Incloination display as standardized value (65540 → 0%)
1146 Display "inclination sensor" sensor input voltage Display in mV
0% ≅ 2550mV
1147 Display "inclination sensor" standardized sensor voltage Inclination display in mV
1148 Display "inclination sensor" initialization 1 corresponds with OK
11.4 Steering
Input code Description of display function Display values
1300 Function status arm rest contact 1= arm rest up; 2=arm rest down
1301 Voltage of arm rest contact Display in mV
1302 Travel operation status by arm rest contact 1=travel enabled; 2= travel disabled
2000 activates Function "teach steering start current" see chapter "Determine steering system surge currents"
2001 Function "teach steering start current" see chapter "Determine steering system surge currents"
2010 activates Function "teach steering potentiometer limits" see chapter "Determine steering system end stops"
2011 Deactivates Function "teach steering potentiometer limits" 0000
2012 Function "teach steering potentiometer right hand limit" see chapter "Determine steering system end stops"
2013 Function "teach steering potentiometer left hand limit" see chapter "Determine steering system end stops"
2060 Activates function „Change steering unit“ see chapter "Changing the steering unit“
2061 Activation of electric steering unit see chapter 3.6
2062 Activation of hydraulic steering unit see chapter "Changing the steering unit“
2110 Display of voltage value from steering angle sensor on articulated joint 0...8,5VDC
2112 Steering angle actual position -1000...0...1000
2120 Steering angle nominal position -1000...0...1000
2130 Steering wheel sensor 1 track 1 absolute pulses Number of total pulses
2131 Steering wheel sensor 1 track 2 absolute pulses Number of total pulses
2132
2133 Steering wheel sensor 1 direction 1=steering wheel steers to the right; 2=steering wheel steers to
the left
2140 Steering wheel sensor 2 track 1 absolute pulses Number of total pulses
2141 Steering wheel sensor 2 track 1 absolute pulses Number of total pulses
2142
2143 Steering wheel sensor 2 direction 1=steering wheel steers to the right; 2=steering wheel steers to
11.5 Vibration
Input code Description of display function Display values
3000 Display "switch vibration mode" Off = 0
On = 1
3001 Display "Status of vibration relay" 0 = Relay K43 not switched
1= Relay K43 switched
3002 Display "Vibration pump valve current" Display value = mA
The actual pump current is displayed.
11.6 Engine
Input code Description of display function Display values
5024 Display "Status engine coolant level" 0= coolant level OK; 1= coolant level too low
5026 Display "Status engine air filter" 0= air filter OK; 1= air filter soiled
5028 Display "Status water separator" 0= water separator OK; 1= water or dirt in fuel filter
11.7 Hydraulics
Input code Description of display function Display values
5002 Display "Status hydraulic oil – filter" 0= hydraulic oil filter OK; 1= hydraulic oil filter soiled
Wire breakage
This generally means that a connection is interrupted. Possible reasons may be:
Line:
• torn (not necessarily visible from outside)
• rubbed through
• chafed mostly in connection with a short circuit to ground
Digital
There are only two permissible states, e.g. switched on or off; lamp on / off; current flows /
does not flow; valve open / closed (black-white valve)
Analogue
In contrast to Digital many conditions are permitted within a certain range. For instance room
temperature 0° to 40°; current 4mA to 20mA; voltage 0V to 8,5V; resistance 100 Ω to 300 Ω;
valve 0% to 100% opened (proportional valve)
Control
Controlling describes the process during which an input value influences a distance (the
value to be controlled), following a fixed command. For this purpose all possible interfering
factors (e.g. temperature, humidity ...) must be known.
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 an fault message, because this condition is normally not
possible.
GND - AGND
Besides the "normal" battery ground (terminal 31) in the vehicle there is an additional
analogue ground, which is only to be used for sensors. (see description of the signals on the
ESX-control)
28.06.2004
Seis Stromlaufplan 001 001 582 700 95
28.06.2004 circuit diagram
Werner 001
30
K11
2:10
87
K30 11:1
30 4:1 K11:87 5:1
X1:9
X1:10
F13 1 F05 1 F95 1 F23 1 F39 1
30A 15A 15A 15A 15A
2 2 2 2 2
X1:15A X1:16A X1:27A X1:28A
X1:30A
6:17
X36:B
X36:A
4:9
X37:A X1:151
30 21 11 31 41 51 61
Startschalter NOT−Aus
K32:86
starting swwitch 15 54 58 19 17 50a Emerg.−Stop 11:1
X1:152 X1:155
X1:79
Sicherung Heizflansh
S01:22 3:1
X37:B
F05:2
Hauptsicherung
K05 30
X34:P
main fuse
2 1 7:3
125mA
5
87 87a
K14 86 30
K61 K61
13 23
3:19 3 2:6 S03
2 2
F48 F00
125A 125A 85 87 87a X1:7 X1:8 Taster Hupe
push button, horn 14 24
D+ MESX 8:2
Anzugsw.:50A / Haltew.:10A
G01 G03 X38:A X1:97 X1:98
+ +
− −
X1:1 X1:101 X1:102
X1:109
167A
30 50
1 B+ D+ 86 86 B11 B11
1 K09 K11 1 2 2 1
G02 M01 V02 XS +
R19 S30 M
12V
2 2 1 V03 1 2 −
85 85 −
2
31 EMR 3:5 B− W
31 31 3:1
28.06.2004
1 1 582 700 95
Seis Versorgung, Starten, Hupe
28.06.2004
Werner supply, starting unit, signal horn 002
2:17 S01:22 S01:22 6:1
X1:95
1
K14
Relais Heizflansch
relay heating−flange 2
X1:179 X1:96
X1:185
Steckerschnittstelle Deutz
connector interface Deutz
X33:7
X33:2
X33:3
X33:5
X33:6
X33:1
X33:4
X33:8
max 7A
8−polig PNEUTRON
A48
Motorsteuerung EMR2
X30:14
engine−controller EMR2
X31:21
X31:22
X31:13
X31:11
X31:14
X31:15
X31:24
X31:25
X31:4
X31:9
X31:5
X31:6
X31:3
X31:2
X31:7
X30:10
X30:11
X30:12
X30:13
X31:20
X31:12
X31:10
X31:17
X31:18
X31:19
X31:16
X31:23
X30:1
X30:2
X31:8
X31:1
AGND
AGND
AGND
AGND
AGND
STG−
STG+
K
L
+5V
+5V
CAN low
CAN high
Signal
Signal
Signal
Signal
Ubat −
Signal Druck
Signal Temperatur
X1:180
X1:181
X57:20
X57:21
X57:22
X57:12
X57:13
X57:10
X57:11
X57:14
X57:15
X57:17
X57:18
X57:19
X57:16
X57:23
X57:24
X57:25
CAN2− 4:11
X57:4
X57:9
X57:8
X57:1
X57:6
X1:183
X1:184
ESX Fahrst.
CAN2+ 4:11
RF REF
RF MESS
RF−
1 2 3 1 2 1 2 7 2 6 1 1 4 3 2 1 2
EMR Stellglied
EMR commander
X32:G
X32:H
X32:K
X32:B
X32:A
X32:L
X1:182
Diagnosestecker EMR
diagnosis interface EMR
2:4
X1:186
31 EMR
2:20 31 31 4:1
2:2
Motordrehzahlsensor
sender engine rpm 2
28.06.2004
1 1 582 700 95
Seis Motor Deutz EMR II
28.06.2004
Werner engine Deutz EMR II 003
2:14 30 30 5:1
F24:2 5:3 X1:2 3:4 CAN2+ CAN2+ 7:6
EMR Deutz Fahrhebel
3:4 CAN2− CAN2− 7:6
X1:145
X1:42 CAN1+ 5:8
31 CAN1− 5:8 LC−Display, OPUS 21
X1:119 X1:120
S01
2:16
120 OHM 120 OHM
X52:1
X52:2
X1:146 32 1 2 1 2
R22 R20
rt sw X1:17E X1:34E
Diagnosestecker Fahrzeug
F67 1 F84 1 X34:G X34:H X34:C X34:D X34:A X34:B diagnosis interface equipment
B112
15A 10A
2 2
Drucksensor Fahrpumpe X1:17A X1:34A
X1:51
X1:52
X1:53
X1:54
X1:47
X1:48
X1:49
X1:50
pressure sensor drive pump
X1:34A
8:2
120 OHM 120 OHM
1 2 1 2
Drucksensor
Elektronik
Leistung
R23 R21
CAN2+
CAN2−
CAN1+
CAN1−
RxD
TxD
A34
X35:31
X35:56
X35:57
X35:59
X35:60
X35:53
X35:33
X35:5
X35:58
X35:27
X35:26
X35:28
X35:54
X35:4
Fahr−Steuerung
driving controller
X35:38
X35:12
X35:37
X35:34
X35:30
X35:15
X35:24
X35:49
X35:64
X35:46
X35:47
X35:55
X35:65
X35:66
X35:67
X35:68
Gehäuse
housing
Neigung
speed
speed
Richtung
Richtung
Achsmotor
Bandagenmotor
Fahrpumpe vorw.
Fahrpumpe rückw.
Rückfahrwarnsum.
Sitzkontakt
X1:45
X1:44
X1:173
X1:175
X1:177
X1:176
+ −45_G=0,5V
B57 1V
ws
br
bl
speed
+ + 0,46A
dir. dir.
B60 B59 2,5V X14:B X9:1
speed
S06 + + X16:1 1 X15:1 1 1 1
− X1:172 −
8:2
4V H14 Y17 Y16 Y30 Y31
sw
sw
DIR MESX −
− 2 2 2 2
X1:124
X1:142
X1:142
X1:143
X1:143
11:6 − S X1:46 X16:2 X15:2
X1:82
SPEED TAC X14:A X9:2
X1:174 8:2 X1:178 X1:55 6:4 8:2 X1:149 X1:117 X1:123 X1:123 X1:144 X1:144
SPEED MESX
PITCH MESX
3:20 31 31 5:1
Sensor Achse Sensor Bandage Neigungssensor Sitzkontaktschalter Prop.−Pumpe Vorw. Prop.−Ventil Bandagenmotor
sender axle sender drum slope sensor switch, seat contact prop.−pump forwards prop.−Valve drum motor
28.06.2004
1 1 582 700 95
Seis Fahrantrieb, Neigungssensor, Sitzkontakt
28.06.2004
Werner driving system, slope sensor, seat contakt switch 1 004
30 30 8:1
4:20
2:20 K11:87 K11:87 7:14
4:3 F24:2 F24:2 6:15
X1:40
X34:R
not connected
not connected
CAN1 high
CAN1 high
CAN1 low
CAN1 low
Ub "30"
Ub "15"
Ub out
VCC
X27:8
X28:6
X29:8
Steckerfarbe: X26−grau; X27−schwarz
A80 A81
X28:1
X27:6
X27:7
X29:7
X28:3
X28:5
connector−colour: X26−grey; X27−black
X28:4
Datensammler LC−Display
data−collector LC−display
X26:10
X26:11
X27:10
X27:11
X27:12
X26:3
X26:5
X26:8
X27:4
X27:9
X27:2
X26:7
X26:9
X26:1
X26:2
X26:6
X26:4
X27:1
X27:3
X29:2
X29:1
X29:3
X29:4
X29:5
X29:6
X26:12
X27:5
X28:2
DIN11
UIN1
GND
GND
GND
DIN10
DIN1
DIN1
AIN1
UIN3
UIN2
DIN3
DIN5
DIN7
DIN9
DIN6
DIN3
DIN5
DIN6
DIN8
DIN2
DIN2
Sepa1
GND/UIN3
DIN4
DIN4
AIN2
Sepa2
BR 10:17 23 13 23 13
coolant stock level
hydraulic oil filter
water−seperator
Füllstand Diesel
Kühlmittelvorrat
Hydraulikölfilter
BEL S120
10:4
KLIMA
12:6 S139
air cleaner
fuel−level
24 14 24 14
Luftfilter
D+ R03
2:6 P P Q
Schalter Motordrehzahl
2 2 switch engine−rpm mode switch frequency−control
X21:2 X8:2 X10:3 Schalter Frequenzverstellung
28.06.2004
1 1 582 700 95
Seis Datensammler, LC−Display
28.06.2004
Werner data−collector, LC−display 005
3:20 S01:22 S01:22
5:20 F24:2 F24:2
X1:148 Lenkwinkelsensor
X23:1 steering angle sensor
7:1
X1:41
X1:201
X51:1 Lenkeinheit X1:187
B65 + A45 steering unit
Aufnehmer Vibrationsmotor
S X22:1 sensor vibration motor
br +
X1:161 X41:1 X39:1 VCC X39:2
S1 B − X22:2
−
X1:160 X41:3 X40:1 VCC X40:2
X1:203
X1:55 X1:202
bl
B B16
0V S1 A X22:4
Vib.− Richtung
armrest−switch
1 1 1
X41:5
X41:7
X41:8
X41:6
BTS BREMSE 7:2
X34:J
X1:189
X1:188
−
Sig.
AGND
Vib.− Frequenz
BTS Bremse
X1:205
X1:207
X1:206
X1:208
X1:55
X1:42
4:6
nur BVC
only BVC
8,5V
A34
X35:1
X35:19
X35:17
X35:18
X35:41
X35:35
X35:29
X35:23
X35:40
Fahr−Steuerung
driving controller
X43:2 X43:1
X35:21
X35:20
X35:25
X35:16
X35:22
X35:48
X35:61
X35:2
X35:3
Bremse
Warnsummer
Armlehne
Umsch. Amplitude
Prop. out
K57 30 K56 30
Pumpe Vib.−Platten
30
X51:3
X51:2
6:9 6:8 30
K48 7:2
87 87a 87 87a X1:89
K43 6:12 87 87a
X1:154 87 87a X1:147
KA MESX
8:2 11
X35:16 X1:38
X1:199 X1:198 X1:196 X1:195 X35:16 X35:22 GA MESX
6:9 6:2 7:14 8:2 S01
X1:37
400 ... 1.200mA
2:16
X1:116 X1:115 12
150mA
X1:113 8:2
X6:1 X7:1 BRAKE MESX
Y113 1 Y112 1 1 1 K56 86 K57 86 K43 86 Y08 1 Y07 1 H07
+ Y04 1
Y93 Y92
2 2 2 2 85 85 85 2 2 − 2
max.1.8A
X6:2 X7:2
X1:149 X1:200 X1:200 X1:197 X1:197 X1:82 X1:117 X1:190
X1:118
5:20 7:1
31
31 Anbau 177DH: h.r. Anbau 177DH: h.l.
6:4 6:3 6:14 Anbau 213DH: oben Anbau 213DH: unten
28.06.2004
1 1 582 700 95
Seis Lenkung, Vibration
28.06.2004
Werner TS022 steering, vibration 006
6:2 X23:1 4:17 CAN2+ 5:14 CAN1+ CAN1+ 8:16
ESX Fahrst. LC−Display BTM
4:17 CAN2− 5:14 CAN1− CAN1− 8:16
5:20 K11:87 K11:87 8:1
Taster 1 = Platten rechts
push button 1 = plates right X1:31E
Taster 2 = Platten heben
push button 2 = lift plates 1 F145
Taster 3 = Vibration EIN/AUS Näherungssch. Platten oben
push button 3 = vibration ON/OFF 15A
Taster 4 = Platten links
sensor plates up 2
push button 4 = plates left
Taster 5 = platten senken
Näherungssch. Platten Mitte X1:31A
sensor plates centered
X1:213
X1:214
push button 5 = lower plates
X1:156
X1:157
Taster 7 = Infotaste 1
push button 7 = info button 1
X1:209
Taster 8 = Infotaste 2
BTS BREMSE
push button 8 = Info button 2
B135 + B134 +
6:18 − −
3 2
1 7 Fahrstufenschalter S S
4
5 8 speed range selector
S42
X62:12
X62:10
X62:1
X62:3
X62:9
X62:2
X62:4
+ − S A54
Platten Steuerung
plate−controller
X25:4
X25:2
X25:3
Ub in CAN−
Bremse zu = 0V 1 7
Bremse auf = Ub BTS Bremse CAN+
3 S55 6 X35:22
6:11
X62:11
X62:13
X62:14
X62:5
X62:6
X62:7
X62:8
X1:153 BTS zus.
4 Fahrhebel 5 +5V out
travel lever
0V in 0V (Ref PIN5)
2 8
Add1 AK Ext1
9 11
Add2 AK Ext2
10 12
Stecker X23
Stecker X24
1 2 3 4 5 6 7 8
DK Ext1
DK Ext3
DK Ext5
DK Ext6
DK Ext2
OV out
DK Ext4
Ub out
400 .. 1.200 mA
X50:3
X50:2
X50:1
X1:210
S − + Y123 1 Y143 1 Y145 1
nicht bei BVC Nur bei BVC Schalter Schwimmstellung Platten MV Platten heben MV Platten rechts
not at BVC Only at BVC sw. swimming pos. plates plates up plates right
Frequenzverstellung Platten
freq. adjust plates MV Platten senken MV Platten Schwimmst
Schalter Amplitude Schalter Vibration Ein/Aus Schalter Betriebsart Platten Prop−Pumpe Platten plates down plates float−pos.
switch amplitudes switch vibration on/off modesw. plates prop.−valve plates MV Platten links MV Platten Priorität
plates left plates priority
28.06.2004
1 1 582 700 95
Seis Fahrhebel, Vibrationsplatten
28.06.2004
Werner TS022 joystick, vibration−plates 007
Beschleunigungssensoren Beschleunigungssensoren Aufnehmer Verstellmotor Drucker Bedieneinheit BEM Display Messtechnik BOP
acc. sensor front acc. sensor rear sens. adjust. motor printer control−unit BEM display measurem. BOP
X1:34A
4:9 GND
5:20 30 30 10:1
Pot 30
X2:47
Pot 15
31.1
X2:48 X2:49
+ −
X2:66
X2:70
8:19
nur bei BEM
X42:1
only at BEM
X42:5
X42:3
X42:2
X1:32E X1:35E
X2:77 P16 F1 F2
CAN+
CAN−
X1:32A X1:35A X48:2 X48:1 X49:2 X49:1 X2:78 P33
X2:67 X2:68
X4:C
X4:E
X4:D
F148:2 B62 B62
+/sw
+/sw
9:15
−/gg −/gg X47:A X47:B
X42:6
X42:7
X42:8
X42:4
X74:3
X74:5
X74:4
−/sw
20g/br
20g/br
7:20
X2:57 CAN1−
DIOS Platten
B61 P11
+/rt 7:20
X48:3 X48:4 X49:3 X49:4 S/ws
CAN1+
X74:1 X74:2
1 R20 2
X2:54 X2:55 X2:58 X2:59 X47:C
AGND MESX
Aufn. hinten 15g
X2:50 X2:51
Erregerpos.
Pot. 15
R21
8.5V
X2:69 X2:64 X2:65 1 2
RxD TxD CAN1+ 120 OHM CAN1−
X44:27
X44:26
X44:31
X44:1
X44:56
X44:57
X44:59
X44:60
X44:30
X44:7
X44:9
X44:5
X44:58
X44:29
X44:23
X44:28
X44:54
X44:4
A83
X44:15
X44:38
X44:35
X44:14
X44:32
X44:36
X44:37
X44:41
X44:47
X44:46
X44:53
X44:33
X44:55
X44:65
X44:66
X44:67
X44:68
X44:3
Messtechnik−Rechner
measurement calc. unit
CAN3+ CAN3−
KA MESX
EVIB
0..6VDC
6:15
Prop.
Prop.
400 .. 1.200mA
400 .. 1.200mA
GND
6:15 GA MESX
SPEED MESX X1:85 9:15
4:3 CAN3−
DIR MESX X2:75 X2:73 X2:60 +
4:3
P07 E 9:15
8:20
4:8 PITCH MESX Y140 1 Y141 1 VIB CAN3+
BRAKE MESX
v.r.
v.l.
6:17 −
31.1
D+ MESX BEL MESX 2 2
2:6 10:4 X2:76 X2:74 X2:63 X2:66 X1:82
31 31 9:1
7:20
28.06.2004
1 1 582 700 95
Seis Variocontrol, Messtechnik
28.06.2004
Werner TS022 Variocontrol, measurement equipm. 008
F148:2
8:4
CAN3−
8:18
8:18 CAN3+
CAN3+
1 R242 CAN3−
120 OHM
X2:61 X2:62
R25
1 2
120 OHM
X4:N X4:M
X75:7 X75:2
A87
USB−CAN Schnittst.
USB−CAN Interface BCM
X2:70
X76:1 X4:G
P15 X76:2
X4:F
X2:63
BCM 05
BCM 05
nur bei BCM
only at BCM
8:20 31 31 10:1
28.06.2004
1 1 582 700 95
Seis Bomag Compaction Management BCM
28.06.2004
Werner TS022 Bomag Compaction Management BCM 009
8:3 K11:87 K11:87
8:19 30 30
X1:18E X1:26E X1:19E X1:25E
X1:2
F11 F18 F07 F08
15A 10A 15A 15A
30
X1:301
X1:18A K06 X1:19A X1:25A
X1:26A
10:4 X1:305
X1:83
Schalter StvZO 87 87a
switch, StvZO
13 23
012 31 11 23 Anschluß Arbeitsschein− L0R
werfer ohne StvZO L0R Schalter Blinker
S37
connection working head X1:21E X1:22E switch indicator
lights without StvZO 5 4 14 24
S15 F22 F19
32 12 24 15A 15A
Anschluß Arbeitsscheinwerfer
X1:306
X1:307
X1:21A E X1:22A D bei Kabine
Connection head lights
X1:302
X1:304
werfer ohne StvZO
X1:311
X1:310
X1:319
X1:313
X1:312
X1:321
X1:314
X1:309
X1:303
X1:320
X1:322
13 23
01
01
S14
X1:84
X61:1
X61:3
X60:1
X59:5
X60:3
X59:3
X58:5
X58:3
X59:2
X58:2
Warnblinkschalter 14 24
BEL MESX
8:7 switch, hazard light
0,125A
X1:43
E16 1 E17 1 E13 1 E12 1 E14 1 E15 1 E27 1 E28 1 E23 1 E25 1 E08 1 E09 1 E10 1 E11 1
0,125A
2 2 86 2 2 2 2 86 2 2 2 2 + 2 2 2 2
4,6A
4,6A
4,6A
4,6A
K06 K16
X1:324 X61:2
X1:324 X61:4
X1:316 X59:6
X1:316 X59:6
X1:316 X59:6
X1:315 X58:6
X1:315 X58:6
X1:315 X58:6
X1:323 X60:2
X1:323 X60:4
H06
0,42A
0,42A
0,42A
0,42A
1,75A
1,75A
1,75A
1,75A
4,6A
4,6A
85 85 −
X3:1
9:20 11:1
31 10:10 Schlußleuchte links 10:2 Bel. Warnbinkschalter 31
Scheinwerfer links tail light, LH illumination, switch hazard light
head light LH Parkleuchte links Blinkleuchte VL Blinkleuchte HR
Anschluß Arbeitsscheinwerfer
parking light, LH bei ROPS/SD Aufbau indicator front, LH indicator rear, RH
Scheinwerfer rechts
Parkleuchte rechts Blinkleuchte HL
head light RH parking light, RH Connection head lights indicator rear, LH
acc.to ROPS/SD
Schlußleuchte rechts Blinkleuchte VR
tail light, RH indicator front, RH
28.06.2004
1 1 582 700 95
Seis Beleuchtung und StvZO
28.06.2004
Werner illumination and StvZO 010
K30 X3:6
2:14 K32:87 12:2
X3:7
K32 30 STV2
X3:8 10:13
11:1 10:13 STV1
87 87a
G H A B C E F
F143 F42 F43 F44 F130 F41 F144
15A 10A 15A 15A 10A 10A 15A
7 8 1 2 3 6
5
F42 12:8
F130 11:9 F130 F130 12:7
11:14
A12
1,75A
0,83A
15
K141 30 1 B51 + + 30 01W 7 2 01W 7 2
+ + B51 1 S163 5 1 S38 5
01 01 E72
K32:86 11:16 E29 E70
− − − − 1
87 87a 2 2 2 1
2:19 31 S21 5 4 S20 5 4
Radio
night illumination
radio
Nachtleuchte
inside light, cabin
1 Tachographenmodul
Kontrolleuchte
E71 1
Innenleuchte
module, tachograph
indicator
R80 A2+A3
X3:17
X55:1
X56:1
X55:3
X56:3
X55:4
X56:4
4,6A
4,6A
4,6A
4,6A
2 4 6 A1
Steckdose
4:3 P09 +
2 1 E28 1 E23 1 E25 1 XS
socket
SPEED TAC A16 E27
Heizung Heckscheibe
1 B3 12V
−
heating rear screen
max. 13A
+ 7,8,9 2 B4 2 2 2 2
Schalter Innenleuche
3,8A
3,8A
3
5A
86 S86 + + + S158 I 15 +
K32 E32
M05 M M04 M K141
M M
31
− − M07 −
Abfallverzögert
− M06 4
3 min
85 2,9A
4,7A
ZA
X55:2 X56:2 option
12:18
KABINE 31
Relais Kabine Türkontaktschalter Tachograph Schalter Nachtleuchte
relais cabin door switch tachograph switch, night illumination
X3:1
X3:2
Schalterbel.
switch illum.
10:20 31 31 12:1
28.06.2004
1 1 582 700 95
Seis Kabinenausrüstung, Beleuchtung, Radio, Tachograph
28.06.2004
Werner cabin−equipment, headlights, radio, tachograph 011
11:19 K32:87
Potential 15 aus Kabine
11:17 F130
F42 Potential 15 aus Kabine
11:9
F31 D Potential 30 aus Kabine
F40 H F15 A
20A 20A 5A
4 8 1
Bedienteil Kabinenheizung/Klimaanlage
1 2 3 12 11 13 14 16
X53:B X53:C control−unit cab−heater /air conditioning X54:4 X54:3 X54:2
Schalter Kabinenzusatzheizung
0123 4 3 2
S44 A72
X53:H
X53:L
K09 30
X3:14
temperature sensor air conditioning
2:8
87 87a X1:167 10 9 5 6 8 7 4 15
X3:12
X3:9
X1:169 X18:1
Thermofühler Klimaan
X19:1
Thermofühler Heizung
B131
B103 1
X17:1 X1:163
X17:2 X1:165
X17:3 X1:166
1
_t _t
2 2
monitoring coolant pressure
X19:2
X20:1 X18:2
B104 4
Überwachung Kühlmitt
P
LP 3 HP
1A
X20:4
ge rt or ge rt or
X20:3
Y138 1 1
X1:170 11:19
V06 Y14 KABINE 31
M09 M M09 M 5:9
KLIMA 2 2
Stromaufnahme Lüfter / current blower br br
Stufe 1: 3.0A pro Lüfter
X20:2
Stufe 2: 4.5A pro Lüfter
Stufe 3: 11.5A pro Lüfter
Y15 1 2
X17:4 V04 X1:168
3,5A
2 1
X1:164
11:20 31 31
28.06.2004
1 1 582 700 95
Seis Kabinenheizung, Klimaanlage, Zusatzheizung
28.06.2004
Werner cabin−heater, air conditioning, add. heater 012
Name Bl. Pf. Benennung title TYP
A02 010 17 Blinkrelais indicator relay
A12 011 5 Radio Radio
A16 011 6 Elektronik Tachograph Electronic system, tachograph
A34 004 6 Prozessorplatine Prozessing circuit board
A34 006 5 Prozessorplatine Prozessing circuit board
A45 006 9 Lenkrad Steering wheel
A48 003 3 Elektronische Motorsteuerung Electronic engine management
A54 007 17 Modul Pumpenansteuerung Modul pump control
A72 012 11 Steuergeraet Klimaanlage, Heizung Control unit,air conditioning,heating
A80 005 3 Modul Datensammler modul data−collector
A81 005 18 Anzeigeeinheit Display−Unit
A83 008 6 Elektronik Messtechnik electronic measurement−equipment
A87 009 15 USB−CAN Schnittstelle BCM USB−CAN Interface BCM
Werner
28.06.2004
Seis
28.06.2004
E08 010 17 Blinkleuchte vorne links Indicator, front, lh. MAX. 1,75A
Bauteilliste
E09 010 18 Blinkleuchte hinten links Indicator, rear, lh. MAX. 1,75A
E10 010 19 Blinkleuchte vorne rechts Indicator, front, rh. MAX. 1,75A
E11 010 19 Blinkleuchte hinten rechts Indicator, rear, rh. MAX. 1,75A
E12 010 7 Parkleuchte links Parking light, lh. MAX. 0,42A
E13 010 6 Schlussleuchte links Tail light, lh. MAX. 0,42A
E14 010 7 Parkleuchte rechts Parking light, rh. MAX. 0,42A
E15 010 8 Schlussleuchte rechts Tail light, rh. MAX. 0,42A
E16 010 2 Scheinwerfer links Head light, lh. MAX. 4,6A
E17 010 2 Scheinwerfer rechts Head light, rh. MAX. 4,6A
E23 010 11 Arbeitsscheinwerfer vorne links Working head light, front, lh. MAX. 4,6A
E23 011 18 Arbeitsscheinwerfer vorne links Working head light, front, lh. 4,6A
E25 010 12 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. MAX. 4,6A
E25 011 19 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. 4,6A
E27 010 10 Arbeitsscheinwerfer hinten links Working head light, rear, lh. MAX. 4,6A
E27 011 17 Arbeitsscheinwerfer hinten links Working head light, rear, lh. 4,6A
E28 010 11 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. MAX. 4,6A
E28 011 17 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 4,6A
E29 011 3 Innenleuchte Kabine Inside light, cabin 1,75A
E30 012 13 Heizgeraet Heating unit
E32 011 19 Kennleuchte Warning light 5A
E70 011 15 Nachtleuchte Night lamp 0,83A
E71 011 3 Kontrolleuchte Schalter Heckscheibenheizung indicator light switch rear screen 1,75A
E72 011 16 Beleuchtung Bedienschalter illum. Switches
F67 004 7 Sicherung Steuerung (Potential 30) Fuse, controller (pot.30) 15A
F84 004 9 Sicherung Steuerung (Klemme 54) Fuse, controller (Pin 54) 10A
F95 002 16 Sicherung Motormanagement intern Fuse, engine controller (internal) 15A
FM1 006 6 Platinensicherung Multifuse MULTIFUSE
FM2 006 5 Platinensicherung Multifuse MULTIFUSE
101
H06 010 15 Meldeleuchte Warnblinker Indicator light, hazard light LED ROT
H07 006 16 Warnsummer Betriebsstoerung Warning buzzer, breakdown 0.15A
H14 004 11 Warnsummer Rueckwaertsfahrt Back−up alarm buzzer MAX O,46A
Werner
28.06.2004
Seis
28.06.2004
A80
X1:1 … X1:61
A02 K05
K16 K06
K11
K09 K43
K48
K61
B57
K57
K56
X32:1-12 X34:1-19
CAN 1
A34
Fahrsteuerung
LCD +
CAN 1 Datensammler
+ OPUS 21
A83
Messtechnik Steuerung
CAN 3 BCM
1 05756417
6 05756537
7 3 x 05756540 "R" + 793-501
10 05756537
11 05756540 "R" + 793-501
13 05756537
14 2 x 05756538 "R" + 793-501
18 05756537
19 4 x 05756540 "R" + 793-501
23 05756537
24 4 x 05756540 "R" + 793-501
30 05756537
31 05756540 "R" + 793-501
33 05756537
34 4 x 05756540 "R" + 793-501
39 05756537
40 4 x 05756540 "R" + 793-501
Optional1 : Zeichnungsnummer :
Projektgruppe : Walzenzüge-4 Klemmenleisten
Artikelnummer :
Optional2 : Projekt : Artikelnummer lang :
Zeichnung : Konstrukteur :
Optional3 : Plan : geprüft :
Ort :
Optional4 :
Betriebsmittel : Kabelbäume DH-4 VErsion Lieferadresse: :
Optional5 : ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick
Optional6 : Artikelnummer : 210-112
Bohrungsabmessungen : 5.20 x 25.00 [mm]
Optional7 :
44 05756537
45 05756540 "R" + 793-501
47 05756537
48 05756540 "R" + 793-501
50 05756537
51 05756538 "R" + 793-501
55 05756537
56 3 x 05756540 "R" + 793-501
60 05756537
61 3 x 05756540 "R" + 793-501
65 05756537
66 2 x 05756540 "R" + 793-501
69 05756537
70 3 x 05756540 "R" + 793-501
74 05756537
75 2 x 05756540 "R" + 793-501
78 05756537
79 05756417
Optional1 : Zeichnungsnummer :
Projektgruppe : Walzenzüge-4 Klemmenleisten
Artikelnummer :
Optional2 : Projekt : Artikelnummer lang :
Zeichnung : Konstrukteur :
Optional3 : Plan : geprüft :
Ort :
Optional4 :
Betriebsmittel : Kabelbäume DH-4 VErsion Lieferadresse: :
Optional5 : ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick
Optional6 : Artikelnummer : 210-112
Bohrungsabmessungen : 5.20 x 25.00 [mm]
Optional7 :
Optional1 : Zeichnungsnummer :
Projektgruppe : Walzenzüge-4 Klemmenleisten
Artikelnummer :
Optional2 : Projekt : Artikelnummer lang :
Zeichnung : Konstrukteur :
Optional3 : Plan : geprüft :
Ort :
Optional4 :
Betriebsmittel : Kabelbäume DH-4 VErsion Lieferadresse: :
Optional5 : ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick
Optional6 : Artikelnummer : 210-112
Bohrungsabmessungen : 5.20 x 25.00 [mm]
Optional7 :
Optional1 : Zeichnungsnummer :
Projektgruppe : Walzenzüge-4 Klemmenleisten
Artikelnummer :
Optional2 : Projekt : Artikelnummer lang :
Zeichnung : Konstrukteur :
Optional3 : Plan : geprüft :
Ort :
Optional4 :
Betriebsmittel : Kabelbäume DH-4 VErsion Lieferadresse: :
Optional5 : ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick
Optional6 : Artikelnummer : 210-112
Bohrungsabmessungen : 5.20 x 25.00 [mm]
Optional7 :
1 05756417
6 05756537
7 2 x 05756540 "R" + 793-501
15 05756537
16 05756417
Optional1 : Zeichnungsnummer :
Projektgruppe : Walzenzüge-4 Klemmenleisten
Artikelnummer :
Optional2 : Projekt : Artikelnummer lang :
Zeichnung : Konstrukteur :
Optional3 : Plan : geprüft :
Ort :
Optional4 :
Betriebsmittel : Optionen Beleuchtung Lieferadresse: :
Optional5 : ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick
Optional6 : Artikelnummer : 210-112
Bohrungsabmessungen : 5.20 x 25.00 [mm]
Optional7 :
Optional1 : Zeichnungsnummer :
Projektgruppe : Walzenzüge-4 Klemmenleisten
Artikelnummer :
Optional2 : Projekt : Artikelnummer lang :
Zeichnung : Konstrukteur :
Optional3 : Plan : geprüft :
Ort :
Optional4 :
Betriebsmittel : Optionen Beleuchtung Lieferadresse: :
Optional5 : ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick
Optional6 : Artikelnummer : 210-112
Bohrungsabmessungen : 5.20 x 25.00 [mm]
Optional7 :
1 05756417
5 05756537
6 05756538 "R" + 793-501
7 2 x 05756540 "R" + 793-501
10 05756537
11 2 x 05756540 "R" + 793-501
14 05756537
15 05756540 "R" + 793-501
16 05756538 "R" + 793-501
18 05756537
19 05756540 "R" + 793-501
20 05756539 "R" + 793-501
21 05756537
22 2 x 05756438 "R" + 793-501
24 05756421
25 05756417
Optional1 : Zeichnungsnummer :
Projektgruppe : Walzenzüge-4 Klemmenleisten
Artikelnummer :
Optional2 : Projekt : Artikelnummer lang :
Zeichnung : Konstrukteur :
Optional3 : Plan : geprüft :
Ort :
Optional4 :
Betriebsmittel : Klemmenleiste X2 / Lieferadresse: :
Optional5 : ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick
Optional6 : Artikelnummer : 210-112
Bohrungsabmessungen : 5.20 x 25.00 [mm]
Optional7 :
Optional1 : Zeichnungsnummer :
Projektgruppe : Walzenzüge-4 Klemmenleisten
Artikelnummer :
Optional2 : Projekt : Artikelnummer lang :
Zeichnung : Konstrukteur :
Optional3 : Plan : geprüft :
Ort :
Optional4 :
Betriebsmittel : Klemmenleiste X2 / Lieferadresse: :
Optional5 : ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick
Optional6 : Artikelnummer : 210-112
Bohrungsabmessungen : 5.20 x 25.00 [mm]
Optional7 :
X29
X28 X21
X39 X23 X24 X50
X59 X40 X25 X41
X58 X42 X51 X43 X57
X20
X14
X61
X9
X21
X74 X75 X72
X59 X62
X76
X8
X42 X23 X24 X50 X57
X10
X25 X41 X51
X55
X53
X20
X29 X18
X17 X14
X28 X19 X56 X6 X7
X54 X15 X16
X39
X43
X40
X30
X58 X52 X33
X31 X4 X3
X36 X35 X1 X26
X37 X44 X2 X27
X38 X32 X34 X60
X47
X45
X48 X49
X46 (BVC) (BVC)
X48 X49
X22