BW177-213-226 Series 4 Service Training

Service Training
12/2004 Teile-Nr. 008 099 94

Variocontrol
Single drum roller - 4
BW 177 / 213 / 226 BVC
Service Training
Variocontrol Single Drum Rollers Series 4
Table of contents
Foreword A 1
Documentation A 2
General B 1
Peculiarities B 3
Electric steering C 1
Steering circuit C 2
Steering pump C 4
Steering wheel C 5
Steering valve C 6
Steering angle sensor C12
Trouble shooting C15
Compaction measuring system D 1
BEM D 1
BTM plus D 2
BTM prof. D 3
BVC D 4
BVC - System E 1
Exciter system E 4
Gear pump E 5
Valve block E 7
Swashing motor E 9
Acceleration transducer E 10
MESX-control E 11
BOP E 12
Working principle of the system F 1
Service Training
Variocontrol Single Drum Rollers Series 4
Repair and adjustments G 1
Replacement of swashing motor G 2
Replacement of potentiometer G 3
Potentiometer adjustment G 4
Trouble shooting H 1
Electrics I 1
Service Training
MESX - Service Training
Wiring diagram
Hydraulic diagrams
Service Training
Variocontrol Single Drum Rollers Series 4 - A 1 -
Foreword
Reliable construction equipment is of greatest advantage for all parties involved:
for the customer/user it is a basis for an exact calculation of utilization periods and the completion of
projects as scheduled.
in the rental business it means that the equipment can be reliably used and planned without having
to stock a large number of stand-by machines.
for the manufacturer it means that customers are satisfied, provides him with a good image and gives
him a feeling of confidence.
It is BOMAGs philosophy to design and produce the machines with highest possible reliability. This
aspect of simple and easy maintenance was one of the key issues when developing and designing the
machine:
the location of components in the machine eases maintenance work,
the high quality standard of BOMAG is the basis for the considerable extension of the service and
maintenance intervals.
the After Sales Service of BOMAG, including excellent operating and maintenance instruction
manuals, high quality training courses and on-site machine demonstrations helps the customer to
maintain their machines in good condition over a long period of time.
Permanent training of BOMAGs own service personnel as well as the service personnel of BOMAG
Profit Centres and dealers is therefore a general prerequisite for BOMAGs 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.
Service Training
Variocontrol Single Drum Rollers Series 4 - A 2 -
Documentation
These Variocontrol training documents are valid for the following single drum rollers of series 4:
BW 177 DH-4 BVC
BW 213 DH-4 BVC
BW 213 DH-4 BVC + vibratory plates
BW 226 DH-4 BVC
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.
1. Operating and maintenance instructions
2. Spare parts catalogue
3. Wiring diagram *
4. Hydraulic diagram *
5. Repair instructions
6. Service Information
* The document versions valid at the date of printing are part of this training manual.
Service Training
Variocontrol Single Drum Rollers Series 4 - B 1 -
General
BOMAG VARIOCONTROL (BVC)
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
2. fulfilment of a task according to specification
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.
BOMAG VARIOCONTROL offers the user the following advantages:
1.Automatic adaptation of the emitted compaction energy to the actual compaction status
2. Better, reproducible results on all materials
3.No jump operation and therefore no particle destruction or loosening of material
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.
5.Low vibration loads for driver and environment
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.
Service Training
Part of this new further development is the new display and control element BOP (Bomag
Operation Panel) in connection with the MESX.
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).
BOP ----- Bomag Operation Panel
Service Training
Specialities
All BVC single drum rollers of series 4 are equipped with an electric steering
system as standard.
The hydraulic steering is also available as an option.
Service Training
Variocontrol Single Drum Rollers Series 4 - C 1 -
Electric steering
The electric steering consists of an electronically controlled closed control loop and a hydraulic steering
circuit.
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.
Service Training
Service Training
Hydraulic steering circuit
to charging
06
from
hydr.
tank
to emergency steering
and Vario control valve
MG
Service Training
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.
Pos. Designation Pos. in wiring diagram Pos. in hydraulic
diagram
Measuring values
05 one steering cylinder on BW 177 05
05 two steering cylinders
on BW 213 and 226
05
06 Steering valve with 2 proportional
solenoids and an integrated
accumulator
Y92 / Y93
Page 006
06
07 High pressure filter 12m 07
09 Steering pump and charge pump 09 / MB 200 +/-10 bar
17 additional gear pump 5.5 cm on
BW 177 BVC
17 / MG 80 bar
17 additional gear pump 8 cm on BW
213 and 226 BVC
17 / MG 120 bar
20 High pressure line filter for
Variocontrol 100 m
20
21 Optional emergency steering valve
with 2 B/W solenoids
Y112 / Y113
Page 006
21
Service Training
Steering pump with filter
Steering pressure
Steering pump
Pressure test port
12 m with

Steering circuit
High pressure filter
Pressure differential switc
3,5 bar
Filter outlet
Filter inlet
Service Training
Steering wheel
The small steering wheel is located in the left hand armrest of the driver's seat
diagram
Measuring values
Electric steering wheel A 45
Page 006
VCC 8,5 V
Service Training
Steering valve, electrically proportional
The steering valve, together with the optional emergency steering valve, is located
behind a protection box on the right hand side of the frame under the operator's stand
or the cabin.
to the
Steerin
cylinder
from the

to the charge
system
pump
Service Training
Steering valve
diagram
Measuring values
1 Steering valve port P 06
2 Steering valve port T 06
3 Steering valve ports A and B 06
4 Steering valve, pressure relief valve 06 175 + 25 bar
5 Steering valve, shock valves 06 230 bar
6 Steering valve, accumulator 06 Accumulator
pressure 50bar
7 Steering valve, prop. solenoid Y 93 Page 006 0,4 - 1,2 A
8 Steering valve, prop. solenoid Y 92 Page 006 0,4 - 1,2 A
9 Emergency steering valve B/W
solenoid
Y 113 Page 006 0/12 V
10 Emergency steering valve B/W
solenoid
Y 112 Page 006 0/12 V
1 2
3
4
5
6
7 8
Service Training
Emergency steering valve (option, can only be operated via input code) !!!
9
10
Service Training
BW 177 BVC
diagram
Measuring values
1 Steering valve Y92 / Y93 06
2 Optional emergency steering valve Y112 / Y113 21
3 High pressure line filter 100m in
Vario-circuit
20
1
2
3
Service Training
Piping BW 177
Service Training
BW 213 and 226 BVC
diagram
Measuring values
1 Steering valve Y92 / Y93 06
2 Optional emergency steering valve Y112 / Y113 21
3 Pressure retaining valve,
Variocontrol circuit
22 110 / 99 bar
4 Accumulator for Variocontrol circuit 23 Accumulator
pressure 85bar
5 High pressure line filter 100m in
Vario-circuit
20
5
4
2
1
3
Service Training
Piping BW 213 and 226
Service Training
Steering angle sensor
The steering angle potentiometer is located on the articulated joint BW 177 and BW 213
The steering angle potentiometer is located inside the articulated joint BW 226
Service Training
BW 177 and 213 BVC
Service Training
BW 226 BVC
Service Training
Trouble shooting
The display shows error codes
A detailed description of how to read out the error codes and on the display
can be found in chapter "Electrics" (Service Training "Electrics")
All electric faults are primarily displayed in the display.
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.
Service Training
Procedure:
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.
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BVC-4 Maschinen
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Lenkventil 2 2 1
Lenk- Speisepumpe 1 1 2
Lenkzylinder 3 3 3
Knickgelenk 3 3 2
F E H L E R S U C H E
Service Training
Variocontrol Single Drum Rollers Series 4 - D 1 -
Compaction measuring system for single drum rollers:
BEM
(Bomag E-vib Meter) for circular exciters

!
MESX
Bedienfunktionen
E vib
0
50
150
200
250
E VIB
MN/mm

BMFSA
Beschleunigung
VV / VL 15g
Beschleunigung
VH / VL 15g
Befehle
Neutral
Pos.
D+ Signal
Vibrationspumpe
Stromsignal
S
i
g
n
a
l
e
C
A
N

B
u
s

I
Service Training
BTM prof
(Bomag Terrameter) for circular exciters

!
MESX
Bedienfunktionen
R
S

2
3
2
Drucker
BOP
Beschleunigung
VV / VL 15g
Beschleunigung
VH / VL 15g
Drehzahlsensor
hinten
Neutral
Pos.
D+ Signal
Vibrationspumpe
Stromsignal
S
i
g
n
a
l
e
C
A
N

B
u
s

I
Service Training
BTM plus
(Bomag Terrameter) for circular exciters

!
MESX
Bedienfunktionen
BOP
Beschleunigung
VV / VL 15g
Beschleunigung
VH / VL 15g
Drehzahlsensor
hinten
Neutral
Pos.
D+ Signal
Vibrationspumpe
Stromsignal
S
i
g
n
a
l
e
C
A
N

B
u
s

I
Service Training
BVC
(Bomag Variocontrol) for Vario exciters

!
MESX
Bedienfunktionen
R
S

2
3
2
Drucker
BOP
Lageregelung
Ventil 1 vorn
Lageregelung
Ventil 2 vorn
Beschleunigung
VV / VL 15g
Beschleunigung
VH / VL 15g
Befehle
Erreger
Position vorn
Drehzahlsensor
hinten
Neutral
Pos.
D+ Signal
Vibrationspumpe
Stromsignal
S
i
g
n
a
l
e
C
A
N

B
u
s

I
Service Training
Variocontrol Single Drum Rollers Series 4 - E 1 -
BVC - System
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.
The VARIOCONTROL system consists of the following primary
components:
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
Service Training
BVC Circuit diagram for BW 177 DH-4
Legend from the hydraulic
diagram:
17) External gear pump
5.5 cm
18) Valve block with 80
bar pressure relief valve
19) Swivel drive, variable
displacement motor
20) High pressure line
filter
20
to filter
to steering system
from
tank
to the
tank
rear front
Y141 Y140
Service Training
BVC Circuit diagram for BW 213 / 226 DH-4
Legend from the hydraulic diagram:
17) External gear pump 8cm
18) Valve block with pressure relief valve (120 bar)
19) Swivel drive, variable displacement motor
20) High pressure line filter
22) Pressure override valve (99-110 bar)
23) Accumulator (1.4l, 85bar)
to filter
from
tank
to
Emergency
steering
to the
tank
Steering valve
Y141 Y140
front rear
Service Training
Exciter unit
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.

General design of the VARIOCONTROL - exciter unit
Service Training
Gear pump with high pressure filter
BW 177 BVC
additional
gear pump
for Variocontrol system
Test port input
Variocontrol system
Filter
Input
High pressure
Line filter
Filter
Output
Service Training
BW 213 and 226 BVC
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.
diagram
Measuring values
1 P3 Input 22
2 P5 to valve block 22
3 T 22
4 T 22
5 Pressure retaining valve, opens and
closes
22 110 bar / 99 bar
6 P6 to accumulator 23 Preload pressure
85bar
7 High pressure line filter 22
8 T1 22
9 P4 22
1
2
3
4
6
5
8
9
7
Service Training
Valve block
The valve block has the function of triggering the adjusting motor. It consists of an electrical proportional
valve.
On BW 213 and BW 226 the valve is equipped with an upstream pressure retaining valve.
Assignment of valves to adjusting motor with exciter:
Y140 ---- valve outlet B ----- control Direction vertical forward
Y141 ---- valve outlet A ----- control Direction vertical backward
diagram
Measuring values
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
1
2
3
4
5
6
7
8
9
10
8
11
Service Training
Valve block installation front left and protection housing for electric connections
11 Pressure relief valve BW 213 and
226
18 120 bar
diagram
Measuring values
Potentiometer
Pressure relief valve
Service Training
Under the protection
housing there are the
cable connections for
X 22 - speed sensor
X 47 - potentiometer for swa
X 48 - Acceleration
tranducer front
X 49 - Acceleration
transducer rear
Service Training
Swashing motor
with integrated potentiometer based distance measuring
system
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:
Vertical forward approx. 2 V, Horizontal approx. 4,25 V, Vertical backward
approx. 6,5 V
Swashing motor, principle cross-sectional view (Pleiger)
Service Training
Service Training
Acceleration transducer
The Variocontrol system is equipped with two acceleration transducers arranged one after the other on
the gearbox on the left hand side of the drum. These are mounted under an angle of 45 on either side
of the vertical. These transducer permanently deliver acceleration signals, which form the basis for the
entire control system.
There are two connection assignments
the signal outputs of the transducers:
BW 177 BVC signal brown 20g
BW 213 and 226 BVC signal blue 15g
see wiring diagram, page 008, path 8 and10, B62
Service Training
MESX-control
The MESX-control is located inside the electric junction box, below the ESX-travel control inside the
door of the electrics terminal box. The MESX takes over the function to control the Variocontrol system.
The sticker on the MESX control informs about the installed software version.
A detailed description can be found in the chapter "Electrics", Service
Training MESX.
MESX
Service Training
BOP
Bomag Operation Panel
The operation of the BOP is described in detail in the operating and maintenance instructions!
1 E
VIB
display 11) Rotary switch for mode selection (Automatic/Manual)
2 not used 12) Push button F12 automatic operation
3 Push button F5 START 13) Push button F11 manual operation
4 Push button F6 STOP 14) Rotary switch, manual setting of amplitude direction
5 Push button F7 PRINT 15) Push button F10 vertical effective direction
6 Push button F8 DELETE 16) Push button F9 horizontal effective direction
7 Display of vibration frequency 17) Travel speed display
8 Rotary switch for setpoint adjustment (automatic operation) 18) Amplitude display
9 Push button F14 setpoint increase 19) Optional measuring value printer
10 Push button F13 Setpoint reduction
Service Training
Variocontrol Single Drum Rollers Series 4 - F 1 -
Working principle of system
Die Messung der Bodenkontaktkraft zwischen der Bandage und dem Einbaumaterial
erfolgt durch die beiden Beschleunigungsaufnehmer an der Bandage, die das
dynamische Verhalten kontinuierlich berwachen. Die Beschleunigungssignale, die
aus der dynamischen Wechselwirkung zwischen dem Walzenkrper und der
Unterlage resultieren, werden an die MESX-Steuerung weitergeleitet.
Werden bestimmte Grenzzustnde bzw. Sollzustnde erreicht, wird von der MESX ein
Signal auf die Verstelleinheit gegeben und dadurch die Verdichtungsenergie an den
neuen Einbauzustand angepat.
Signalisieren die Beschleunigungsaufnehmer eine geringe Bodensteifigkeit, schwenkt
das Erregersystem so weit in Richtung der vertikalen Arbeitsrichtung, bis die maximal
mgliche 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, da das VARIOCONTROL-System die maximal
mgliche Verdichtungsenergie automatisch an den jeweiligen Einbauzustand anpat.
Das System mu dabei sehr schnell auf die Steifigkeitsnderungen reagieren. Die
Verstellzeiten von vertikaler zu horizontaler Arbeitsrichtung liegen unter einer Sekunde.
Damit kann das System
1. auf Vernderungen der Bodensteifigkeit unmittelbar reagieren
2. und zerstrende Bewegungen der Bandage verhindern.
Service Training
Variocontrol Single Drum Rollers Series 4 - F 2 -
Vibration parameters
Fr den Verdichtungserfolg ist schon die erste dynamische berfahrt von entscheidender
Bedeutung.
Die VARIOCONTROL Walzenzge sind daher auf besonders hohe Zentrifugalkrfte bzw.
Amplituden ausgelegt. Hierdurch wird eine sehr hohe Verdichtung und eine gute
Tiefenwirkung erzeugt.
Durch die groe Amplitude wrde die VARIOCONTROL Walzenzge frher springen als
Standardwalzenzge gleichen Betriebsgewicht. Durch die Automatik wird aber der
Vertikalanteil der Amplitude dann automatisch zurckgenommen und so ein Springen der
Walze verhindert.
Dichte
BW 177 BW 213 BW 219 BW 225
BVC Standard BVC Standard Standard BVC Standard
Schwingende Masse kg 2440 1970 4800 4250 5500 6630 6300
Zentrifugalkraft kN 189 126/100 365 275/198 326/250 402 330/182
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
0 1 2 3 4 5 6 7
Hochleistungswalze
groe Amplitude
Standardwalze
bergnge
Service Training
Variocontrol Single Drum Rollers Series 4 - G 1 -
Repair and adjustments
Replacement of swashing motor and potentiometer
Swashing motor
Potentiometer
Fastening
screws
Potentiometer
Service Training
Locking screw
horizontal
Locking screw
vertical reverse
Service Training
Replaceing the swashing motor
1. If necessary remove the vibration motor
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.
6. Remove the manual pump
7. Remove the swashing motor
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.
11. Tighten all fastening screws with the specified torque.
Service Training
Service Training
Adjusting the potentiometer
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.
Service Training
5. Switch on the ignition and measure the supply voltage between X2:67 and X2:68 (e.g. U=8,42V).
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.
8. Fasten the potentiometer.
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
This process 1 - 10 must also be performed when changing a potentiometer.
Wiring diagram Bl 008, Pf 11, B61
Service Training
Exciter lock in vertical reverse
Exciter lock in horizontal
Service Training
Variocontrol Single Drum Rollers Series 4 - H 1 -
Trouble shooting
In case of a fault in the Vario system the red triangular lamp lights up.
Show the fault code by pressing button ? followed by button F5
For detail info on reading out fault codes please refer to the chapter "Electrics, Training MESX".
Red fault light
Button F5
Button ?
Status: 06.12.2004 Page 1 of 48
Author: T.Lw / TE
Dateiname: p:\schulung\wz-4\elektrik\englisch\06_12_04\mesx_schulung_v3.00_berndnick_gb.doc
Service Training
Electrics
MESX
Version 3.00
Service Training MESX
Status:06.12.2004 Page 2 of 48
Author: T.Lw / TE
Table cof contents
1 Document updating record................................................................................................................3
2 Software updating record ..................................................................................................................4
3 Known faults......................................................................................................................................5
4 How to proceed when replacing components? .................................................................................6
4.1 How to proceed when replacing an ESX control? .......................................................................6
4.2 How to proceed when replacing a rear axle sensor? ..................................................................6
4.3 Which components can be replaced without a subsequent adjustment procedure? ..................6
4.4 List of machine types...................................................................................................................7
5 Adjustment possibilities on machines without BOP...........................................................................8
5.1 Description of the display module................................................................................................8
5.2 Input of code numbers.................................................................................................................8
5.3 Changing the machine type (only via display module).................................................................9
5.4 Inverting the direction signal (only via display module)..............................................................10
5.5 Changing the bit rate (only with display module) .......................................................................11
6 Adjustment/display possibilities on machines with BOP .................................................................12
6.1 Setting the machine type (BOP) ................................................................................................12
6.2 Inverting the direction signal via the BOP control terminal ........................................................14
6.3 Calling up the diagnostics menu................................................................................................16
6.3.1 Extended diagnose for machines with circular exciter (BTMplus, BTMprof) ................... 18
6.3.2 Extended diagnostics for BVC machines................................................................................ 19
6.4 Changing the printer language ..................................................................................................20
6.5 Setting the machine serial number ............................................................................................22
6.6 Teaching distance impulses ......................................................................................................24
7 Block diagram BEM.........................................................................................................................27
8 Block diagram BTMplus / VARIOCONTROL ..................................................................................28
9 Description of the signals on the ESX-control .................................................................................29
10 Error codes of the ESX control ..................................................................................................34
10.1 Overview ...............................................................................................................................34
10.2 Description of error reactions ................................................................................................35
10.3 Detailed description of fault codes and their possible causes..............................................36
11 Input codes for ESX control (only via BEM display module)......................................................40
11.1 Travel system........................................................................................................................40
11.2 Vibration ................................................................................................................................41
11.3 Light.......................................................................................................................................41
11.4 Acceleration transducer.........................................................................................................42
11.5 Diesel engine.........................................................................................................................42
11.6 Setting the machine type.......................................................................................................43
11.7 Parameter change.................................................................................................................44
12 Terminology in connection with ESX.........................................................................................45
Author: T.Lw / TE
1 Document updating record
Version Date Description of changes resp.
0.00 27.04.2004 Creation of first version Lw
1.00 05.05.2004 ! Block diagrams included
! Description of display module extended
! "Software updating record" included
Lw
1.01 23.07.2004 ! Description of BOP display pages added. Lw
2.00 31.08.04 ! Input code 4602 replaced by code 4606
! Machine type BW219D added
Lw
3.00 15.10.2004 ! Subject "How to proceed when replacing components?"
added
! Description for ESX Pin 0:35 added
! Description of error code 4601 and 4606 corrected
! Description of software version 3.00 added
Lw
Author: T.Lw / TE
2 Software updating record
Version Date Description of changes resp.
1.00 25.03.2004 Creation of version 1.00 Lw
1.01 05.04.2004 ! Printout modified
! Amplitude limitation Automatic limited to 0,3 mm
! Default settings in Automatic changed to "MAX"
Lw
1.02 13.04.2004 ! BW213 BVC implemented
! Printer control modified (Xon, Xoff protocol)
! Software version and revision documented on printout
! Finished criterion extended (2 m of weak spots are
checked)
! Bmfsa code input for DH machines modified
Lw
1.03 05.05.2004 ! Teach mode for travel distance modified (value range
check)
! Finished criterion for polygonal drum deactivated
! 2-stage jump information included
! Self-latching of control at shut down implemented
! Storage of the current adjustment values at shut-down
implemented
! Bmfsa code input for DH machines modified
! BW211 D, BW213 D and BW213 DH implemented
! Interrogation of BOP software version implemented
Lw
1.04 16.04.2004 ! BW226 BVC Polygon implemented
! Max. swashing angle limited to 80
! Max valve current for BW177 limited to 1000mA
Lw
1.05 26.07.2004 ! BW219DH and BW213 BVC Polygon implemented
! Cancellation criterion for while loops added in Evib
calculations
Lw
2.00 31.08.2004 ! Number of machine variants extended to 25 (BW219D)
! Problem with sporadic software crashes eliminated
Lw
3.00 15.10.2004 ! Distance impulse changed to 10m for BW226
! Amplitude limitation in automatic mode realized
! Simulation mode realized
! Change-over metric/imperial realized
! minimum required OPUS version changed to 3.00 (always
the same version as MESX)
Lw
Author: T.Lw / TE
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.
Behaviour of machine Possible cause
During initial start-up the display shows "ct0" Bit rate on bmfsa not set to 125 kBit
=> see "Change bit rate"
Author: T.Lw / TE
4 How to proceed when replacing components?
Each machine is individually adjusted during initial start-up. This is mainly accomplished by setting the
correct machine type (see "4.4 List of machine types", or "6.1 Setting the machine type (BOP)").
The following describes the generally required adjustment measures on the control, if individual
components of the measuring system have to be changed.
4.1 How to proceed when replacing an ESX control?
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!
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 following points after setting the machine type:
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
4.2 How to proceed when replacing a rear axle sensor?
Check the direction signal and invert it if necessary, see 5.4, or 5.4.
4.3 Which components can be replaced without a subsequent
adjustment procedure?
BOP
Exciter adjustment valve block
Printer
Bmfsa display module
All switches in the dashboard
Note: A final function test of the complete machine is highly recommended.
Author: T.Lw / TE
4.4 List of machine types
Since the same control is used for all single drum rollers with the new measuring technology, it is
necessary to adjust the machine type after installing a new control.
This work must be carried out during first time commissioning as well as in case of a spare parts
installation. This setting of the machine type is necessary, because the machines e.g. have different
axle loads or different drum widths and the computation of measuring values needs to be adapted for
this reason. A description of the setting procedure can be found under the items "5.3 Changing the
machine type (only via display module)" or "6.1 Setting the machine type (BOP)".
The following machine types can be set:
Code Machine type Available from version
7500 177 D 1.00
7501 177 DH 1.00
7502 177 PDH not available at present
7503 177 BVC 1.00
7511 179 DH not available at present
7520 211 D 1.03
7530 213 D 1.03
7531 213 DH 1.03
7533 213 BVC 1.02
7534 213 BVC Plates not available at present
7535 213 BVC Polygon 1.05
7550 216 D not available at present
7560 219 D 2.00
7561 219 DH 1.05
7573 226 BVC not available at present
7575 226 BVC Polygon 1.04
Status: 06.12.2004 Functions of the ESX control Page 8 of 48
Author: T.Lw / TE
5 Adjustment possibilities on machines without BOP
5.1 Description of the display module
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).
The following description describes the input of code numbers.
5.2 Input of code numbers
For the diagnostics of control inputs and outputs various code numbers can be entered via the display
module of the control. The input of a code number is performed as follows:
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.
1
5
/
5
4
V
o
r
z
e
i
c
h
e
n
0
5
7
6
6
7
7
2
Author: T.Lw / TE
5.3 Changing the machine type (only via display module)
For simple checking the currently adjusted machine type is displayed for approx. 3 seconds on the
display module of the central electrics when switching the ignition on. It can also be checked at any
time by entering code 7000.
The machine type is set in the following sequence:
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 code 7 0 1 0 .
select and enter the machine from the table above.
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.
Switch the ignition off and on again.
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!
New controls are delivered with a default machine type setting 7 5 0 0 .
Author: T.Lw / TE
5.4 Inverting the direction signal (only via display module)
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.
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").
Author: T.Lw / TE
5.5 Changing the bit rate (only with display module)
The multi-function display can be operated with different CAN-transmission speeds. Operation in our
machines requires the bit rate 125 kBit/s. The bit rate is changed as follows:
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.
Author: T.Lw / TE
6 Adjustment/display possibilities on machines with BOP
6.1 Setting the machine type (BOP)
The machine type is set in the following sequence:
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:
Author: T.Lw / TE
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.
Author: T.Lw / TE
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.
Press key "F1" to call up the screen page "Invert direction signal". The following screen appears:
Author: T.Lw / TE
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.
Press "ESC" to leave the page.
After this check on the printout or in the diagnostics menu whether the travel direction is now correctly
recognized.
Author: T.Lw / TE
6.3 Calling up the diagnostics menu
Press key "F5" to call up the screen page "Diagnose1". The following screen appears:
Author: T.Lw / TE
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).
Author: T.Lw / TE
6.3.1 Extended diagnose for machines with circular exciter
(BTMplus, BTMprof)
4,23 V Ubv: actual voltage of front acceleration transducer
4,24 V Ubh: actual voltage of rear acceleration transducer
98% Small Ampl: Control of solenoid valve for low amplitude in percent
0% Big Ampl: Control of solenoid valve for high amplitude in percent
Direction: Status MESX input travel direction (LED on = 12V)
Ligths: Status MESX input light detection (LED on = 12V)
MD+ Status MESX input MD+ (sensing of engine operation) (LED on = 12V)
Vibration: Status of vibration detection in the MESX (LED on = Vibration ON)
+01234 Distance pulses (10 cm steps) detected by MESX. The actually detected travel
direction can be seen by the roller symbol above.
Author: T.Lw / TE
6.3.2 Extended diagnostics for BVC machines
4,25 V Uexciter: actual voltage exciter position potentiometer
4,23 V Ubv: actual voltage of front acceleration transducer
4,24 V Ubh: actual voltage of rear acceleration transducer
98% Ampl: Control of solenoid valve for vibration pump in percent
Direction: Status MESX input travel direction (LED on = 12V)
Ligths: Status MESX input light detection (LED on = 12V)
MD+ Status MESX input MD+ (sensing of engine operation) (LED on = 12V)
Vibration: Status of vibration detection in the MESX (LED on = Vibration ON)
+01234 Distance pulses (10 cm steps) detected by MESX. The actually detected travel
direction can be seen by the roller symbol above.
Author: T.Lw / TE
6.4 Changing the printer language
Press key "F6" to call up the screen page "Printer language". The following screen appears:
Author: T.Lw / TE
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.
Author: T.Lw / TE
6.5 Setting the machine serial number
Press key "F7" to call up the screen page "Serial number". The following screen appears:
Author: T.Lw / TE
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.
Author: T.Lw / TE
6.6 Teaching distance impulses
The distance impulses for the different machine types have already been set by the setting of the
correct machine type. However, due to slippage of the rear wheels the detected distance measurement
may differ from the actual distance travelled. In this case the distances impulses can be adapted
accordingly.
Note: The distance impulses can only be adapted within the range of +/- 10% of the
previously adjusted value.
Press key "F8" to call up the screen page "Distance impulses". The following screen appears:
Author: T.Lw / TE
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!
Service Training MESX Block diagram
Status: 06.12.2004 Block diagram Page 27 of 48
Author: T. Lw / TE
7 Block diagram BEM
Service Training MESX Block diagram
Status: 06.12.2004 Block diagram Page 28 of 48
Author: T. Lw / TE
8 Block diagram BTMplus / VARIOCONTROL
Service Training MESX Description of signals
Status: 06.12.2004 Description of signals Page 29 of 48
Author: T. Lw / TE
9 Description of the signals on the ESX-control
Notes:
1. Wherever the value of 12 V is mentioned in the following text it refers to the current battery
voltage under due consideration of voltage drops in the lines.
ESX terminal Signal description Nominal values (voltage / current)
X0:1 AGND = Analogue ground: Ground potential for sensors (steering
joystick, speed range switch etc.)
approx. 0 V measured against ground (terminal 31)
X0:2
X0:3 Output Evib display
PWM (max. 2.5 A)
PWM signal (100Hz): " approx. 0..6 V
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
Analogue input / voltage input 0..8.5 V
Acceleration signal (measured against AGND)
Open-circuit voltage (vibration off): " 4,2..4,3 V
X0:8
X0:9 Input exciter position front
Position exciter front (measured against AGND)
Bottom stop " approx. 2,2 V
Neutral position " approx. 4,25 V
Top stop " approx. 6,6 V
Author: T. Lw / TE
X0:10
X0:11
X0:12
X0:13
X0:14
X0:15 Input vibration 1 On
Digital input active high
Vibration on " > 6 V
Vibration off: "approx.0 V
X0:16 Input "START" button (option)
Push button pressed " 12 V
Push button not pressed " 2 V
X0:17 Input "STOP" button (option)
X0:18 Input "PRINT" button (option)
X0:19 Input "CLEAR" button (option)
X0:20
X0:21
X0:22
X0:23 Output voltage supply for sensors
This output supplies steering joystick, travel speed range switch, etc.
Without this voltage the control cannot work correctly and will switch to
override condition (emergency operation).
Nominal voltage = 8,5 V
Permissible range: approx. 7,65..9,35 V
This voltage must be measured against AGND.
X0:24
Author: T. Lw / TE
X0:25
X0:26 Interface CAN-Bus1 Wire -, is used to communicate with the BOP-
operating panel.
Measurement not possible!
X0:27 Interface CAN-Bus1 Wire +, is used to communicate with the BOP-
operating panel.
X0:28 Input potential terminal 15
This signal must be present, so that the control can work.
Control switched on " 12 V
Control switched off "approx.2 V
X0:29 Input acceleration transducer VV/VL15g
X0:30 Input acceleration transducer VH/VR15g
X0:31 Input acceleration transducer VV20g/HR15g
X0:32
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.
Author: T. Lw / TE
X0:36
X0:37 Input D+ generator
Engine running / engine is started " 12 V
Engine not running " 0 V
X0:38 Input vibration 2 On
Vibration on " > 6 V
Vibration off: "approx.0 V
X0:39
X0:40
X0:41
X0:42
X0:43
X0:44
X0:45
X0:46 Output valve 1 front
PWM digital output (max. 4 A)
permissible current range: approx. 0..1,5 A
X0:47 Output valve 2 front
X0:48
X0:49
X0:50
X0:51
X0:52
Author: T. Lw / TE
X0:53 Interface CAN-Bus2 Wire +, is used to communicate with the BCM05. Measurement not possible!
X0:54 Voltage supply for electronics Emergency stop not actuated " 12 V
Emergency stop actuated " 0 V
X0:55 Ground connection electronics 0 V measured against ground
X0:56 Voltage supply for outputs approx. 12 V measured against ground
X0:61
X0:62
X0:63
X0:64
X0:65 Mouse port Baby Boards approx. 0 V
Service Training Error codes of the ESX control
Status: 06.12.2004 Error codes of the ESX control Page 34 of 48
Author: T.Lw / TE
10 Error codes of the ESX control
10.1 Overview
Error code Description of error
4 5 0 1 -
4 5 4 0
Position controller (exciter potentiometer, valves)
4 6 0 1 -
4 6 2 0
8 0 0 0 -
8 2 5 0
Internal software error
Service Training MESX Description of error codes on the ESX control
Status: 06.12.2004 Description of error codes on the ESX control Page 35 of 48
Author: T. Lw / TE
10.2 Description of error reactions
Error reaction Description of error reaction
1 Warning.
Error code is displayed.
Signal light in BOP (option) lights in 5 second intervals.
2 Function affected, the emergency function overrides the faulty function.
3 Partial function faulty, overriding of the partial function by the emergency function is not possible .
After the occurrence of the fault the machine is stopped, after returning the travel lever to neutral the machine can move
again.
The machine can still be driven to a limited extent, but must be repaired by the service department as soon as possible.
4 Partial function faulty, overriding of the partial function by the emergency function is not possible .
The machine is no longer able to drive, e.g. because parts of the travel system are defective
" the diesel engine is shut down.
5 Fatal fault. The function of the control can no longer be guaranteed.
Control is switched off.
Signal light in BOP (option) lights permanently.
Note: Faults with fault reaction 1 are only warnings and are NOT stored in the error log!
Author: T. Lw / TE
10.3 Detailed description of fault codes and their possible causes
Error
code
Description of error Possible cause Terminal
on ESX
Input
code for
diagnose
Error
reaction
4 5 0
1
Input exciter potentiometer front
The voltage applied to the input is below the
specified range (see signal description).
" Wire breakage in current path
" Current path has short circuit to ground
" No voltage supply to potentiometer
" Fuse FM ? has tripped or wire breakage in voltage supply
current path
" Potentiometer defective
X0:09 5
4 5 0
2
Input exciter potentiometer front
The voltage applied to the input is above the
" Current path connected to +12 V / +8,5 V
" Potentiometer not connected to ground
" Potentiometer defective
X0:09 5
Author: T. Lw / TE
Error
code
on ESX
Input
code for
diagnose
Error
reaction
4 5 2
1
Output proportional solenoid front
Valve exciter up
Output current too low.
" Current path has short circuit to voltage supply
" Current path has non-permitted connection to another current
path
" Current path is interrupted
X0:46 2
4 5 2
2
Valve exciter up
Output current too high.
path
X0:46 2
4 5 2
3
Valve exciter up
Fault when calibrating the valve
" Current path has unpermitted connection to another current
path / ground
X0:46 2
4 5 2
6
Valve exciter down
Output current too low.
" Current path has short circuit to voltage supply
path
X0:47 2
4 5 2
7
Valve exciter down
Output current too high.
path
X0:47 2
4 5 2
8
Valve exciter down
Fault when calibrating the valve
" Current path has impermissible connection to another current
path / ground
X0:47 2
Author: T. Lw / TE
Error
code
on ESX
Input
code for
diagnose
Error
reaction
4 5 3
1
Position controller has reached positive limit
The exciter does not move to the desired
direction or does not move at all.
" Supply and ground terminals on exciter potentiometer mixed
up+
" Valves "exciter up" and "exciter down" mixed up
" MD+ input has 12 V potential, even though the engine is not
running
X0:09
X0:37
5 0 0 0
2
4 5 3
2
Position controller has reached negative limit
The exciter does not move to the desired
direction or does not move at all.
" Supply and ground terminals on exciter potentiometer mixed
up+
" Valves "exciter up" and "exciter down" mixed up
" MD+ input has 12 V potential, even though the engine is not
running
X0:09
X0:37
5 0 0 0
2
4 6 0
1
Input acceleration transducer 1
" Current path has no connection to +12 V / +8,5 V
" Current path connected to ground
" Transducer defective
X0:29,
or
X0:31
4 6 0 1
2
4 6 0
2
" Current path not connected to ground
X0:29,
or
X0:31
4 6 0 1
2
4 6 0
6
" Current path has no connection to +12 V / +8,5 V
" Current path connected to ground
X0:30,
or
X0:07
4 6 0 6
2
4 6 0
7
" Current path not connected to ground
X0:30,
or
X0:07
4 6 0 6
2
Author: T. Lw / TE
Error
code
on ESX
Input
code for
diagnose
Error
reaction
8 0 0
0
Error message "BOP Software version incorrect"
The BOP software version is too old, i.e. various
functions cannot be displayed.
This fault cannot be rectified on the machine. The
BOP needs to be replaced.
-
-
2
8 0 0
1 -
8 9 9
9
Error message severe software fault in control
This fault cannot be rectified on the machine. The
control must be immediately replaced.
- - - 5
9 0 0
0 -
9 9 9
8
Error message "Communication via CAN Bus
disturbed"
The modules controlled via the CAN Bus cannot
be addressed by the main control (ESX). The
related machine functions are not available
" Wire breakage in CAN Bus lines
" Short circuit between CAN Bus lines
" One or both CAN Bus line(s) has (have) connection to +12V or
ground
X0:26
X0:27-
- 2
C t 0
Display module has no connection to ESX-
control.
" Wire breakage in CAN Bus lines
" Short circuit between CAN Bus lines
" 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)
X0:26
X0:27
- -
Service Training MESX Description of input codes for the control
Status: 06.12.2004 Description of input codes for the control Page 40 of 48
Author: T. Lw / TE
11 Input codes for ESX control (only via BEM display module)
11.1 Travel system
Input code Description of display function Display values
1 0 0 0
Travel direction sensor
Displays the status of sensor.
0 0 0 0 " 0 V
0 0 0 1 " 12 V
1 0 0 1
Travel direction
Displays the travel direction derived from the "Travel direction sensor"
by the control.
1 0 0 0 " Forward travel detected
0 0 0 0 " Neutral position
0 0 0 I " Reverse travel detected
1 0 0 2
Distance impulse sensor
The accumulated distance impulses since starting the machine are
displayed. If the machine has travelled a greater distance in reverse
than in forward, the displayed value will be negative.
Display value = travel distance in 10 cm
1 0 0 3
Travel speed
Displays the actual speed.
Display value = speed in km/h
1 0 1 0
Parameter "Display distance impulses per 10m"
Eeprom parameter is displayed
Depending on selected machine type, e.g. 5896 at BW177 BVC
1 0 1 1
Parameter "Invert travel direction"
Eeprom parameter is displayed
0 0 0 0 " Direction signal is not inverted
0 0 0 I " Direction signal is inverted
Author: T. Lw / TE
11.2 Vibration
3 0 0 0
Vibration status general
The status of vibration is displayed.
0 0 0 0 " Vibration OFF
0 0 0 1 " Vibration ON
3 0 0 1
Vibration status low amplitude
The status of vibration with low amplitude is displayed.
3 0 0 2
Vibration status high amplitude
The status of vibration with high amplitude is displayed.
11.3 Light
3 0 1 0
Input light switch
The status of the lighting system is displayed.
0 0 0 0 " Light OFF
0 0 0 1 " Light ON
Author: T. Lw / TE
11.4 Acceleration transducer
4 6 0 1
Acceleration transducer 1
Displays voltage for transducer 1.
Display value = voltage in V
4 6 0 6
Acceleration transducer 2
Displays voltage for transducer 2.
Display value = voltage in V
11.5 Diesel engine
5 0 0 0
Input MD+
Displays the status of the diesel engine.
0 0 0 0 " Engine OFF
0 0 0 1 " Engine ON
Author: T. Lw / TE
11.6 Setting the machine type
7 0 0 0
Displays the set machine type see adjustment instructions (page Fehler! Textmarke nicht
definiert.)!
7 0 1 0
Switches on function Set machine type see adjustment instructions (page Fehler! Textmarke nicht
definiert.)!
7 0 1 1
Confirms entered machine type see adjustment instructions (page Fehler! Textmarke nicht
definiert.)!
7 5 0 0 . . 7 5
9 9
Preselection of machine type see adjustment instructions (page Fehler! Textmarke nicht
definiert.)!
Author: T. Lw / TE
11.7 Parameter change
7 6 0 0
Switches on function "Invert travel direction" Display value 7 6 0 0
7 6 0 1
Inverts the actually set travel direction see adjustment instructions (page Fehler! Textmarke nicht
definiert.)!
Status: 06.12.2004 General terminology Page 45 of 48
Author: T.Lw / TE
12 Terminology in connection with ESX
Short circuit
A direct, unwanted connection between two different cables or between machine and cables.
Examples:
Two lines rub against each other until the insulation has worn off.
A conductive line rubs off the insulation at the vehicle ground.
Wire breakage
This generally means that a connection is interrupted. Possible reasons may be:
Line:
torn (not necessarily visible from outside)
chafed
chafed mostly in connection with a short circuit to ground
Terminal, cable lug
loosened, slipped off
broken off,
corroded,
socket / plug faulty

Author: T.Lw / TE
Short circuit to ground
Line, terminal has direct connection to vehicle ground, often in connection with wire breakage
Digital
There are only two permissible states, e.g. switched on or off; lamp on / off; current flows /
does not flow; valve open / closed (black-white valve)
Analogue
In contrast to Digital many conditions are permitted within a certain range. For instance room
temperature 0 to 40; current 4mA to 20mA; voltage 0V to 8,5V; resistance 100 to 300 ;
valve 0% to 100% opened (proportional valve)
Author: T.Lw / TE
Control
Controlling describes the process during which an input value influences a distance (the
value to be controlled), following a fixed command. For this purpose all possible interfering
factors (e.g. temperature, humidity ...) must be known.
Closed loop control
Closed loop control is a process during which a value, the closed loop control value (e.g.
pressure), is continually measured and compared with a nominal value (guide value). The
result of this comparison will affect the closed loop control value, thereby adapting the closed
loop control value to the guide value.
This sequence occurs in a closed circuit, the co-called closed loop control circuit.
Marking Closed loop control Control
Operating path: closed
(closed loop control circuit)
open
(control chain)
Measurement and
comparison of value to
be adjusted:
Value to be adjusted is
measured and compared.
Values to be controlled
are not measured and
compared.
Reaction to faults
(generally):
Counteracts to all faults
targeting the system to be
controlled.
Does not respond to
unknown faults
Technical expense: Low expense:
Measurement of the value to
be controlled, comparison of
nominal and actual value,
power amplification
High expense if many
faults have to be
considered, low expense
if not faults occur.
Performance in
unstable systems
For unstable systems closed
loop controls must be used.
In unstable systems
controls cannot be used.
Author: T.Lw / TE
Current and voltage measurement
Ohms 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.
Override / emergency operation
In the event of a major fault the control will switch off and the override function will take over.
This has the effect that the machine can still be moved and steered with reduced speed.
Steering and dozer blade movements are only possible with a constant speed.
(see also: page 28, "")
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.
Status: 06.12.04 Page 1 of 46
Author: Seis / TE
Dateiname: p:\schulung\wz-4\elektrik\englisch\dez04\esx_schulung_wz4 v1.03_gb.doc
Service Training
Electrics
Single Drum Rollers 4
From -DH Version 1.10
Version 1.03
Service Training WZ-4 from version DH
Author: Seis / TE
Table of contents
1 LIST OF CHANGES............................................................................................. 4
2 SELECTED FAULT REACTIONS OF THE ESX CONTROL............................... 5
3 DESCRIPTION OF FAULT DISPLAY IN THE LC DISPLAY ............................... 7
3.1 Calling up service mode............................................................................................................................ 7
3.2 Entering input codes ................................................................................................................................. 7
3.3 Adjusting the machine type...................................................................................................................... 9
3.4 Changing the steering unit on BVC-4 machines (from version 1.09).................................................. 10
3.5 Teaching the travel direction sensor...................................................................................................... 11
3.6 Automatic detection of surge currents in the travel system................................................................. 11
3.7 Automatic detection of surge currents on steering valves (BVC) ....................................................... 13
3.8 Teaching the electronic end stops of the steering angle sensor (BVC) ............................................... 14
3.9 Driving against the closed brake............................................................................................................ 15
3.10 Showing stored faults.............................................................................................................................. 15
3.11 Deleting all stored faults ......................................................................................................................... 15
4 HOW TO PROCEED WHEN REPLACING COMPONENTS? ........................... 16
4.1 How to proceed when replacing an ESX control?................................................................................ 16
4.2 How to proceed when replacing a travel pump / axle drive motor / drum drive motor?.................. 16
4.3 How to proceed when replacing a steering valve (BVC)? ................................................................... 16
4.4 How to proceed when replacing a steering angle transducer?............................................................ 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
5 DESCRIPTION OF THE SIGNALS ON THE ESX-CONTROL........................... 18
6 DESCRIPTION OF SIGNALS ON THE DATA COLLECTOR............................ 23
7 DESCRIPTION OF SIGNALS ON THE TRAVEL LEVER................................. 25
8 DESCRIPTION OF SIGNALS ON THE LC - DISPLAY ..................................... 27
Author: Seis / TE
9 DESCRIPTION OF SIGNALS ON THE DIOS MODULE (ONLY WITH
OPTIONAL EXTENSION PLATES) ......................................................................... 28
10 FAULT CODES OF THE ESX CONTROL ...................................................... 29
10.1 Overview.................................................................................................................................................. 29
10.2 Description of fault reactions ................................................................................................................. 30
10.3 Detailed description of fault codes and their possible causes ............................................................. 31
11 INPUT CODES FOR ESX CONTROL............................................................. 38
11.1 General ..................................................................................................................................................... 38
11.2 Brake ........................................................................................................................................................ 38
11.3 Travel lever / driving ............................................................................................................................. 39
11.4 Steering .................................................................................................................................................... 41
11.5 Vibration.................................................................................................................................................. 42
11.6 Engine....................................................................................................................................................... 42
11.7 Hydraulics................................................................................................................................................ 42
11.8 Changing the machine code.................................................................................................................... 42
12 TERMINOLOGY IN CONNECTION WITH ESX.............................................. 43
Author: Seis / TE
1 List of changes
No. Date Description of changes resp.
1 23.04.2004 Creation of version 1.00 Werner
2 06.05.2004 Revision, teach functions Fondel
3 11.05.2004 Revision, supplements to version 1.01 Seis
4 24.06.2004 Revision, supplement to version 1.02 Seis
Ver. Date Description of changes resp.
1.03 02.09.2004 ! Jump currents travel drive teach function changed
! Known faults
! Fault - codes revised
! Deactivation of electric steering on BVC machines
! How to proceed when replacing components?
Schroeder,
Fondel
Author: Seis / TE
2 Selected fault reactions of the ESX control
Symbol in fault
message display
Warning
Code output
without buzzer
Warning
Code output
with buzzer
Engine stop
Code output
with buzzer
Engine oil pressure
(from EMR)
5100
5112
1)
5101
5112
2)
after 10s
Coolant temperature
(from EMR)
5100
5116
1)
5101
5116
2)
after 15s
Coolant level
5024
after 5s
5025
after 10s
Engine air filter
5026
after 5s
5027
after 2min
3)
Charge control light
Pre-heating of engine
Brake
ASC
Different fault causes and reaction times.
See fault codes
Hydraulic oil filter
5502
after 5s
5503
after 2min
Water separator on fuel
filter
5028
after 5s
5029
after 2min
Theft warning system
(Option)
Seat contact
(Option)
Fault in air conditioning
(Option)
1)
After reaching the warning limit!
3)
Shut-down currently deactivated by parameter
2)
After reaching the shut-down limit!
Reaktion
Signal
Author: Seis / TE
Known faults
Despite the fault monitoring of inputs and outputs on the ESX control, the ESX control is not able to
detect all faults. The following list contains a selection of known fault reactions of the control, which
mostly have a different cause to the one described in this documentation.
Effect: Cause:
Display stay dark, no voltage PIN in display plug X 28 bent
Status: 06.12.04 Functions of ESX control Page 7 of 46
Author: Seis/ TE
3 Description of fault display in the LC Display
Apart from its normal display function the LC Display is also able to show fault codes, which were
previously visualized by means of a 3-digit fault code display.
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.
3.1 Calling up service mode
For this purpose the display must be switched to service mode via input mode. This is accomplished by
the two yellow information buttons "INFO 1" and "INFO 2" on the back of the travel lever. The green
and blue buttons on the front of the travel lever are used to navigate through the input and service
mode.
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.
3.2 Entering input codes
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.
Navigieren
(blau)
Werte ndern
(grn)
Navigieren
(blau)
Werte ndern
(grn)
INFO 1 Taste
(gelb)
INFO 2 Taste
(gelb)
Author: Seis/ TE
Eingabe - Modus:
Umschaltung Displayfunktion
Einstellungen Display
Plattenverstellung inaktiv!
Bettigen INFO 1
+ INFO 2 ca. 3s
Eingabe
Zugangangscode
9999
Bet. INFO 1 +
INFO 2 ca. 3s
oder Fahrhebel
aus Bremsr.
Normalmodus (Fahrhebel in Bremsraste!)
Aufruf optionaler Anzeigen ber INFO - Taste 1
und INFO - Taste 2
CODE - Eingabe 0000" oder
Zndung aus
Service- Modus:
Eingabe Diagnosecodes
Fehlerspeicher abrufen / lschen
Maschinentypen umstellen
Plattenverstellung inaktiv!
Fahrhebel aus Bremsraste:
Diagnosemodus im Vordergrund aktiv!
Author: Seis/ TE
3.3 Adjusting the machine type
Since the same control is used for all single drum rollers of series DH-4 with electronically controlled
engines (EPA II), it is necessary to adjust the machine type after installing a new control.
This work must be carried out during first time commissioning as well as in case of a spare parts
installation. This type adjustment is absolutely necessary, because the machines have e.g. wheel and
axle drive motors or different tire sizes and therefore different rolling speeds or are equipped with
extension plates or other attachments.
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 .
The following machine types can be set:
72XX
0 1 2 3 4 5 6 7 8 9
0 Default BW 177
DH-4
(Dozer
blade)
BW 177
PDH-4
BW 179
DH-4
BW 179
PDH-4
BW 213
DH-4
BW 213
PDH-4
BW 213
DH-4
USA
BW 213
PDH-4
USA
BW 216
DH-4
DH
1 BW 216
PDH-4
BW 219
DH-4
BW 219
PDH-4
BW 226
DH-4
147kW
BW 226
PDH-4
147kW
BW 226
DH-4
174kW
BW 226
PDH-4
174kW
DH
2 DH
3 DH
4 DH
5 BW 177
DH-4
BVC
BW 213
DH-4
BVC
BW 213
DH-4
BVC w.
plates
BW 226
DH-4
BVC
147 kW
BW 226
DH-4
BVC
174 kW
BVC
6 BVC
7 BVC
8 BVC
9 BVC
EXAMPLE: Machine code for BW 219 PDH-4: 7212
Note: This function can only be activated / deactivated when the travel lever is in brake lock
position. (! !! ! Input mode)
The following method must be used for initial start-up of a control:
Author: Seis/ TE
Control was installed in the machine.
Switch on the machine. After switching on the inscription C O D E is automatically displayed for
approx. 3 seconds. After this the code 7200 appears in the display.
Use the arrow up or down keys to select the correct machine code from the listed codes.
Confirm the selection by pressing the arrow right key.
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.
Enter code number 9 9 9 9 (activation of service mode).
Enter code number 7 0 1 0 . This code number activates the function "Adjusting machine type.
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.
3.4 Changing the steering unit on BVC-4 machines (from version
1.09)
By standard all BVC-4 machines (code 72xx) are equipped with electric steering. If the option
"hydraulic steering" is selected, the electric steering must be deactivated as follows.
Enter code number 9999 (activation of service mode).
Enter code number 2 0 6 0 . This code number activates the function "Adjusting steering unit.
The following code numbers are available to activate the installed steering unit.
Hydraulic steering
2062
Electric steering
2061
The display shows O K
Attention: The steering unit can only be changed when the engine is not running!
Author: Seis/ TE
3.5 Teaching the travel direction sensor
Teaching of the travel direction sensor is required for first commissioning or after replacing a travel
motor. Use the following procedure.
Turn the travel stage switch to "MAX"
Slowly displace the travel lever, until the speedometer shows a reading of approx. 1 km/h.
If one of the two travel direction sensors detects an opposed direction after the machine has
travelled approx. one machine length, fault code 1106 or/and 1116 is displayed. Otherwise no
fault code is displayed. The travel direction detection has now been automatically set.
However, should one of these error messages still be displayed after this measure, there must be
a sensor fault present.
3.6 Automatic detection of surge currents in the travel system
This function sequence is only valid from software version 1.09!
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 9999). 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
1106 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
Author: Seis/ TE
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:
Determination of surge currents
1 0 9 1
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.
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:
Determine surge current for control forward
1 0 9 1
Determine surge current for control reverse
1 0 9 2
After entering one of the above code numbers the measurement 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.
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.
Author: Seis/ TE
3.7 Automatic detection of surge currents on steering valves (BVC)
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:
Example BW 177 BVC:
After entering the respective code numbers the current is increased by the control solenoid in steps of
5 mA, starting from 650 mA.. After each increasing step the system waits for 2 seconds. If a change in
drum angle is measured after the waiting time, the surge current is reached. In order to enhance the
measuring result this measurement is performed three times. The final surge current is the mean value
of these three measurements. This surge current is automatically stored and is valid from the next start
of the machine.
For all other machine types the same procedure is used, however, currents and times will vary.
Before the measurement you must strictly make sure that the steering system is bled, because an air
cushion in the steering cylinders would have a negative effect on the measurement and therefore on
the steering performance of the machine. Sufficient bleeding is achieved by performing a few quick
steering movements at full engine speed.
The automatic measurement of the steering valve surge currents is performed as follows:
The engine must be operated in ECO mode!
Enter code number 9 9 9 9 to 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.
Author: Seis/ TE
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 .
Causes for faults (code 9 9 9 9 ) :
If the standardized values are not within the specified ranges, the steering angle sensor on the
articulated joint needs to be adjusted.
Author: Seis/ TE
3.9 Driving against the closed brake
After entering code number 0 5 0 0 the brake is no longer released. When disengaging the travel
lever out of brake lock position and shifting it to one of the travel directions, the travel pumps will be
actuated in accordance with the selected travel direction. At the same time a warning (fault code
0 5 0 0 ) appears on the display and the warning buzzer is triggered, in order to keep the operator
informed about the condition. The brake control light in the LC-Display remains active.
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.
3.10 Showing stored faults
Switch on function Show stored faults:
Enter code number 0 7 0 0 . This code number enables the function Show stored faults.
The faults stored in the ESX are displayed in flashing mode. If several faults are stored, these are
successively displayed in cycles of 3 second. After the last fault has been displayed, the first fault will
appear again. If no faults are stored in the ESX the display will show "- - - - - "
Switch off function Show stored faults:
Enter code number 0 7 0 1 . This code number disables the function Show stored faults.
Note: Apart from the stored faults the current faults are also displayed.
position. (! Input mode)
3.11 Deleting all stored faults
Execute the function Delete all stored faults:
The engine must not be running!
Enter code number 0 7 1 0 .
All stored function are now deleted.
Note: The stored faults can only be deleted when the engine is not running.
Author: Seis/ TE
4 How to proceed when replacing components?
Each machine is individually adjusted during initial start-up. This adjustment or teaching process is
necessary to make sure that the travel and steering functions are almost identical on all machines.
Background of these adjustment procedures are the tolerances of the components used, e.g. hydraulic
pump for travel system, proportional valves for steering, steering angle sensors and ESX control.
These tolerances apply for both mechanical as well as electrical functions and are unavoidable for
manufacturing reasons.
To enable simple and quick adjustment procedures we have decided to do without expensive tools. All
that is needed is this manual and a bit of time. By following the described procedure it is possible to
take a machine back into operation after the replacement of one of the components specified above
and to re-establish the usual functional quality, with almost any previous knowledge. Even an
incorrectly or incompletely conducted teaching procedure can be repeated without problems as often
as necessary. At the first glance it seems to be at bit awkward to perform this adjustment on every
machine, but this procedure enables the operation of all machines with the same operating software.
At the end of the day this considerably increases the spare parts availability.
4.1 How to proceed when replacing an ESX control?
Since the control stores all teach values of the machine, each teaching procedure must be performed
with the new control after a replacement.
Attention: Before performing one of the following steps you must first 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!
Now you must follow the commissioning instructions.
Electric pre-adjustment (see commissioning instructions chapter 3)
Engine start, heating flange inspection, teaching of travel drive and steering (see commissioning
instructions chapter 4)
Inspection of display and shut-down functions (see commissioning instructions chapter 5)
Inspection of seat contact circuitry (see commissioning instructions chapter 6)
Inspection of travel ranges and vibration (see commissioning instructions chapter 7)
Inspection of ASC function DH-single drum rollers (see commissioning instructions chapter 8)
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.)
4.3 How to proceed when replacing a steering valve (BVC)?
Automatic detection of surge currents of the steering valve (BVC) (see chapter 3.7 Fehler! Es
wurde kein Textmarkenname vergeben.)
4.4 How to proceed when replacing a steering angle transducer?
Teaching electric end positions of the steering angle sensors (see chapter 3.8)
4.5 How to proceed when replacing an front / rear axle sensor?
Teaching the travel direction sensor
Author: Seis/ TE
4.6 Which components can be replaced without a subsequent
adjustment procedure?
Display
Data collector
Joystick
Electric steering wheel
Diesel engine
All switches in the dashboard
Vibration motor
Vibration pump
Note: A final function test of the complete machine is highly recommended.
Service Training WZ 4 Description of signals on the ESX control
Status: 06.12.04 Description of signals on the ESX control Page 18 of 46
Author: Seis/ TE
5 Description of the signals on the ESX-control
Notes:
Wherever the value of 24 V is mentioned in the following text, it refers to the current battery voltage
under due consideration of voltage drops in the lines.
X35:1 AGND = Analogue ground: Ground potential for sensors (steering
angle sensor, steering unit etc.)
X35:2 Output amplitude changeover
Digital output (max. 2.5 A)
active, i.e. high amplitude "approx.12 V
inactive, i.e. low amplitude " 0 V
X35:3 Output warning buzzer
Warning buzzer active "approx.12 V
Warning buzzer inactive " 0 V
X35:4 Interface RS 232 RxD, not used for normal operation. Measurement not possible!
X35:5 Interface RS 232 TxD, not used for normal operation. Measurement not possible!
X35:6 Not used ---
X35:7 Not used ---
X35:8 Not used ---
X35:9 Not used ---
X35:10 Not used ---
X35:11 Not used ---
X35:12 Input axle speed
Frequency input (0....7,5kHz)
Signal changes between approx. 0V and 12V, when machine is driving.
Frequency with travel speed m/min
Machine type:
XX m/min "approx.XX Hz
Machine type:
Machine type:
X35:13 Not used ---
X35:14 Not used ---
Author: Seis/ TE
X35:15 Input seat contact switch
Seat occupied " 0 V
Seat not occupied " ? V
X35:16 Not used ---
X35:17 Input BTS brake (from travel lever)
Release brake "approx.12 V
Apply brake " 0 V
X35:18 Input steering sensor (S1/A)
Signal changes between approx. 0V and 12V, when steering wheel is
turned.
Frequency depends on speed of rotation
X35:19 Input steering sensor (S1/B)
turned.
X35:20 Output steering left
Steering left active " 0,4..1,2 A
Steering left inactive " 0 A
X35:21 Output steering right
Steering right active " 0,4..1,2 A
Steering right inactive " 0 A
X35:22 Output vibration pump for extension plate
PWM current output (max. 4 A)
Vibration pump active " 0,0..2,0 A
Vibration pump not active " 0 A
X35:23 Voltage supply for sensors
This output supplies steering angle sensor and steering unit.
Without this voltage the control cannot work correctly and will switch to
override mode (emergency function).
Nominal voltage = 8,5 V
X35:24 Output Backup alarm
Backup alarm inactive " 0 V
Backup alarm active "approx.12 V
X35:25 Not used ---
X35:26 Interface CAN-Bus 1 Wire -, is used for communication with the
MESX, the data collector, the LC-Display and the BOP.
MEASUREMENT NOT POSSIBLE!
X35:27 Interface CAN-Bus 1 Wire +, is used for communication with the
MESX, the data collector, the LC-Display and the BOP.
X35:28 Input potential terminal 15
This signal must be present, so that the control can work.
Control switched on "approx.12 V
Control switched off "approx.2 V
X35:29 Input steering angle sensor
Position steering angle sensor (measured against AGND)
right hand stop " 0,50..1,00 V
Author: Seis/ TE
straight ahead / neutral / middle " .. V
left hand stop " 6,80..8,70 V
X35:30 Input longitudinal inclination of machine
Inclination of machine (measured against AGND)
-45 axle at top " 0,50..2,49 V
Neutral position " 2,50 V
maximum down " 2,51..4,50 V
X35:31 Input hydraulic pressure travel pump circuit
Analogue input (current input 4mA..20mA) from pressure sensor on
travel pump
0 bar " approx.4 mA
600 bar " approx.20 mA
X35:32 Not used ---
X35:33 Interface CAN-Bus 2 Wire -, is used for communication with travel
lever and engine EMR.
X35:34 Input drum speed
Signal changes between approx. 0V and 12V, when machine is driving.
Frequency with travel speed m/min
Machine type:
Machine type:
Machine type:
X35:35 Input vibration motor
Frequency at vibration frequency in Hz
Machine type:
Vib. frequency XX Hz "approx.XX Hz
Machine type:
Machine type:
X35:36 Input vibration motor sense of rotation
(currently not used)
Sense of rotation forward "approx.12 V
Sense of rotation reverse "approx.2 V
Author: Seis/ TE
X35:37 Input drum sense of rotation
X35:38 Input axle sense of rotation
X35:39 Not used ---
X35:40 Input steering sensor (S2/A)
turned.
X35:41 Input steering sensor (S2/B)
turned.
X35:42 Output emergency steering Emergency steering active "approx.12 V
Emergency steering inactive " 0 V
X35:43 Not used ---
X35:44 Not used ---
X35:45 Not used ---
X35:46 Output drum drive motor
Drum drive motor active " 0,0..2,0 A
Drum drive motor not active " 0 A
X35:47 Output axle drive motor
Axle motor active " 0,0..2,0 A
Axle motor not active " 0 A
X35:48 Output vibration pump
Axle motor active " 0,0..2,0 A
Axle motor not active " 0 A
X35:49 Output travel pump forward
Travel forward active " 0,0..2,0 A
Travel forward inactive " 0 A
Sauer components with EDC
Travel forward active "18..80 mA
Travel forward inactive " 0 mA
X35:50 Not used ---
X35:51 Not used ---
X35:52 Not used ---
Author: Seis/ TE
X35:53 Interface CAN-Bus 2 Wire +, is used for communication with travel
lever and engine EMR.
X35:54 Voltage supply for electronics (permanent voltage) Control running "approx.12 V
Control not running " 0 V
X35:55 Ground connection electronics 0 V (measured against ground)
X35:56 Voltage supply for outputs (permanent voltage) approx. 12 V (measured against ground)
X35:61 Output brake
Digital output (max. 4 A)
Open brake "approx.12 V
Close brake " 0 V
X35:62 Output blower coupling stage 2 (currently not used)
Active "approx.12 V
Inactive " 0 V
X35:63 Output blower coupling stage 3 (currently not used)
Active "approx.12 V
Inactive " 0 V
X35:64 Output travel pumps reverse
Travel forward active " 0,0..2,0 A
Travel forward inactive " 0 A
Sauer components with EDC
Travel forward active "18..80 mA
Travel forward inactive " 0 mA
X35:65 Test connection Baby Boards approx. 0 V
Service Training WZ 4 Description of signals on the data collector
Status: 06.12.04 Description of signals on the data collector Page 23 of 46
Author: Seis/ TE
6 Description of signals on the data collector
Notes:
Wherever the value of 12 V is mentioned in the following text it refers to the current battery voltage
PIN data
collector
Signal description Nominal values (voltage / current)
X26:1 Input direction indicator right
Direction indicator right active "approx.12 V
Direction indicator left active " 0 V
X26:2 Input direction indicator left
Direction indicator left active "approx.12 V
Direction indicator left active " 0 V
X26:3 Input engine running (D+)
Engine running "approx.12 V
Engine not running " 0 V
X26:4 Not used ---
X26:5 Input differential pressure hydraulic oil filter
Digital input active low
Filter clogged " 0 V
Filter OK " ? V
X26:6 Not used ---
X26:7 Input air conditioning
Air conditioning on "approx.12 V
Air conditioning off " 0 V
X26:8 Input engine air filter
Filter clogged " 0 V
Filter OK " ? V
X26:9 Input background illumination
Illumination on "approx.12 V
Illumination off " 0 V
X26:10 Input coolant level
Coolant level too low " 0 V
Coolant level sufficient " ? V
X26:11 Not used ---
X26:12 Ground connection 0V (measured against ground)
X27:1 Not used
X27:2 Input fuel level
Analog input
The voltage signals change with the fuel level in the diesel tank
Fuel tank empty " ?? V
Fuel tank full " ?? V
X27:3 Not used ---
X27:4 Voltage supply for monitoring of the water separation (PIN X27:9) Voltage supply O.K. "approx.12 V
Service Training WZ 4 Description of signals on the data collector
Status: 06.12.04 Description of signals on the data collector Page 24 of 46
Author: Seis/ TE
PIN data
collector
No voltage supply " 0 V
MESX, the ESX, the LC-Display and the BOP.
MESX, the ESX, the LC-Display and the BOP.
X27:8 Voltage supply (permanent voltage) Control running "approx.12 V
Control not running " 0 V
X27:9 Input water separation
Current input
If a sufficient amount of water has been separated a low current flows
through the contacts and the water in the separator bowl. This current is
evaluated in this input.
No water separated " I= 0A
Water separated " I 0,03mA
X27:10 Not used ---
X27:11 Not used ---
X27:12 Not used ---
Service Training WZ 4 Description of signals on the travel lever
Status: 06.12.04 Description of signals on the travel lever Page 25 of 46
Author: Seis/ TE
7 Description of signals on the travel lever
Notes:
PIN Travel
lever
X23:1 Voltage supply (permanent voltage) Electronics working "approx.12 V
Electronics not working " 0 V
X23:3 Output BTS brake
Brake opens "approx.12 V
Brake closing " 0 V
X23:4 Output BTS (not used)
X23:5 Output voltage supply for additional analog evaluations
This output supplies the 24-stage travel speed range switch. Without
this voltage no additional analogue switches can be connected to the
travel lever and evaluated.
Nominal voltage = approx. 5,0 V
X23:6 Interface CAN-Bus 2 Wire +, is used for communication with the ESX
and the engine EMR.
X23:7 Interface CAN-Bus 2 Wire -, is used for communication with the ESX
and the engine EMR.
X23:8 AGND = Analogue ground: Ground potential for additional analog
evaluation
Relation to PIN X23:5
X23:9 Node address addressing 1 Connection to machine ground (0V)
X23:10 Node address addressing 2 Connection to machine ground (0V)
X23:11 Input travel speed range switch
Analog input
The voltage signal changes with the adjusted travel range
Travel stage min. " ?? V
Travel stage max. " ?? V
X23:12 Not used ---
X24:1 Not used ---
X24:2 Input high amplitude High amplitude active "approx.12 V
Service Training WZ 4 Description of signals on the travel lever
Status: 06.12.04 Description of signals on the travel lever Page 26 of 46
Author: Seis/ TE
PIN Travel
lever
Digital input active high High amplitude inactive " 0 V
X24:3 Input low amplitude
Low amplitude active "approx.12 V
Low amplitude inactive " 0 V
X24:4 Not used ---
X24:5 Not used ---
X24:6 Input left hand armrest (not yet realized)
---
X24:7 Output voltage supply for additional digital evaluations
This output supplies the amplitude pre-selection switch. Without this
voltage no additional digital switches can be connected to the travel
lever and evaluated.
Voltage supply active "approx.12 V
Voltage supply inactive " 0 V
X24:8 Output voltage supply ground potential
This output in connection with PIN X24:7 enables the control of
additional components (relay, displays etc.)
0V (measured against ground)
Service Training WZ 4 Description of signals on the LC - display
Status: 06.12.04 Description of signals on the LC - display Page 27 of 46
Author: Seis/ TE
8 Description of signals on the LC - Display
Notes:
PIN Display Signal description Nominal values (voltage / current)
X28:1 Voltage supply (permanent voltage "ignition on") Electronics working "approx.12 V
MESX, the ESX, the data collector and the BOP.
MESX, the ESX, the data collector and the BOP.
X28:5 Voltage supply (permanent voltage "Battery +" for RTC) Electronics working "approx.12 V
X28:6 Not used ---
X29:1 Input frequency adjustment lower
Adjustment active "approx.12 V
Adjustment inactive " 0 V
X29:2 Input frequency adjustment higher
Adjustment active "approx.12 V
Adjustment inactive " 0 V
X29:3 Input engine speed high idle
High idle active "approx.12 V
High idle inactive " 0 V
X29:4 Input engine speed low idle
Low idle active "approx.12 V
Low idle inactive " 0 V
X29:5 Not used ---
X29:6 Not used ---
X29:7 Output voltage supply for additional digital evaluations
This output supplies the engine speed switch and the switch for
frequency adjustment. Without this voltage no additional digital
switches can be connected to the LCD and evaluated.
Voltage supply active "approx.12 V
Voltage supply inactive " 0 V
X29:8 Not used ---
Service Training WZ - 4 Description of signals on the DIOS module
Status: 06.12.04 Description of signals on the DIOS module Page 28 of 46
Author: Seis / TE
9 Description of signals on the DIOS module (only with optional extension plates)
DIOS terminal Signal description Nominal values (voltage / current)
X0:1 Interface CAN-Bus 1 Wire +, is used to communicate with the ESX-
control.
X0:2 Interface CAN-Bus 1 Wire -, is used to communicate with the ESX-
control.
X0:3 Voltage supply for electronics Ignition ON: "approx.12 V
Ignition OFF: " 0 V
X0:4 Input Proximity switch plates middle
Plates in middle position "approx.12 V
Plate outside middle position " 0 V
X0:5 Output plates up
Lifting active "approx.12 V
Lifting inactive " 0 V
X0:6 Output plates down
Lowering active "approx.12 V
Lowering inactive " 0 V
X0:7 Output plate left
Offset left active "approx.12 V
Offset left inactive " 0 V
X0:8 Output plate right
Offset right active "approx.12 V
Offset right inactive " 0 V
X0:9 Voltage supply for outputs Ignition ON: "approx.12 V
Ignition OFF: " 0 V
X0:10 Voltage supply for outputs Ignition ON: "approx.12 V
Ignition OFF: " 0 V
X0:11 Ground connection 0 V measured against ground
X0:12 Input proximity switch plates middle
Plates at top lift point "approx.12 V
Plates lowered " 0 V
X0:13 Output plates floating position
Float position active "approx.12 V
Lifting inactive " 0 V
X0:14 Output plates priority
Priority active "approx.12 V
Priority inactive " 0 V
X0:15 Not used ---
X0:16 Not used ---
Service Training Error codes of the ESX control
Status: 06.12.04 Error codes of the ESX control Page 29 of 46
Author: Seis / TE
10 Fault codes of the ESX control
10.1 Overview
Fault code Fault description
0 0 0 0 -
0 9 9 9
General faults / warnings / machine tests
1 0 0 0 -
1 9 9 9
Fault in travel system
2 0 0 0 -
2 4 9 9
Fault in steering system
2 5 0 0 -
2 9 9 9
Fault in remote control
3 0 0 0 -
4 4 9 9
Fault of work functions (vibration, rotor, dozer blade, chip
spreader)
4 5 0 0 -
4 9 9 9
Fault in measuring systems
5 0 0 0 -
5 4 9 9
Fault diesel engine
5 5 0 0 -
5 9 9 9
Fault hydraulic system
6 0 0 0 -
6 9 9 9
Fault anti-theft warning system, locating system, access system,
time calculation, etc.
7 0 0 0 -
7 4 9 9
Input of machine codes
7 5 0 0 -
7 8 9 9
Input of measuring technology codes
7 9 0 0 -
7 9 9 9
Operating hours, load spectrum, etc.
8 0 0 0 -
8 9 9 9
Severe software fault
9 0 0 0 -
9 9 9 9
Fault of external I/O-nodes (joystick, data collector, Dios-module,
LCD-display, etc.)
Service Training WZ 4 Description of input codes of the control
Status: 06.12.04 Description of input codes of the control Page 30 of 46
Author: Seis / TE
10.2 Description of fault reactions
Fault reaction Description of fault reaction
1 Warning.
Fault code is displayed.
2 Warning.
Audible signal
3 Function affected, the faulty function is replaced by an emergency function.
Audible signal
4 Partial function faulty, the partial function cannot be overridden by an emergency function.
The machine is stopped if this fault occurs.
The machine can still be driven to a limited extent, but must be repaired by the service department as soon as possible.
Audible signal
5 Partial function faulty, the partial function cannot be overridden by an emergency function.
The machine is no longer able to drive, e.g. because parts of the travel system are defective " the diesel engine is shut
down.
Audible signal
6 Fatal fault. The function of the control can no longer be guaranteed.
Control is switched off.
The fault code is displayed, the signal light in the monitoring board is permanently on.
No audible signal!
Note: Faults with fault reaction 1 and 2 are only warnings and are NOT stored in the error log!
Author: Seis / TE
10.3 Detailed description of fault codes and their possible causes
Fault
Code
Fault description Possible causes Terminal
on ESX
Assignment
DH-4 BVC-4
Input
code for
diagnose
Fault
reaction
500 Warning "Driving against brake
The function "Driving against brake is activated
A corresponding input code was entered X
502 Warning "Simulated engine run"
The function "sumulated engine run" is active
504 Warning "Anti-Slip Control (ASC) deactivated"
The function "Anti-Slup Control (ASC)" is deactivated
507 Warning "Drum drive deactivated"
The test mode "drum drive deactivated" was activated.
508 Warning "Axle drive deactivated"
The test mode "axle drive deactivated" was activated.
560 Fault "Overvoltage 8,5V"
The voltage level of 8,5V range is exceeded in an
unacceptable way
(see signal description)
Connection of the voltage level to operating voltage, another
voltage potential or control defective
X
561 Fault "Undervoltage 8,5V"
The voltage level of 8,5V range is fallen short of in an
unacceptable way
(see signal description)
Connection of the voltage level to ground, another voltage
potential or control defective
X
562 Fault "Voltage override relay"
The voltage level of the 8,5V range is...
X
1001 Fault brake valve
The required control power cannot be transmitted to the
control solenoid.
The connecting line from the output of the control to the control
solenoid is interrupted, or
the proportional solenoid is defective
X X
Signal outside the valid range (see signal description)
Cable breakage in ground line, or
the connecting cable valve / ground connection has come loose
X X
Cable breakage in supply line, or
the connecting cable valve / supply has come loose
X X
1004 Fault BTS brake / travel lever
Overheating of the BTS has the effect that the travel lever
brake position is not recognized correctly
Hardware defect on travel lever X X
Author: Seis / TE
Fault
Code
on ESX
Assignment
DH-4 BVC-4
Input
code for
diagnose
Fault
reaction
1005 Fault BTS brake / plausibility
Plausibility conflict when evaluating X- and Y-axes of the
travel lever to the brake contact signal
Hardware defect of travel lever, input X35:17 has not the same
voltage as the BTS
X35:17 X X
1040 Fault travel range switch "ground connection"
the connecting cable switch / ground connection has come
loose
X X
1041 Fault travel range switch "supply connection"
the connecting cable switch / supply has come loose
X X
1042 Fault travel range switch
Increased transition resistance values on contacts may have led
to a falsification of the signal.
The switch needs to be replaced
X X
1070 Fault output "travel pump forward"
proportional solenoid.
The connecting line from the output of the control to the
proportional solenoid is interrupted, or the proportional
solenoid is defective
X X
1071 Fault of current regulator forward X X
1072 Fault of current regulator forward X X
1073 Fault output "travel pump forward"
Supply voltage UB applied at the output to the proportional
valve.
Short circuit in the connecting line (control to prop valve) to
supply voltage
X X
1074 Fault when teaching surge current forward Machine is mechanically blocked
Bypass valves in travel system are deadjusted
1080 Fault output "travel pump reverse"
proportional solenoid is interrupted, or the proportional solenoid
is defective
X X
1081 Fault of current regulator reverse X X
1082 Fault of current regulator reverse X X
1083 Fault output "travel pump reverse"
valve.
supply voltage
X X
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
NOT YET learned. See 3.6
Function "Learning of pump surge currents" for travel pump not
yet executed.
-> New machine/control change
X X Note
1100 Fault output "front travel motor"
proportional solenoid is interrupted, or the proportional
solenoid is defective
X X
Author: Seis / TE
Fault
Code
on ESX
Assignment
DH-4 BVC-4
Input
code for
diagnose
Fault
reaction
1105 Fault front travel motor "speed sensor"
Faulty or non-existent signal "frequency"
Check connecting lines and plugs to the wheel speed sensor or
replace the speed sensor, if necessary
X X
1106 Fault front travel motor "speed sensor"
Faulty or non-existent signal "direction"
X X
1107 Fault output "front travel motor"
valve.
supply voltage
X X
1110 Fault output "rear travel motor"
proportional solenoid is interrupted, or the proportional solenoid
is defective
X X
1115 Fault rear travel motor "speed sensor"
Faulty or non-existent signal "frequency"
X X
1116 Fault rear travel motor "speed sensor"
Faulty or non-existent signal "direction"
X X
1117 Fault output "rear travel motor"
valve.
supply voltage
X X
1140 Fault pressure switch travel system "signal"
The current signal is not transmitted (see signal
specification)
pressure sensor is interrupted, or
The pressure sensor is defective
X X
1141 Fault pressure switch travel system "signal range"
The current signal is outside the permissible range (see
signal specification)
The pressure sensor is defective X X
1142 Fault pressure switch travel system "no pressure"
The current signal indicates that no permanent travel
pressure is built up.
No pressure connection on sensor, of
supply line clogged or
no travel pressure is built up
X X
1145 Fault inclination sensor "supply connection"
the connecting cable sensor / voltage supply has come loose
X X
1146 Fault inclination sensor "ground connection"
the connecting cable sensor / ground connection has come
loose
X X
Author: Seis / TE
Fault
Code
on ESX
Assignment
DH-4 BVC-4
Input
code for
diagnose
Fault
reaction
1300 Seat contact switch not occupied Cable breakage in signal line, or
driver's seat not occupied (driver not seated!)
X X
1500 Warning "dangerous situation ASC" X X
2060 Fault output "steering valve right"
proportional solenoid is interrupted, or
X
2061 Fault output "steering valve left"
X
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
NOT YET learned. See 3.7
(Only machines with electric steering)
Function "Learning of pump surge currents" for steering pump
not yet executed.
(X) Note
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"
Measuring value of sensor 1 and 2 difference too strong
Steering sensor in left hand arm rest defective. X
2172 Fault steering wheel "sensor 1 pulse range"
The detected steering pulses on steering sensor 1 are
outside the valid range (see signal description)
Check connecting line to steering sensor sensor 1,
if necessary change the steering sensor in the left hand arm rest
X
2173 Fault steering sensor "sensor 2 pulse range"
The detected steering pulses on steering sensor 2 are
outside the valid range (see signal description)
Check the connecting lines to the steering sensor sensor 2, or
replace the steering sensor in the left hand arm rest.
X
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
2177 Fault steering wheel "sensor 2 cable damage" Check the connecting lines to the steering sensor sensor 2, or
X
2190 Fault steering "steering angle sensor... initialization"
Fault when initializing the steering angle sensor
Steering angle sensor on articulated joint defective X
2191 Fault steering "steering angle sensorADC" Steering angle sensor on articulated joint defective X
2192 Fault steering "steering angle sensorcable damage
supply"
Voltage supply line to steering angle sensor interrupted or
Steering angle sensor on articulated joint defective
X
2193 Fault steering "steering angle sensorcable damage Ground supply line to steering angle sensor interrupted or X
Author: Seis / TE
Fault
Code
on ESX
Assignment
DH-4 BVC-4
Input
code for
diagnose
Fault
reaction
ground" Steering angle sensor on articulated joint defective
2198 Informative message! Steering stops of the electric
steering NOT YET learned. See 3.8
(Only machines with electric steering)
Function "Learning of steering stops" for electric steering not yet
executed.
(X) Note
2300 Fault "driver's seat armrest lifted" Arm rest is raised or magnetic switch under left hand arm rest
defective
X
2301 Fault "driver's seat armrest"
Cable breakage in signal line, or
magnetic switch under left hand arm rest defective
X
2302 Fault "driver's seat armrest cable damage supply" Voltage supply line to magnetic switch interrupted or
X
2303 Fault "driver's seat armrest cable damage ground" Ground supply line to magnet switch interrupted or
X
3000 Fault vibration sensor "no signal"
The sensor in the vibration motor does not detect any
pulses.
Check connecting lines and plugs to the vibration sensor
or replace the sensor in the vibration motor, if
necessary
X X
3001 Fault vibration pump "valve for low amplitude"
proportional solenoid is interrupted, or the
proportional solenoid is defective, or the changeover
relay / bridge is missing
X X
3002 Fault vib. pump valve low amplitude "hysteresis"
The...
X X
3003 Fault vib. pump valve low amplitude "current range"
Fault in connecting line or connection to another potential (e.g.:
operating voltage)
X X
3004 Fault vibration pump "valve for high amplitude"
the proportional solenoid is defective, or
the change-over relay / bridge is missing
X
3005 Fault vib. pump valve high amplitude "hysteresis"
The...
X
3006 Fault vib. pump valve high amplitude "current range"
Fault in connecting line or connection to another potential (e.g.:
operating voltage)
X
5024 Fault diesel engine warning "coolant filling level" Coolant level too low or sensor defective X X
Author: Seis / TE
Fault
Code
on ESX
Assignment
DH-4 BVC-4
Input
code for
diagnose
Fault
reaction
5025 Fault diesel engine shut-down "coolant filling level" Coolant level too low or sensor defective X X
5026 Fault diesel engine warning "air filter" Air filter soiled or sensor defective X X
5027 Fault diesel engine shut-down "air filter" Air filter soiled or sensor defective X X
5028 Warning water separator Water or other dirt in fuel filter X X
5029 Shut-down caused by water separator Water or other dirt in fuel filter X X
5100 Fault diesel engine EMR "warning lamp" Collective warning
" see other fault codes for exact fault diagnose
X X
5101 Fault diesel engine EMR "red stop light" Collective fault engine shut-down
" see other fault codes for exact fault diagnose
X X
5110 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
X X
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
" Connection between EMR and speed sensor 1 or 2
interrupted
X X
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
5130 Fault diesel engine EMR "oil pressure sensor" " sensor defective
X X
5131 Fault diesel engine EMR "charge air pressure sensor" " sensor defective
X X
5132 Fault diesel engine EMR "charge air temperature" " sensor defective
X X
Author: Seis / TE
Fault
Code
on ESX
Assignment
DH-4 BVC-4
Input
code for
diagnose
Fault
reaction
5133 Fault diesel engine EMR "coolant temperature sensor" " sensor defective
X X
5134 Fault diesel engine EMR "speed sensor" " Speed sensor 1 or 2 defective X X
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"
This warning appears when the machine type has been
changed.
Only change the machine type after appropriate measures have
been applied; e.g. conversion from D to PD (different rolling
circumference of drum)
X X
7012 Fault "conflict machine type"
This fault message is displayed if the set machines do not
comply with the basic parameters of the machine.
The machine type was changed in a way that the type
parameters no longer comply with the basic parameters enter
the correct machine code or a basic parameter of the machine
was changed (e.g. a different axle)
X X
Author: Seis / TE
11 Input codes for ESX control
11.1 General
0 5 0 0
Activation of function "Driving against closed brake" 500 and brake control light stays on when shifting the travel
lever out of the neutral gate
0 5 0 1
Deactivation of function "Driving against closed brake" O K for 3sec. then back to 0000
0 5 5 5
Display of "software version" e.g.: 109" for software version 1.09
0 7 0 0
Activation of function "Show stored faults" Fault codes are successively displayed
0 7 0 1
Deactivation of function "Show stored faults"
0000
0 7 1 0
Delete stored faults once the error log is deleted the display will return to 0000
0 7 2 0
Display of "machine code" The machine code is displayed (72xx) (see chapter 3.6)
11.2 Brake
1 0 0 1
Display of output voltage on output of control "brake valve" Display in V (e.g. 126 corresponds with 12,6V)
Author: Seis / TE
11.3 Travel lever / driving
1 0 2 5
Display "travel lever direction" 100 = forward
0 = neutral
1 = reverse
1 0 2 6
Display "movement direction" 0 = neutral
1 = forward
2 = reverse
1 0 2 7
Display "travel lever enable" 1
1 0 4 0
Display "speed range / gear" The display shows the travel range switch position from 1...24
1 0 4 1
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
1 0 4 2
Display "voltage value for speed range / gear standardized" Stage 1 956
Stage 4 835
Stage 7 716
Stage 10 597
Stage 13 478
Stage 16 357
Stage 19 238
Stage 22 120
Stage 2 916
Stage 5 795
Stage 8 675
Stage 11 557
Stage 14 436
Stage 17 318
Stage 20 200
Stage 23 80
Stage 3 875
Stage 6 756
Stage 9 637
Stage 12 517
Stage 15 396
Stage 18 279
Stage 21 160
Stage 24 40
1 0 4 4
Display "speed range / gear" end value Stage 1 = 417
Stage 4 = 1'667
Stage 7 = 2'917
Stage 10 = 4'167
Stage 13 = 5'417
Stage 16 = 6'667
Stage 19 = 9'167
Stage 22 = 16'667
Stage 2 = 833
Stage 5 = 2'089
Stage 8 = 3'333
Stage 11 = 4'583
Stage 14 = 5'833
Stage 17 = 7'500
Stage 20 = 10'000
Stage 23 = 20'000
Stage 3 = 1'250
Stage 6 = 2'500
Stage 9 = 3'750
Stage 12 = 5'000
Stage 15 = 6'250
Stage 18 = 8'333
Stage 21 = 13'334
Stage 24 = 23'333
1 0 7 0
Display "nominal current travel pump forward 0 1200 mA
1 0 7 1
Display "Actual current travel pump forward Display in mA
Author: Seis / TE
1 0 8 0
Display "nominal current travel pump reverse 0 1200mA
1 0 8 1
Display "actual current travel pump reverse Display in mA
1 0 9 0
Activates Function "detect surge currents in travel system
automatically"
see chapter "Teach travel system surge currents"
1 0 9 1
Function "Determine surge current forward" (only vers.1.07 and 1.08) see chapter "Teach travel system surge currents"
1 0 9 2
Function "Determine surge current reverse" (only vers.1.07 and 1.08) see chapter "Teach travel system surge currents"
1 1 0 6
Display "speed sensor travel motor front / pulses" Counts the pulses up to 99'999 and then starts at 0 again
1 1 0 7
Display "speed sensor travel motor front / direction signal" 2 = forward
1 = standstill and reverse
1 1 0 8
Display "sense of rotation front drive" 1 = forward
0 = standstill
2 = reverse
1 1 1 6
Display "speed sensor travel motor rear / pulses" Counts the pulses up to 99'999 and then starts at 0 again
1 1 1 7
Display "speed sensor travel motor rear / direction signal" 2 = forward
1 = standstill and reverse
1 1 1 8
display "sense of rotation rear drive" 1 = forward
0 = standstill
2 = reverse
1 1 4 0
Display "travel pressure" Display in bar
1 1 4 5
Display "inclination sensor" standardized Incloination display as standardized value (65540 0%)
1 1 4 6
Display "inclination sensor" sensor input voltage Display in mV
0% 2550mV
1 1 4 7
Display "inclination sensor" standardized sensor voltage Inclination display in mV
1 1 4 8
Display "inclination sensor" initialization 1 corresponds with OK
Author: Seis / TE
11.4 Steering
1 3 0 0
Function status arm rest contact 1= arm rest up; 2=arm rest down
1 3 0 1
Voltage of arm rest contact Display in mV
1 3 0 2
Travel operation status by arm rest contact 1=travel enabled; 2= travel disabled
2 0 0 0
activates Function "teach steering start current" see chapter "Determine steering system surge currents"
2 0 0 1
Function "teach steering start current" see chapter "Determine steering system surge currents"
2 0 1 0
activates Function "teach steering potentiometer limits" see chapter "Determine steering system end stops"
2 0 1 1
Deactivates Function "teach steering potentiometer limits"
0000
2 0 1 2
Function "teach steering potentiometer right hand limit" see chapter "Determine steering system end stops"
2 0 1 3
Function "teach steering potentiometer left hand limit" see chapter "Determine steering system end stops"
2 0 6 0
Activates function Change steering unit see chapter "Changing the steering unit
2 0 6 1
Activation of electric steering unit see chapter 3.6
2 0 6 2
Activation of hydraulic steering unit see chapter "Changing the steering unit
2 1 0 0
Display "Nominal current value steering valve right 0 1200mA
2 1 0 1
Display "Actual current value steering valve left Display in mA
2 1 0 2
Display "Nominal current value steering valve left 0 1200mA
2 1 0 3
Display "Actual current value steering valve left Display in mA
2 1 1 0
Display of voltage value from steering angle sensor on articulated joint 0...8,5VDC
2 1 1 2
Steering angle actual position -1000...0...1000
2 1 2 0
Steering angle nominal position -1000...0...1000
2 1 3 0
Steering wheel sensor 1 track 1 absolute pulses Number of total pulses
2 1 3 1
2 1 3 2
2 1 3 3
Steering wheel sensor 1 direction 1=steering wheel steers to the right; 2=steering wheel steers to
the left
2 1 4 0
2 1 4 1
2 1 4 2
2 1 4 3
Steering wheel sensor 2 direction 1=steering wheel steers to the right; 2=steering wheel steers to
Author: Seis / TE
the left
11.5 Vibration
3 0 0 0
Display "switch vibration mode" Off = 0
On = 1
3 0 0 1
Display "Status of vibration relay" 0 = Relay K43 not switched
1= Relay K43 switched
3 0 0 2
Display "Vibration pump valve current"
The actual pump current is displayed.
Display value = mA
11.6 Engine
5 0 2 4
Display "Status engine coolant level" 0= coolant level OK; 1= coolant level too low
5 0 2 6
Display "Status engine air filter" 0= air filter OK; 1= air filter soiled
5 0 2 8
Display "Status water separator" 0= water separator OK; 1= water or dirt in fuel filter
11.7 Hydraulics
5 0 0 2
Display "Status hydraulic oil filter" 0= hydraulic oil filter OK; 1= hydraulic oil filter soiled
11.8 Changing the machine code
7 0 1 0
Change "machine code" see chapter "Changing the machine code
Service Training WZ 4
Author: Seis / TE
12 Terminology in connection with ESX
Short circuit
A direct, unwanted connection between two different cables or between machine and cables.
Examples:
Two lines rub against each other until the insulation has worn off.
A conductive line rubs off the insulation at the vehicle ground.
Wire breakage
This generally means that a connection is interrupted. Possible reasons may be:
Line:
torn (not necessarily visible from outside)
rubbed through
chafed mostly in connection with a short circuit to ground
Terminal, cable lug
loosened, slipped off
broken off,
corroded,
socket / plug faulty

Author: Seis / TE
Short circuit to ground
Line, terminal has direct connection to vehicle ground, often in connection with wire breakage
Digital
There are only two permissible states, e.g. switched on or off; lamp on / off; current flows /
does not flow; valve open / closed (black-white valve)
Analogue
In contrast to Digital many conditions are permitted within a certain range. For instance room
temperature 0 to 40; current 4mA to 20mA; voltage 0V to 8,5V; resistance 100 to 300 ;
valve 0% to 100% opened (proportional valve)
Author: Seis / TE
Control
Controlling describes the process during which an input value influences a distance (the
value to be controlled), following a fixed command. For this purpose all possible interfering
factors (e.g. temperature, humidity ...) must be known.
Closed loop control
Closed loop control is a process during which a value, the closed loop control value (e.g.
pressure), is continually measured and compared with a nominal value (guide value). The
result of this comparison will affect the closed loop control value, thereby adapting the closed
loop control value to the guide value.
This sequence occurs in a closed circuit, the co-called closed loop control circuit.
Marking Closed loop control Control
Operating path: closed
(closed loop control circuit)
open
(control chain)
Measurement and
comparison of value to
be adjusted:
Value to be adjusted is
measured and compared.
Values to be controlled
are not measured and
compared.
Reaction to faults
(generally):
Counteracts to all faults
targeting the system to be
controlled.
Does not respond to
unknown faults
Technical expense: Low expense:
Measurement of the value to
be controlled, comparison of
nominal and actual value,
power amplification
High expense if many
faults have to be
considered, low expense
if not faults occur.
Performance in
unstable systems
For unstable systems closed
loop controls must be used.
In unstable systems
controls cannot be used.
Author: Seis / TE
Current and voltage measurement
Ohms 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)
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.
I
U
R
R
U
I
I R U
=
=
=
Inhaltsverzeichnis:
table of contents:
BW177..226DH4
Blatt Nr.:
sheet no.:
Zeichnungsnummer
drawing no.
Funktionsgruppe function unit
001 582 700 95 Stromlaufplan Circuit Diagram
002 582 700 95 Versorgung, Starten, Hupe supply, starting unit, signal horn
003 582 700 95 Motor Deutz EMR II engine Deutz EMR II
004 582 700 95 Fahrantrieb, Neigungssensor, Sitzkontakt driving system, slope sensor, seat contakt switch
005 582 700 95 Datensammler, LCDisplay datacollector, LCdisplay
006 582 700 95 Lenkung, Vibration steering, vibration
007 582 700 95 Fahrhebel, Vibrationsplatten joystick, vibrationplates
008 582 700 95 Variocontrol, Messtechnik Variocontrol, measurement equipm.
009 582 700 95 Bomag Compaction Management BCM Bomag Compaction Management BCM
010 582 700 95 Beleuchtung und StvZO illumination and StvZO
011 582 700 95 Kabinenausrstung, Beleuchtung, Radio, Tachograph cabinequipment, headlights, radio, tachograph
012 582 700 95 Kabinenheizung, Klimaanlage, Zusatzheizung cabinheater, air conditioning, add. heater
101 582 700 95 Bauteilliste component listing

582 700 95
28.06.2004
001
Seis Stromlaufplan
circuit diagram
001 001

28.06.2004
Werner

582 700 95
28.06.2004
002
Seis

Werner
1 1

Versorgung, Starten, Hupe
supply, starting unit, signal horn
G02
Generator
B+
B
D+
W
S00
Startschalter
30
15 54 58 1917 50a
M01
Starter
30
50
K05
7:3
30
87a 87
B+
2:6
K11

86
85
battery generator
starter
starting swwitch
m
a
i
n

f
u
s
e
M
K61

86
85
K61
2:6
30
87a 87
31

31
3:1

1
2
5
m
A
A
n
z
u
g
s
w
.
:
5
0
A

/

H
a
lt
e
w
.
:
1
0
A

F13
30A

1
2
F95

1
2
K09

86
85
n
u
r

b
e
i

K
l
i
m
a
a
n
l
a
g
e
o
n
l
y

a
c
c
.
t
o

a
i
r

c
o
n
d
i
t
i
o
n
i
n
g
28.06.2004
D+
5:2
Emerg.Stop
h
e
a
t
i
n
g
f
l
a
n
g
e
battery
break switch battery

K11:87
5:1
V01

1 2
S30
Trennschalter Batter
1
2
G03
Batterie
+
G01
Batterie
+
125A 125A
15A
B+
2:11
R19
Heizflansch
1
2
heatingflange
F23

1
2
F05:2
5:8
15A
K11
2:10
30
87
K14
3:19
5
3
S01
NOTAus
21
22
6
:
1
7
11
12
4
:
9
31
32

41
42

51
52

61
62
F00
H
a
u
p
t
s
i
c
h
e
r
u
n
g
1
2
F48
S
i
c
h
e
r
u
n
g

H
e
i
z
f
l
a
n
s
h
1
2
2

x

1
0
q
m
m
X
3
6
:
A
X
3
6
:
B
30
4:1
X1:1
X1:109
X1:110 X1:168 X1:123
X1:15E X1:28E
X1:28A
X1:7 X1:8
X37:B
X38:A
X1:27E
X1:27A
X1:151
X1:152
S01:22
3:1
S03
Taster Hupe
13
14
23
24
B11

1
2
B11
Signalhrer
1
2
V02
1
2
V03

1
2
warning horns
push button, horn
X1:155
X1:97 X1:98
X1:101 X1:102
X1:103 X1:104
15A
F05

1
2
X1:16E
X1:16A
K30
11:1
X
1
:
9
X1:15A
X1:4 X1:3
X37:A
X1:79
D+ MESX
8:2
X1:30E
F39

1
2
K32:86
11:1
X1:30A
15A
X
3
4
:
P
X
1
:
1
0
1
6
7
A
31 EMR
3:5
X3:3
XS
Steckdose
12V
+
socket
Nur bei Gelnder/ROPS/SD
only at handrail/ROPS/sunroof
12:7 2:8 2:16
582 700 95
28.06.2004
003
Seis
28.06.2004
Werner
1 1

Motor Deutz EMR II
engine Deutz EMR II
31
2:20
31
4:1
X
3
0
:
1
X
3
0
:
2
X
3
0
:
1
0
X
3
0
:
1
1
X
3
0
:
1
2
X
3
0
:
1
3
X
3
2
:
A
X
3
2
:
L
X
3
2
:
K
X
3
2
:
H
X
3
2
:
G
X
3
2
:
B
Diagnosestecker EMR
diagnosis interface EMR
X
3
0
:
1
4
A48
Motorsteuerung EMR2
X
5
7
:
9
X
5
7
:
8
B113
EMR Khlmitteltemperatur
1 2
X
5
7
:
2
3
X
5
7
:
2
4
X
5
7
:
2
5
X
3
1
:
2
3
X
3
1
:
2
5
X
3
1
:
2
4
A
G
N
D
S
ig
n
a
l
A
G
N
D
S
ig
n
a
l
D
r
u
c
k
+
5
V
X
3
1
:
2
0
X
3
1
:
2
1
X
3
1
:
2
2
X
5
7
:
2
0
X
5
7
:
2
1
X
5
7
:
2
2
A
G
N
D
S
ig
n
a
l
+
5
V
B88
EMR Motorldruck
1 3 2
X
3
1
:
1
0
X
3
1
:
1
1
X
5
7
:
1
0
X
5
7
:
1
1
A
G
N
D
S
ig
n
a
l
X
3
1
:
1
2
X
3
1
:
1
3
X
5
7
:
1
2
X
5
7
:
1
3
A
G
N
D
S
ig
n
a
l
X
3
1
:
1
4
X
3
1
:
1
5
X
3
1
:
1
7
X
3
1
:
1
8
X
3
1
:
1
9
X
5
7
:
1
4
X
5
7
:
1
5
X
5
7
:
1
7
X
5
7
:
1
8
X
5
7
:
1
9
Y137
EMR Stellglied
5
1 6 2 7
S
T
G
S
T
G
+
R
F
R
F

R
E
F
R
F

M
E
S
S
X
3
1
:
9
m
a
x

7
A
EMR coolant temperature
EMR engine oil pressure
EMR commander
charging air pressure + temperature
sender engine rpm 1
X
3
1
:
2
X
3
1
:
4
X
3
1
:
5
X
5
7
:
4
X
3
1
:
6
X
3
1
:
1
6
X
3
1
:
8
X
3
1
:
7
relay heatingflange
B114
Motordrehzahlsensor
1 2
sender engine rpm 2
X
5
7
:
1
6
X
5
7
:
1
X
5
7
:
6
X
3
1
:
1
X
3
3
:
3
X
3
3
:
5
X
3
3
:
6
X
3
3
:
1
X
3
3
:
2
X
3
3
:
7
Steckerschnittstelle Deutz
connector interface Deutz
X
3
3
:
8
8polig PNEUTRON
S01:22
2:17
S01:22
6:1
B130
Motordrehzahlsensor
1 2
S
ig
n
a
l
T
e
m
p
e
r
a
t
u
r
B115
Ladeluftdruck + Temp
1 2 4 3
CAN2+
4:11
CAN2
4:11
C
A
N

h
ig
h
C
A
N

lo
w
LK
U
b
a
t

X1:95
X1:96 X1:179
X
1
:
1
8
6
X
1
:
1
8
2
X
1
:
1
8
3
X
1
:
1
8
4
X
3
3
:
4
X
3
1
:
3
X
1
:
1
8
0
X
1
:
1
8
1
X1:185
X
3
4
:
N
K14
Relais Heizflansch
2
1
enginecontroller EMR2
E
S
X

F
a
h
r
s
t
.
31 EMR
2:4
2:2
582 700 95
28.06.2004
004
Seis
28.06.2004
Werner
1 1
1
Fahrantrieb, Neigungssensor, Sitzkontakt
driving system, slope sensor, seat contakt switch
X
3
5
:
6
4
L
e
is
t
u
n
g
A34
FahrSteuerung
Y16
Prop.Pumpe Rckw.
1
2
Y17
Prop.Pumpe Vorw.
1
2
X
3
5
:
2
4
4
0
0

.
.
.

1
.
2
0
0
m
A
4
0
0

.
.
.

1
.
2
0
0
m
A
4
0
0

.
.
.

1
.
2
0
0
m
A
4
0
0

.
.
.

1
.
2
0
0
m
A
B60
Sensor Achse
+
dir.
s
p
e
e
d
B59
Sensor Bandage
+
dir.
speed
X
3
5
:
3
8
X
3
5
:
1
2
X
3
5
:
3
7
X
3
5
:
3
4
b
r
s
w
w
s
b
l
R
c
k
f
a
h
r
w
a
r
n
s
u
m
.
b
r
s
w
w
s
b
l
B57
Neigungssensor
+45_G=4,5V
45_G=0,5V +
S
1V
2,5V
4V
N
e
ig
u
n
g
X
3
5
:
5
3
X
3
5
:
3
3
C
A
N
2
+
C
A
N
2
E
le
k
t
r
o
n
ik
X
3
5
:
2
8
30
2:14
30
5:1
15A 10A
X
3
5
:
2
6
X
3
5
:
2
7
F24:2
5:3
CAN2+
3:4
CAN2+
7:6
CAN2
3:4
CAN2
7:6
CAN1
5:8
CAN1+
5:8
S01
2:16
31
32
C
A
N
1
+
C
A
N
1
X1:42
B112
Drucksensor Fahrpumpe
rt sw
X
5
2
:
1
X
3
5
:
3
1
D
r
u
c
k
s
e
n
s
o
r
X1:119 X1:120
pressure sensor drive pump
X
1
:
5
2
X
1
:
5
4
X
1
:
4
8
X
1
:
5
0
X1:17E
X1:17A
X1:34E
X1:34A
X1:146
X1:145
X
1
:
1
7
1
X
1
:
1
7
3
X1:174
X
1
:
1
7
5
X
1
:
1
7
6
X
1
:
1
7
7
X1:178
sender axle sender drum slope sensor
X1:121 X1:122
X16:1
X16:2
X15:1
X15:2
X1:123 X1:123 X1:144 X1:144
X1:143 X1:141
driving controller
s
p
e
e
d
R
ic
h
t
u
n
g
s
p
e
e
d
R
ic
h
t
u
n
g
X
1
:
4
4
X
1
:
4
5
F
a
h
r
p
u
m
p
e

v
o
r
w
.
F
a
h
r
p
u
m
p
e

r
c
k
w
.
B
a
n
d
a
g
e
n
m
o
t
o
r
A
c
h
s
m
o
t
o
r
X
3
5
:
6
5
X
3
5
:
6
6
X
3
5
:
6
7
X
3
5
:
6
8
X
3
5
:
5
5
G
e
h
u
s
e
h
o
u
s
i
n
g
prop.pump forwards
proppump backwards
31
3:20
31
5:1
F67

1
2
F84

1
2
X
3
5
:
3
0
X
3
5
:
4
9
X
3
5
:
5
6
X
3
5
:
5
7
X
3
5
:
5
8
X
3
5
:
5
9
X
3
5
:
6
0
X
3
5
:
5
4
H14
Rckfahrwarnsummer
+
back up alarm buzzer

0
,
4
6
A
LCDisplay, OPUS 21
Fahrhebel EMR Deutz
S06
Sitzkontaktschalter
+
X
3
5
:
1
5
S
it
z
k
o
n
t
a
k
t
X1:158
X1:149
switch, seat contact
X1:114
X1:117
X14:B
X14:A
X
3
5
:
4
6
X
3
5
:
4
7
X
1
:
8
2
X
1
:
1
2
4
X
1
:
1
4
2
X
1
:
1
4
2
X
1
:
1
4
3
X
1
:
1
4
3
prop.Valve drum motor
prop.Valve axle motor
X
1
:
4
7
X
1
:
4
9
X34:A X34:B
X
1
:
5
1
X
1
:
5
3
X34:C X34:D
X
3
5
:
4
R
x
D
X
3
5
:
5
T
x
D
X34:H X34:G
R22
120 OHM

1 2
R23
120 OHM

1 2
R20
120 OHM

1 2
R21
120 OHM

1 2
X9:1
X9:2

Diagnosestecker Fahrzeug
diagnosis interface equipment
X1:34A
8:2
DIR MESX
8:2
SPEED TAC
11:6
SPEED MESX
8:2
X1:46
PITCH MESX
8:2
X
5
2
:
2
Y30
Prop.Ventil Bandagenmotor
1
2
Y31
Prop.Ventil Achsmotor
1
2
X1:2
X1:172
X1:55
6:4
582 700 95
28.06.2004
005
Seis
28.06.2004
Werner
1 1

Datensammler, LCDisplay
datacollector, LCdisplay
30
4:20
30
8:1
31
4:20
31
6:1
B03
L
u
f
t
f
i
l
t
e
r
P
1
2
h
y
d
r
a
u
l
i
c

o
i
l

f
i
l
t
e
r
a
i
r

c
l
e
a
n
e
r
c
o
o
l
a
n
t

s
t
o
c
k

l
e
v
e
l
B55
K
h
l
m
i
t
t
e
l
v
o
r
r
a
t
Q

B21
H
y
d
r
a
u
l
i
k
l
f
i
l
t
e
r
P
1
2
datacollector
D+
2:6
B124
W
a
s
s
e
r
a
b
s
c
h
e
i
d
e
r

CAN1+
4:17
CAN1+
7:14
CAN1
4:17
CAN1
7:14
w
a
t
e
r
s
e
p
e
r
a
t
o
r
K11:87
2:20
K11:87
7:14
R03
0

.
.

6
7

O
H
M
F
l
l
s
t
a
n
d

D
i
e
s
e
l

f
u
e
l
l
e
v
e
l
F24

1
2
15A
X
2
6
:
1
X
2
6
:
5
X
2
6
:
6
X
2
6
:
8
X
2
6
:
1
0
X
2
6
:
1
1
X
2
6
:
1
2
X
2
7
:
1
X
2
7
:
2
X
2
7
:
3
X
2
7
:
4
X
2
7
:
5
X27:8
X
2
7
:
9
X
2
7
:
1
0
X
2
7
:
1
1
X
2
7
:
1
2
A80
Datensammler
D
I
N
1
D
I
N
2
D
I
N
3
D
I
N
4
D
I
N
5
D
I
N
6
D
I
N
7
D
I
N
8
D
I
N
9
D
I
N
1
0
D
I
N
1
1
G
N
D
A
I
N
1
U
I
N
1
G
N
D
/
U
I
N
3
S
e
p
a
1
G
N
D
C
A
N
1

h
ig
h
C
A
N
1

lo
w
V
C
C
S
e
p
a
2
U
I
N
3
U
I
N
2
A
I
N
2
X
2
7
:
6
X
2
7
:
7
F24:2
4:3
F24:2
6:15
A81
LCDisplay
LCdisplay
X
2
8
:
3
X
2
8
:
4
X
2
8
:
1
X
2
8
:
2
X
2
8
:
5
C
A
N
1

lo
w
n
o
t

c
o
n
n
e
c
t
e
d
U
b

"
1
5
"
C
A
N
1

h
ig
h
G
N
D
U
b

"
3
0
"
F05:2
2:17
F05:2
2:17
X
2
9
:
7
U
b

o
u
t
X
2
9
:
5
X
2
9
:
6
X
2
8
:
6
X
2
9
:
8
n
o
t

c
o
n
n
e
c
t
e
d
D
I
N
1
D
I
N
2
D
I
N
4
D
I
N
3
D
I
N
5
D
I
N
6
S120
Schalter Motordrehzahl
23
24

14
13
switch enginerpm mode switch frequencycontrol
Low

down
X1:29E
X1:29A
X
1
:
3
9
X
1
:
4
0
X1:87 X1:88 X1:80 X1:86
X1:82
X1:107 X1:108
X8:1
X8:2
X1:154
X10:2
X10:3
X1:105
X1:117 X1:149
X21:1
X21:2
X1:94 X1:94 X1:117
X1:106 X1:111 X1:112
BEL
10:4
KLIMA
12:6
ESX Fahrsteuerung DIOS Platten
X
2
6
:
7
X
2
6
:
9
X
2
6
:
3
X
2
6
:
4
BL
10:17
BR
10:17
X
2
9
:
2
X
2
9
:
1
X
2
9
:
3
X
2
9
:
4
X34:R
X
2
6
:
2
X
1
:
4
1
Steckerfarbe: X26grau; X27schwarz
connectorcolour: X26grey; X27black
High
ECO
up
S139
Schalter Frequenzverstellung
23
24

14
13
TS022
582 700 95
28.06.2004
006
Seis
28.06.2004
Werner
1 1

Lenkung, Vibration
steering, vibration
A34
FahrSteuerung
X
3
5
:
2
1
X
3
5
:
2
0
X
3
5
:
3
31
5:20
31
7:1
K43

86
85
X
3
5
:
4
0
X
3
5
:
4
1
X
3
5
:
2
9
X
3
5
:
1
8
X
3
5
:
4
8
X
3
5
:
1
9
K43 6:12
30
87a 87
P
r
o
p
.

o
u
t
W
a
r
n
s
u
m
m
e
r
4
0
0

.
.
.

1
.
2
0
0
m
A
4
0
0

.
.
.

1
.
2
0
0
m
A
4
0
0

.
.
.

1
.
2
0
0
m
A
L
e
n
k
w
in
k
.
B65
Lenkwinkelsensor

+
S
B16
Aufnehmer Vibrationsmotor
+

X22:1
br
bl
sw
ws
X
3
5
:
3
5
V
ib
.

F
r
e
q
u
e
n
z
V
ib
.

R
ic
h
t
u
n
g
A45
Lenkeinheit
S1
S2
VCC
VCC
0V
0V
B
B
A
A
B
T
S

B
r
e
m
s
e
X
3
5
:
1
7
X
3
5
:
2
U
m
s
c
h
.

A
m
p
lit
u
d
e
X
3
5
:
6
1
B
r
e
m
s
e
solenoid valve brake
warning buzzer, failure
prop. valve steering left
prop. valve steering right
prop. valve vibration small
prop. valve vibration big
A
G
N
D
X
3
5
:
2
3
8,5V
X1:82
X
1
:
1
8
8
X
1
:
1
8
9
X22:2
X22:4
X1:187
X1:190
K48 7:2
30
87a 87
X1:117
X1:147
S01
2:16
11
12
X1:113
X1:150
X1:115 X1:116
X
1
:
2
0
2
X
1
:
2
0
3
X1:196 X1:195
X1:197 X1:197
X1:118
S1
X
1
:
2
0
8
X
1
:
2
0
6
X
1
:
2
0
5
X
1
:
2
0
7
X
4
1
:
6
X
4
1
:
8
X
4
1
:
5
X
4
1
:
7
X1:148
steering unit
steering angle sensor
sensor vibration motor
X
5
1
:
3
X35:16
6:9
X43:1
X39:3
X1:149
H07
Warnsummer Strung
+

X
1
:
5
5
n
u
r

B
V
C
o
n
l
y

B
V
C
S01:22
3:20
S01:22

X1:41
F24:2
5:20
F24:2

X
3
4
:
J
X6:2
X6:1 X7:1
X7:2
X22:3
VIB
11:6
BRAKE MESX
8:2
X
1
:
4
2
BTS BREMSE
7:2
K56
6:8
30
87a 87
K57
6:9
30
87a 87
X1:199 X1:198
X1:200 X1:200
K56

86
85
K57

86
85
X
3
5
:
2
5
emerg. valve steering left
emrg. valve steering right
X23:1
7:1
X35:16
6:2
X
3
5
:
1
6
X
3
5
:
2
2
X35:22
7:14
X1:201
F
M
5

1
2 X
1
:
6
1
X
1
:
6
0
Y08
Prop.Ventil Vibration klein
1
2
Y07
PropVentil Vibration gro
1
2
X
1
:
5
8
X
1
:
5
6
F
M
2

1
2
F
M
1

1
2 X
1
:
5
9
X
1
:
5
7
X41:1
X41:3
X39:1
X40:1
X41:4
X41:2
X40:4
X39:4
X1:159
X1:162
X43:2
X
5
1
:
2
X51:1
X1:161
X1:160
X
3
5
:
1
X40:3
X40:2
X39:2
Y113
Notlenkung links
1
2
Y112
Notlenkung rechts
1
2
Y04
Magnetventil Bremse
1
2
driving controller
Y93
Prop. Ventil lenken links
1
2
Y92
Prop. Ventil lenken rechts
1
2
A
r
m
le
h
n
e
P
u
m
p
e

V
ib
.
P
la
t
t
e
n
B132
S
c
h
a
l
t
e
r

A
r
m
l
e
h
n
e
S
i
g
.
a
r
m
r
e
s
t
s
w
i
t
c
h
1
5
0
m
A
m
a
x
.
1
.
8
A
X1:154
GA MESX
8:2
X1:38
X1:37
X1:89
KA MESX
8:2
Anbau 177DH: h.r.
Anbau 213DH: oben
Anbau 177DH: h.l.
Anbau 213DH: unten
X1:55
4:6
6:3 6:4 6:14
TS022
582 700 95
28.06.2004
007
Seis
28.06.2004
Werner
1 1

Fahrhebel, Vibrationsplatten
joystick, vibrationplates
S55
Fahrhebel

Stecker X23
Stecker X24
1
3
4
2
9
10
7
6
5
8
11
12
1 2 3 4 5 6 7 8
CAN2+
4:17
CAN2
4:17
K48
86
85
K05

86
85
X
1
:
1
5
7
X
1
:
1
5
6
X1:153
X1:149
S35
Schalter Amplitude
13
14
23
24
Taster 1 = Platten rechts
push button 1 = plates right
Taster 2 = Platten heben
push button 2 = lift plates
Taster 3 = Vibration EIN/AUS
push button 3 = vibration ON/OFF
Taster 4 = Platten links
push button 4 = plates left
Taster 5 = platten senken
push button 5 = lower plates
Taster 7 = Infotaste 1
push button 7 = info button 1
Taster 8 = Infotaste 2
push button 8 = Info button 2
4
3
7
8
Ub in
0V in
BTS zus. +5V out
CAN+
CAN
0V (Ref PIN5)
Add1
Add2
AK Ext1
AK Ext2
D
K

E
x
t
1
D
K

E
x
t
2
D
K

E
x
t
3
D
K

E
x
t
4
D
K

E
x
t
5
D
K

E
x
t
6
U
b

o
u
t
O
V

o
u
t
BTS Bremse Bremse auf = Ub
Bremse zu = 0V
travel lever
speed range selector
K0G
switch amplitudes
1
2
5
31
6:20
31
8:1
X23:1
6:2
BTS BREMSE
6:18
S139
Frequenzverstellung Platten
S +
freq. adjust plates
S09
Schalter Vibration Ein/Aus
13
14
switch vibration on/off
Nur bei BVC
Only at BVC
S64
Schalter Schwimmstellung Platten
13
14
S36
Schalter Betriebsart Platten
13
14
S42
Fahrstufenschalter
S
+
X
2
5
:
3
X
2
5
:
2
X
2
5
:
4
sw. swimming pos. plates
modesw. plates
X
5
0
:
3
X
5
0
:
2
X
5
0
:
1
CAN1+
5:14
CAN1+
8:16
CAN1
5:14
CAN1
8:16
K11:87
5:20
K11:87
8:1
X35:22
6:11
Y98
PropPumpe Platten
1
2
prop.valve plates
A54
Platten Steuerung

Y122
MV Platten heben
1
2
Y142
MV Platten links
1
2
Y144
MV Platten Schwimmst
1
2
Y123
MV Platten senken
1
2
Y143
MV Platten rechts
1
2
Y145
MV Platten Prioritt
1
2
plates up
plates down
plates left
plates right
plates floatpos.
plates priority
X1:31E
F145

1
2
X1:31A
B135
Nherungssch. Platten Mitte
+
S
B134
Nherungssch. Platten oben
+
S
sensor plates centered
sensor plates up
X1:209
platecontroller
ESX Fahrst. LCDisplay BTM
15A
nicht bei BVC
not at BVC
X72:1
X72:2
X
6
2
:
4
X62:12
X
6
2
:
3
X
6
2
:
9
X
6
2
:
1
0
X
6
2
:
1
X
6
2
:
2
X
6
2
:
1
1
X
6
2
:
5
X
6
2
:
6
X
6
2
:
8
X
6
2
:
1
3
X
6
2
:
1
4
X
6
2
:
7
4
0
0

.
.

1
.
2
0
0

m
A
X
1
:
2
1
4
X
1
:
2
1
3
X1:211 X1:212
X1:210
2:12 6:17
TS022
582 700 95
28.06.2004
008
Seis
28.06.2004
Werner
1 1

Variocontrol, Messtechnik
Variocontrol, measurement equipm.
X
4
4
:
4
7
X
4
4
:
2
9
A
u
f
n
.

v
o
r
n
e

1
5
g
X
4
4
:
3
3
X
4
4
:
5
3
X
4
4
:
4
6
X
4
4
:
5
6
X
4
4
:
5
7
X
4
4
:
5
8
X
4
4
:
5
9
X
4
4
:
6
0
X
4
4
:
5
4
L
e
is
t
u
n
g
P
r
o
p
.
E
le
k
t
r
o
n
ik
measurement calc. unit
P
r
o
p
.
CAN3 CAN3+
CAN1
31
7:20
31
9:1
X2:75
X2:76
X2:73
X2:74
solenoidvalve exciter up
solenoid valve exciter down
B62
Beschleunigungssensoren
+
/
s
w
/gg
15g/bl
2
0
g
/
b
r
X
4
4
:
3
1
A
u
f
n
.

v
o
r
n
e

2
0
g
B62
Beschleunigungssensoren
+
/
s
w
/gg
15g/bl
2
0
g
/
b
r
X
4
4
:
3
0
A
u
f
n
.

h
in
t
e
n

1
5
g
X
4
4
:
7
A
u
f
n
.

h
in
t
e
n

2
0
g X2:54 X2:55 X2:58 X2:59
X48:3 X48:4 X49:3 X49:4
X
4
4
:
9
E
r
r
e
g
e
r
p
o
s
.
P11
Drucker

RxD
X
4
4
:
5
TxD CAN1+
P33
Display Messtechnik BOP

X2:50 X2:51
X
4
2
:
4
X
4
2
:
6
X
4
2
:
7
X
4
2
:
8
X
4
2
:
3
X
4
2
:
5
X
4
2
:
2
X
4
2
:
1
X
4
4
:
1
A
G
N
D

M
E
S
X
P07
EVIBMeter
+
E
VIB
E
V
I
B
X
4
4
:
2
3
8
.
5
V
X
4
4
:
2
8
P
o
t
.

1
5
X2:57
X1:34A
4:9
G
N
D
X
4
4
:
5
5
X2:60
X1:35A
X1:35E
X
4
4
:
6
5
X
4
4
:
6
6
X
4
4
:
6
7
X
4
4
:
6
8
X2:63 X2:66
30
5:20
30
10:1
CAN1+
7:20

CAN1
7:20

GA MESX
6:15
X
4
4
:
3
8
SPEED MESX
4:3
X
4
4
:
3
5
X
4
4
:
1
4
DIR MESX
4:3
X
4
4
:
3
2
PITCH MESX
4:8
X
4
4
:
3
6
X
4
4
:
3
7 A83
MesstechnikRechner
X
4
4
:
4
1
BRAKE MESX
6:17
D+ MESX
2:6
GND
X2:77
FM4

1
2
X2:78
B61
Aufnehmer Verstellmotor

S/ws
+/rt
/
s
w
X2:68
Pot 15
X48:2 X48:1 X49:2 X49:1
X2:56 X2:53 X2:60 X2:57
Pot 30
acc. sensor front acc. sensor rear
sens. adjust. motor
printer
EVIBmeter
X2:69
X47:A X47:B
X47:C
X2:67
F146

1
2
Y140
PropVentil Erreger auf
1
2
Y141
PropVentil Erreger ab
1
2
X1:82
X
4
4
:
3
X1:85
15A
D
I
O
S

P
la
t
t
e
n
display measurem. BOP
KA MESX
6:15
X
4
4
:
1
5
BEL MESX
10:4
v
.
l.
v
.
r
.
F148

1
2
10A
X1:32E
X1:32A
K11:87
7:20
K11:87
10:1
X2:71
X2:66
X2:70
X
4
:
C
X
4
:
D
X
4
:
E
X
4
4
:
4
X2:64 X2:65
X4:A X4:B
X
7
4
:
3
X
7
4
:
5
X
7
4
:
4
X74:1 X74:2
P16
Bedieneinheit BEM
F1 F2
+
C
A
N
+
C
A
N
n
u
r

b
e
i

B
E
M
o
n
l
y

a
t

B
E
M
R21
120 OHM

1 2
R20
120 OHM

1 2
X
4
4
:
2
7
X
4
4
:
2
6
n
u
r

b
e
i

B
T
M
+
/
B
T
M

p
r
o
f
o
n
l
y

a
t

B
T
M
+
/
B
T
M

p
r
o
f
n
u
r

b
e
i

B
T
M

p
r
o
f
o
n
l
y

a
t

B
T
M

p
r
o
f
X
2
:
4
7
X2:48 X2:49
3
1
.
1
8
:
2
0
3
1
.
1
8
:
1
9
controlunit BEM
CAN3
9:15
CAN3+
9:15
F148:2
9:15
0
.
.
6
V
D
C
4
0
0

.
.

1
.
2
0
0
m
A
4
0
0

.
.

1
.
2
0
0
m
A
TS022
582 700 95
28.06.2004
009
Seis
28.06.2004
Werner
1 1

Bomag Compaction Management BCM
Bomag Compaction Management BCM
CAN3 CAN3+ R24
120 OHM

1 2
R25
120 OHM

1 2
X2:63
BCM 05 BCM 05
nur bei BCM
only at BCM
CAN3+
8:18
CAN3
8:18
X2:61 X2:62
31
8:20
31
10:1
X4:N X4:M
X75:7 X75:2
USBCAN Interface BCM
X76:1
X76:2
X4:F
X4:G
X2:70
F148:2
8:4
P15
BCM 05
A87
USBCAN Schnittst.
582 700 95
28.06.2004
010
Seis
28.06.2004
Werner
1 1

Beleuchtung und StvZO
illumination and StvZO
31
9:20
31
11:1
K11:87
8:3
K11:87

E17
Scheinwerfer rechts
1
2
E16
Scheinwerfer links
1
2
K16
10:9
30
87a 87
S15
Schalter StvZO
31
32
11 23
12 24
K16

86
85
K06

86
85
0 1 2
4
,
6
A
4
,
6
A
0
,
1
2
5
A
15A 10A
0
,
1
2
5
A
head light LH
head light RH
s
w
i
t
c
h
,

w
o
r
k
i
n
g

h
e
a
d

l
i
g
h
t
s
switch, StvZO
30
8:19
30

F11

F18

F07

E13
Schluleuchte links
1
2
E12
Parkleuchte links
1
2
E14
Parkleuchte rechts
1
2
E15
Schluleuchte rechts
1
2
F09

F10

L 0 R
L0R
0
,
4
2
A
0
,
4
2
A
0
,
4
2
A
0
,
4
2
A
1
,
7
5
A
1
,
7
5
A
1
,
7
5
A
1
,
7
5
A
15A
15A
15A
switch indicator
indicator front, RH
indicator rear, LH
indicator front, LH indicator rear, RH
tail light, LH
parking light, LH
parking light, RH
tail light, RH
F08

15A
E08
Blinkleuchte VL
1
2
E09
Blinkleuchte HL
1
2
E10
Blinkleuchte VR
1
2
werfer ohne StvZO
connection working head
lights without StvZO
Anschlu Arbeitsschein
BL
5:9
BR
5:9
E11
Blinkleuchte HR
1
2
S37
Schalter Blinker
13
14 24
23
A02

31
30
82 L R
49L 49R
S14
Warnblinkschalter
13
14 24
23
H06
Bel. Warnbinkschalter
+
0 1
0 1
switch, hazard light
illumination, switch hazard light
E25
A
r
b
e
i
t
s
s
c
h
e
i
n
w
e
r
f
e
r

v
o
r
n
e

r
e
c
h
t
s
1
2
E23
A
r
b
e
i
t
s
s
c
h
e
i
n
w
e
r
f
e
r

v
o
r
n
e

l
i
n
k
s
1
2
E27
A
r
b
e
i
t
s
s
c
h
e
i
n
w
e
r
f
e
r

h
i
n
t
e
n

l
i
n
k
s
1
2
bei Kabine
Connection head lights
E28
A
r
b
e
i
t
s
s
c
h
e
i
n
w
e
r
f
e
r

h
i
n
t
e
n

r
e
c
h
t
s
1
2
15A 15A
4
,
6
A
4
,
6
A
4
,
6
A
4
,
6
A
w
o
r
k
i
n
g

h
e
a
d

l
i
g
h
t
s
,

r
e
a
r

r
h
.
w
o
r
k
i
n
g

h
e
a
d

l
i
g
h
t
s
,

f
r
o
n
t

r
h
.
F22

5
E
F19

4
D
K06
10:4
30
87a 87
STV2
11:17
STV1
11:17
Connection head lights
w
o
r
k
i
n
g

h
e
a
d

l
i
g
h
t
s
,

r
e
a
r

l
h
.
w
o
r
k
i
n
g

h
e
a
d

l
i
g
h
t
s
,

f
r
o
n
t

l
h
.
bei ROPS/SD Aufbau
acc.to ROPS/SD
Anschlu Arbeitsscheinwerfer
Anschlu Arbeitsscheinwerfer
with cabin
X1:18E
X1:18A
X1:26E
X1:26A
X1:23E
X1:23A
X1:24E
X1:24A
X1:21E
X1:21A
X1:22E
X1:22A
X1:19E
X1:19A
X1:25E
X1:25A
X1:2
X
1
:
3
1
9
X
1
:
3
2
0
X
1
:
3
2
1
X
1
:
3
2
2
X
1
:
3
2
3
X
1
:
3
2
4
X
1
:
3
2
4
X
1
:
3
2
3
X1:83
S16
S
c
h
a
l
t
e
r

A
r
b
e
i
t
s
b
e
l
e
13
14
BEL
5:9
X1:84 A
n
s
c
h
l
u

A
r
b
e
i
t
s
s
c
h
e
i
n
w
e
r
f
e
r

o
h
n
e

S
t
v
Z
O
c
o
n
n
e
c
t
i
o
n

w
o
r
k
i
n
g

h
e
a
d
l
i
g
h
t
s

w
i
t
h
o
u
t

S
t
v
Z
O
X
1
:
3
0
9
X
1
:
3
1
0
X
1
:
3
1
5
X
1
:
3
1
6
X
1
:
3
1
1
X
1
:
3
1
2
X
1
:
3
1
5
X
1
:
3
1
6
X
1
:
3
0
3
X
1
:
3
1
3
X
1
:
3
1
4
X
1
:
3
1
5
X
1
:
3
1
6
X
1
:
3
0
2
X
1
:
3
0
1
X3:4 X3:5
X
1
:
3
0
4
X1:305
X
1
:
3
0
6
X
1
:
3
0
7
X3:1
BEL MESX
8:7
X1:43
X
5
8
:
6
X
5
8
:
5
X
5
8
:
6
X
5
8
:
3
X
5
8
:
6
X
5
8
:
2
X
5
9
:
6
X
5
9
:
6
X
5
9
:
6
X
5
9
:
2
X
5
9
:
3
X
5
9
:
5
X
6
0
:
4
X
6
0
:
3
X
6
0
:
2
X
6
0
:
1
X
6
1
:
1
X
6
1
:
2
X
6
1
:
3
X
6
1
:
4
10:10 10:2
582 700 95
28.06.2004
011
Seis
28.06.2004
Werner
1 1

Kabinenausrstung, Beleuchtung, Radio, Tachograph
cabinequipment, headlights, radio, tachograph
A12
Radio
30
31
+
B51

+
B51

+
M M
3
,
8
A
3
,
8
A
washer front washer rear
M06
Wascher vorn
+
M07
Wascher hinten
+
STV1
10:13
STV2
10:13
radio
F43

A
1
S21

2
5
7
4
0 1 W
01
S20

2
5
7
4
0 1 W
01
M05
Wischer hinten

M04
Wischer vorne

M M
E27
Arbeitsscheinwerfer hinten
1
2
E28

1
2
E23
Arbeitsscheinwerfer vorn
1
2
E25

1
2
windscreen wiper, rear windscreen wiper, rear working head lights, rear
working head lights, front
4
,
6
A
4
,
6
A
4
,
6
A
4
,
6
A

rotary beacon
E32
Rundumkennleuchte
+
ZA
option
4
,
7
A
2
,
9
A
0
,
8
3
A
5
A
F41

E
5
31
10:20
31
12:1
S158
Schalter Nachtleuchte
3
4
S45
S
c
h
a
l
t
e
r

I
n
n
e
n
l
e
u
c
h
e
TK
+
S86
Trkontaktschalter
+
E70
N
a
c
h
t
l
e
u
c
h
t
e
1
2
1
,
7
5
A
K30
2:14
E29
I
n
n
e
n
l
e
u
c
h
t
e
1
2
F42

H
8
F130

C
3
F44

B
2
F143

G
7
R80
H
e
i
z
u
n
g

H
e
c
k
s
c
h
e
i
b
e
1
2
F42
12:8
K141

15
31
A
b
f
a
llv
e
r
z
g
e
r
t
3

m
in
K141
11:16
30
87a 87
n
i
g
h
t

i
l
l
u
m
i
n
a
t
i
o
n
switch, night illumination
i
n
s
i
d
e

l
i
g
h
t
,

c
a
b
i
n
s
w
i
t
c
h
e
s

i
n
t
e
r
i
o
r

l
i
g
h
t
s
door switch
h
e
a
t
i
n
g

r
e
a
r

s
c
r
e
e
n
A01
i
n
d
i
c
a
t
o
r
S38

5
1
S163

5
1
K32:87
12:2
A16
Tachographenmodul
5 3
2
1
6
7,8,9

4
P09
Tachograph
A5+A6
C3
B4
B3
A1
A2+A3
tachograph
F130
11:9
F130
12:7
F130
11:14
module, tachograph
X
5
5
:
4
X
5
5
:
3
X
5
5
:
1
X55:2
X
5
6
:
3
X
5
6
:
1
X56:2
X
5
6
:
4
I
X3:6
X3:7
X3:8
VIB
6:18
X3:18
SPEED TAC
4:3
X3:17
X
3
:
2
X
3
:
1
KABINE 31
12:18
15
XS
S
t
e
c
k
d
o
s
e
12V
+
s
o
c
k
e
t
F144

F
6
15A 10A 15A 15A 10A 10A 15A
E71
K
o
n
t
r
o
l
l
e
u
c
h
t
e
1
2
relais cabin
K32:86
2:19
K32
Relais Kabine
86
85
E72
Schalterbel.
1
2
switch illum.
K32
11:1
30
87a 87
m
a
x
.

1
3
A
11:6 11:2
582 700 95
28.06.2004
012
Seis
28.06.2004
Werner
1 1

Kabinenheizung, Klimaanlage, Zusatzheizung
cabinheater, air conditioning, add. heater
31
11:20
31

M09
Kabinenlfter
ge
br
rt or
M09
Kabinenlfter
ge
br
rt or
S44
Schalter Kabinenlfter
0 1 2 3

K32:87
11:19
A72
Steuergert
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12 11 6
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KLIMA
5:9
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5
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Y138
Magnetventil Heizung
1
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Y15
Klimakompressor
1
2
1
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V06

F42
11:9
Potential 15 aus Kabine
F31

D
4
control unit
switch blower cabin
cab ventilator air conditioning compr. solenoid valve, heating unit
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E30
Zusatzheizung

1 2 3 12 11 13 14 16
10 9 5 6 8 7 4 15
groe Stufe = 1.9A
mittleter Stufe = 1,0A
Kleine Stufe = 0,67A
Anlaufstrom beim Start = 8,3A
Regel aus = 0,4A
Power Stufe = 2,8A
add. heater

Y14
Kraftstoffpumpe
1
2
S28
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F130
11:17
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X1:169
X1:168
X1:170
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X3:14
KABINE 31
11:19
20A 20A 5A
K09
2:8
30
87a 87 X1:167
X18:1
X18:2
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X1:164
X17:4
X19:1
X19:2
X20:1
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4
X
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0
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3
X20:2
V04

1
2
Bedienteil Kabinenheizung/Klimaanlage
controlunit cabheater /air conditioning
X54:6
X3:13
X54:11 X54:12 X54:1
X54:4 X54:3 X54:2 X53:B X53:C
Stromaufnahme Lfter / current blower
Stufe 1: 3.0A pro Lfter
cab ventilator
5
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Name Benennung title TYP
Bl. Pf.
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 datacollector
A81 005 18 Anzeigeeinheit DisplayUnit
A83 008 6 Elektronik Messtechnik electronic measurementequipment
A87 009 15 USBCAN Schnittstelle BCM USBCAN Interface BCM

B03 005 3 Unterdruckschalter Luftfilter Vacuum switch, air cleaner
B11 002 16 Signalhorn Warning horn
B11 002 18 Signalhorn Warning horn
B16 006 16 Aufnehmer Vibrationsfrequenz vorne Transducer, vibration frequency, front
B21 005 2 Differenzdruckschalter Hydr.Oelfilter Pressure diff. switch, hydr. oil filter
B51 011 4 Lautsprecher Radio Speaker radio
B51 011 6 Lautsprecher Radio Speaker radio
B55 005 4 Kuehlmittelstand Ausgleichsbehaelter Coolant charge expansion tank
B57 004 6 Neigungssensor Stufenumschaltung Slope sensor, speed range selection
B59 004 4 Aufnehmer Bandagengeschwindigkeit Sensor, drum speed
B60 004 2 Aufnehmer Achsgeschwindigkeit Sensor, axle speed
B61 008 12 Aufnehmer Verstellzylinder Sensor, ajustable zylinder
B62 008 8 Beschleunigungsaufnehmer Acceleration sensor
B62 008 10 Beschleunigungsaufnehmer Acceleration sensor
B65 006 4 Sensor, Lenkwinkel vorn Sensor, angularity steering, front
B88 003 6 Druckgeber Motoroel Sender, engine oil pressure
B103 012 7 Temperaturschalter Klimaanlage Temperature switch, air conditioning
B104 012 7 Druckschalter Klimaanlage Pressure switch, air conditioning
B112 004 3 Druckgeber Fahrpumpe pressure sender, driving pump
B113 003 13 EMR Temperaturgeber Kuehlmittel EMR Temperature switch, collant
B114 003 7 EMR Aufnehmer, Motordrehzahl 1 EMR Trancducer, engine speed 1
B115 003 11 Geber Ladeluftdruck Sender, charging air pressure
B124 005 5 Geber Wasserstandsabscheider Diesel Sender, water separator fuel
B126 003 14 EMR Temperaturgeber Kraftstoff EMR fuel temperature sender
B130 003 8 EMR Aufnehmer, Motordrehzahl 2 EMR Trancducer, engine speed 2
B131 012 10 Temperaturschalter Heizung Temperature switch, heating
B132 006 2 Inititator Armlehne links proximity switch left arm rest
B134 007 17 Nherungsschalter Platten oben proximity switch, plate up
B135 007 16 Nherungsschalter Platten mitte proximity switch, plate middle

E08 010 17 Blinkleuchte vorne links Indicator, front, lh. MAX. 1,75A
E09 010 18 Blinkleuchte hinten links Indicator, rear, lh. MAX. 1,75A
E10 010 19 Blinkleuchte vorne rechts Indicator, front, rh. MAX. 1,75A
E11 010 19 Blinkleuchte hinten rechts Indicator, rear, rh. MAX. 1,75A
E12 010 7 Parkleuchte links Parking light, lh. MAX. 0,42A
E13 010 6 Schlussleuchte links Tail light, lh. MAX. 0,42A
E14 010 7 Parkleuchte rechts Parking light, rh. MAX. 0,42A
E15 010 8 Schlussleuchte rechts Tail light, rh. MAX. 0,42A
E16 010 2 Scheinwerfer links Head light, lh. MAX. 4,6A
E17 010 2 Scheinwerfer rechts Head light, rh. MAX. 4,6A
E23 010 11 Arbeitsscheinwerfer vorne links Working head light, front, lh. MAX. 4,6A
E23 011 18 Arbeitsscheinwerfer vorne links Working head light, front, lh. 4,6A
E25 010 12 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. MAX. 4,6A
E25 011 19 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. 4,6A
E27 010 10 Arbeitsscheinwerfer hinten links Working head light, rear, lh. MAX. 4,6A
E27 011 17 Arbeitsscheinwerfer hinten links Working head light, rear, lh. 4,6A
E28 010 11 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. MAX. 4,6A
E28 011 17 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 4,6A
E29 011 3 Innenleuchte Kabine Inside light, cabin 1,75A
E30 012 13 Heizgeraet Heating unit
E32 011 19 Kennleuchte Warning light 5A
E70 011 15 Nachtleuchte Night lamp 0,83A
E71 011 3 Kontrolleuchte Schalter Heckscheibenheizung indicator light switch rear screen 1,75A
E72 011 16 Beleuchtung Bedienschalter illum. Switches

F00 002 4 Hauptsicherung Batterie Fuse, main, battery 125A
F05 002 14 Sicherung Steckdose Fuse, socket 15A
F07 010 15 Sicherung Warnblinker Fuse, hazard light 15A
F08 010 18 Sicherung Blinker u. Arbeitsscheinw. Fuse, indicators a. work. head light 15A
F09 010 6 Sicherung Park u. Schlussl. links Fuse, parking and tail light, lh. 10A
F10 010 8 Sicherung Park u. Schlussl. rechts Fuse, parking and tail light, rh. 10A
F11 010 2 Sicherung Scheinwerfer links Fuse, head light, lh. 15A
F13 002 10 Sicherung Startschalter Fuse, starter switch 30A
F15 012 18 Sicherung Heizgeraet Fuse, heating unit 5A
F18 010 5 Vorsicherung Arbeitsscheinw. vorne Primary fuse, work. head light, fr. 30A
F19 010 12 Sicherung Arbeitsscheinw. vorne li. Fuse, working head light, front, lh. 30A
F22 010 10 Sicherung Arbeitsscheinwerfer hinten Fuse, working head lights, rear 30A
F23 002 18 Sicherung Signalhorn Fuse, warning horn 15A
F24 005 2 Sicherung Ueberwachungsmodul Fuse, monitoring module 15A
F31 012 3 Sicherung Kabinenluefter Fuse, cabin ventilator 20A
F39 002 19 Hauptsicherung Kabine Main fuse, cab 15A
F40 012 13 Sicherung Kabinenheizung Fuse, heating unit cab 20A
F41 011 19 Sicherung Rundumkennleuchte Fuse, rotary beacon 10A
F42 011 3 Sicherung Kabineninnenleuchte Fuse, inside light cab 10A
F43 011 10 Sicherung Wischermotor hinten Fuse, wipermotor rear 15A
F44 011 13 Sicherung Wischermotor vorn Fuse, wipermotor front 15A
F48 002 3 Sicherung Gluehanlage Fuse, glow plug system 125A
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
F130 011 15 Sicherung Nachtleuchte Fuse, night lamp 10A
5
8
2

7
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8
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6
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F143 011 2 Sicherung Heckscheibenheizung fuse rear screen heating unit 15A
F144 011 20 Sicherung Kabinensteckdose Fuse cabinsocket 15A
F145 007 18 Sicherung Anhngeplatten fuse vibration plates 15A
F146 008 5 Sicherung Steuerung MESX (Potential 30) Fuse Controller (Pot. 30) 15A
F148 008 2 Sicherung Steuerung MESX (Potential 15) Fuse Controller (Pot. 15) 10A

G01 002 3 Batterie Battery 103A
G02 002 5 Generator Generator
G03 002 4 Batterie Battery 103A

H06 010 15 Meldeleuchte Warnblinker Indicator light, hazard light LED ROT
H07 006 16 Warnsummer Betriebsstoerung Warning buzzer, breakdown 0.15A
H14 004 11 Warnsummer Rueckwaertsfahrt Backup alarm buzzer MAX O,46A

K05 007 3 Relais Startstrom Relay, starting current BOSCHW
K06 010 4 Relais Scheinwerfer hinten Relay, head lights, rear BOSCHW
K09 002 8 Relais Klimageraet Relay, air conditioning BOSCHW
K11 002 10 Relais Klemme 30 auf 15 Relay, terminal 30 to 15 BOSCHL
K14 003 19 Relais Vorgluehen Relay, glow plug system TYCOX
K16 010 9 Relais Scheinwerfer vorne Relay, head lights, front BOSCHW
K32 011 1 Relais Kabine Relay, cabin BOSCHW
K43 006 12 Relais Vibration Relay, vibration BOSCHW
K48 007 2 Relais Fahrhebel 0Stellung Relay, travel lever 0position BOSCHW
K56 006 8 Relais Lenkung Relay, steering system BOSCHW
K57 006 9 Relais Lenkung Relay, steering system BOSCHW
K61 002 6 Relais Ladekontrolle Relay, charge control BOSCHW
K141 011 16 Relais Heckscheibenheizung relay, heating rear screen BOSCHW

M01 002 11 Starter Starter 2.3 KW
M04 011 12 Scheibenwischermotor vorne Windscreen wiper motor, front 4,7A
M05 011 10 Scheibenwischermotor hinten Windscreen wiper motor, rear 2,9A
M06 011 13 Scheibenwaschermotor vorne Windscreen washer motor, front MAX. 3,8A
M07 011 11 Scheibenwaschermotor hinten Windscreen washer motor, rear MAX. 3,8A
M09 012 3 Kabinenluefter Cabin ventilator
M09 012 4 Kabinenluefter Cabin ventilator

P07 008 15 Omegameter Omegameter
P09 011 8 Frequenz und Geschwindigkeitsanzeige Frequency and Speedometer
P11 008 14 Drucker Printer
P15 009 16 BCM 03 Bildschirm BCM 03 terminal
P16 008 16 Diagnose, Variomatic Diagnostics, varimatic
P33 008 18 Opus 21 Opus 21

R03 005 6 Geber Tankanzeige Sender, level gauge 0 .. 67 OHM
R19 002 2 Heizflansch heater flange 167A
R20 004 15 Widerstand Resistor 120 OHM
R80 011 2 Heizung Heckscheibe heating rear screen MAX. 13A

S00 002 10 Startschalter Starter switch
S01 002 16 Schalter NOT AUS Switch, emergency off NOTAUSH
S03 002 18 Taster Signalhorn Push button, warning horn
S06 004 10 Sitzkontaktschalter links Switch, seat contact, lh.
S09 007 8 Vibrationsschalter vorne Switch, vibration, front
S14 010 15 Warnblinkschalter Switch, hazard light
S15 010 4 Beleuchtungsschalter StVZO Switch, lighting StVZO
S16 010 4 Schalter Arbeitsbeleuchtung vorne Switch, working head lights, front
S20 011 13 Schalter Scheibenwischer vorne Switch, windscreen wiper, front
S21 011 10 Schalter Scheibenwischer hinten Switch, windscreen wiper, rear
S28 012 18 Schalter Kabinenheizung Switch, cabin heating
S30 002 3 Batterietrennschalter Switch, battery disconnect
S35 007 7 Vibrationsschalter klein/gross Switch, vibration low/high
S36 007 11 Vibrationsschalter Switch, vibration
S37 010 18 Schalter Blinker Switch, indicator
S38 011 19 Schalter Kennleuchte Switch, warning light
S42 007 11 Stufenumschalter schnelllangsam Speed range selector, fastslow
S44 012 3 Schalter Kabinenluefter Switch, cabin ventilator
S45 011 3 Schalter Kabineninnenleuchte Switch, cabin inside light
S55 007 6 Schalter Fahrhebel Switch, travel control lever
S64 007 10 Schalter Schwimmstellung Switch, float position
S86 011 3 Schalter Tuer, links Switch door, lh.
S120 005 17 Schalter Motordrehzahl Switch, engine speed
S139 005 19 Schalter Frequenzverstellung Switch, frequency control
S139 007 13 Schalter Frequenzverstellung Switch, frequency control
S158 011 15 Schalter Nachtbeleuchtung Switch, cabin night lamp
S163 011 16 Schalter Heckscheibenheizung switch rear screen heating unit

V01 002 7 Diode Diode FE5B
V06 012 9 Diode Diode

X1:1 002 6 WAGO ZENTRALELEKTRIK WAGO EBOX
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X1:15A 002 10 WAGO ZENTRALELEKTRIK WAGO EBOX
X1:15E 002 10 WAGO ZENTRALELEKTRIK WAGO EBOX
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Bl. Pf.
X2:47 008 18 WAGOMESSTECHNIK Wagomeasurement equip.
X3:1 010 11 STECKER ROPS/SD conn. ROPS/SR
X3:1 011 10 STECKER KABINE/ROPS conn. cabin/ROPS
X3:3 002 19 SETCKER KABINE/ROPS Con cabin/ROPS
X4:A 008 14 KABINENST. MESST. con. measurem.equipm.
X4:B 008 14 KABINENST. MESST. con. measurem.equipm.
X4:C 008 14 KABINENST. MESST. con. measurem.equipm.
X4:D 008 14 KABINENST. MESST. con. measurem.equipm.
X4:E 008 15 KABINENST. MESST. con. measurem.equipm.
X4:F 009 18 KABINENST. MESST. con. measurem.equipm.
X4:G 009 18 KABINENST. MESST. con. measurem.equipm.
X4:M 009 16 KABINENST. MESST. con. measurem.equipm.
X4:N 009 15 KABINENST. MESST. con. measurem.equipm.
X6:1 006 13 STECKER VIBRATION GRO conn. vibration big
X6:2 006 14 STECKER VIBRATION GRO conn. vibration big
X7:1 006 15 STECKER VIBRATION KLE conn. vibration small
X7:2 006 14 STECKER VIBRATION KLE conn. vibration small
X8:1 005 5 STECKER WASSERABSCHEI connector water separator
X8:2 005 5 STECKER WASSERABSCHEI connector water separator
X9:1 004 11 STECKER RCKFAHRALARM conn. backupalarm
X9:2 004 11 STECKER RCKFAHRALARM conn. backupalarm
XS 002 19 Steckdose Socket
XS 011 20 Steckdose Socket
X10:2 005 6 STECKER TAUCHROHRGEBE connector fuel level sensor
X10:3 005 6 STECKER TAUCHROHRGEBE connector fuel level sensor
X14:A 004 10 STECKER SITZKONTAKT connector seat contact switch
X14:B 004 10 STECKER SITZKONTAKT connector seat contact switch
X15:1 004 13 STECKER FAHRPUMPE RC connectoe driving pump back
X15:2 004 13 STECKER FAHRPUMPE RC connectoe driving pump back
X16:1 004 12 STECKER FAHRPUMPE VOR connector driving pump front
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X16:2 004 12 STECKER FAHRPUMPE VOR connector driving pump front
X17:1 012 3 STECKER LFTER HKL conn. blower
X18:1 012 10 STECKER THERMOFHLER conn. sender temp.
X18:2 012 10 STECKER THERMOFHLER conn. sender temp.
X19:1 012 7 STECKER EISSCHUTZ HKL conn. antiice aircond.
X19:2 012 7 STECKER EISSCHUTZ HKL conn. antiice aircond.
X20:1 012 7 STECKER DRUCKSCH. KLI conn. pressuresitch aircond.
X21:1 005 4 STECKER KHLMITTEL connector coolant sensor
X21:2 005 4 STECKER KHLMITTEL connector coolant sensor
X22:1 006 16 ST. VIBRATIONSAUFNEHM connector vibration sensor
X25:2 007 11 ST. FAHRSTUFENSCHALTE connector switch speed ranges
X26:1 005 8 STECKER DATENSAMMLER connector data collector
X28:1 005 16 STECKER LCDISPLAY 1 connector LCdisplay 1
X30:1 003 5 EMRStecker Fahrzeug EMRconnector compactor
X31:1 003 16 EMRStecker Motor EMRconnector engine
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X32:A 003 2 EMR Diagnose EMRdiagnosis
X32:B 003 3 EMR Diagnose EMRdiagnosis
X32:G 003 3 EMR Diagnose EMRdiagnosis
X32:H 003 3 EMR Diagnose EMRdiagnosis
X32:K 003 2 EMR Diagnose EMRdiagnosis
X32:L 003 2 EMR Diagnose EMRdiagnosis
X33:1 003 19 Trennstelle EMR II conector EMR II
X34:A 004 14 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:B 004 16 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:C 004 12 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:D 004 13 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:G 004 10 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:H 004 11 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:J 006 3 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:N 003 5 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:P 002 14 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:R 005 2 DIAGNOSESTECKER ESX connector diagnosis ESX
X35:1 006 4 ESX STECKER esx connector
X36:A 002 4 EINSPEISUNG SCHALTKAS supply ebox
X36:B 002 5 EINSPEISUNG SCHALTKAS supply ebox
X37:A 002 10 ST. ZNDSCHLOSS EKAS connector ignition switch, ebox
X37:B 002 12 ST. ZNDSCHLOSS EKAS connector ignition switch, ebox
X38:A 002 12 STECKER STARTER EKAS connector starter, eBox
X39:1 006 9 STECKER 1 LENKRAD connector 1 steering unit
X41:1 006 8 ST. LENKRADKABELBAUM conn. steer. wire harn.
X42:1 008 18 STECKER OPUS21 conn. OPUS21
5
8
2

7
0
0

9
5
2
8
.
0
6
.
2
0
0
4
1
0
8
S
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i
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2
8
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0
6
.
2
0
0
4
W
e
r
n
e
r
8
9

B
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e
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t

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Bl. Pf.
X43:1 006 2 STECKER SCHALTER ARML connector switch arm rest
X43:2 006 1 STECKER SCHALTER ARML connector switch arm rest
X44:1 008 13 MESX STECKER MESX Stecker
X47:A 008 11 STECKER AUFN. PLEIGER conn. sender PLEIGER
X47:B 008 12 STECKER AUFN. PLEIGER conn. sender PLEIGER
X47:C 008 12 STECKER AUFN. PLEIGER conn. sender PLEIGER
X48:1 008 8 STECKER AUFN. VORNE conn. sender front
X49:1 008 10 STECKER AUFN. HINTEN conn. sender rear
X50:1 007 13 ST. PLATTENFREQ. conn. platefreq.
X51:1 006 2 ST. 1 LENKRADKABELBAU connector 1 steering wiring
X52:1 004 3 STECKER DRUCKSENSOR connector pressure sensor
X52:2 004 3 STECKER DRUCKSENSOR connector pressure sensor
X53:B 012 3 STECKER LFTERSCHALTE conn. blowerswitch
X53:C 012 4 STECKER LFTERSCHALTE conn. blowerswitch
X53:H 012 4 STECKER LFTERSCHALTE conn. blowerswitch
X53:L 012 3 STECKER LFTERSCHALTE conn. blowerswitch
X53:M 012 3 STECKER LFTERSCHALTE conn. blowerswitch
X54:1 012 11 STECKER HEIZSTEUERUNG conn. heating controller
X55:1 011 11 STECKER WISCHER HINTE connector wiper rear
X56:1 011 14 STECKER WISCHER VORNE conn. wiper front
X57:1 003 15 Stecker Motor connector engine
5
8
2

7
0
0

9
5
2
8
.
0
6
.
2
0
0
4
1
0
9
S
e
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2
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0
6
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2
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4
W
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9
9

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t

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Bl. Pf.
X58:2 010 17 STECKER STVZO VL Con. STVZO FL
X59:2 010 19 STECKER STVZO VR Con. STVZO FR
X60:1 010 18 STECKER STVZO HL Con. STVZO BL
X61:1 010 19 STECKER STVZO HR Con. STVZO BR
X62:1 007 19 STECKER DIOS PLATTEN con. DIOSplates
X72:1 007 14 ST. PROP.PUMPE PLATT con. platepump
X72:2 007 14 ST. PROP.PUMPE PLATT con. platepump
X74:1 008 14 STECKER DRUCKER con. printer
X75:2 009 16 SUBD STECKER BCM INT con. SUBD BCM
X75:7 009 15 SUBD STECKER BCM INT con. SUBD BCM
X76:1 009 17 STECKER VERS. BCM con. Powersup. BCM
X76:2 009 17 STECKER VERS. BCM con. Powersup. BCM

Y04 006 17 Magnetventil Bremse Solenoid valve, brake MAX. 1.8A
Y07 006 15 Magnetventil Vibration vorne gross Solenoid valve, vibration, front, high 0.4 .. 1.2A
Y08 006 13 Magnetventil Vibration vorne klein Solenoid valve, vibration, front, low 0.4 .. 1.2A
Y14 012 14 Kraftstoffpumpe Heizgeraet Fuel pump, heating unit
Y15 012 7 Magnetkupplung Klimakompressor Magnetic clutch, air conditioning compr. 3,5A
Y16 004 13 Magnetventil Fahrtrichtung vorwaerts Solenoid valve, travel direction forw. 0.4 .. 1.2A
Y17 004 12 Magnetventil Fahrtrichtung rueckwaerts Solenoid valve, travel direction backw. 0.4 .. 1.2A
Y30 004 15 Magnetventil Stufenumschaltung vorn Solenoid valve, speed range sel., front 0.4 .. 1.2A
Y31 004 16 Magnetventil Stufenumschaltung hinten Solenoid valve, speed range sel., rear 0.4 .. 1.2A
Y92 006 7 Magnetventil Lenkung vorne rechts Solenoid valve, steering, front rh. 0.4 .. 1.2A
Y93 006 6 Magnetventil Lenkung vorne links Solenoid valve, steering, front lh. 0.4 .. 1.2A
Y98 007 14 Magnetventil Vibrationsfrequenz, hinten Solenoid valve, vibrat.freq.,rear 0.4 .. 1.2A
Y112 006 4 Magnetventil Lenkung (Y1) Solenoid valve, steering (Y1) MAX. 1.8A
Y113 006 3 Magnetventil Lenkung (Y2) Solenoid valve, steering (Y2) MAX. 1.8A
Y122 007 16 Magnetventil Platten heben Solenoid valve, lift plates MAX. 1.8A
Y123 007 17 Magnetventil Platten senken Solenoid valve, let down plates MAX. 1.8A
Y137 003 10 EMR Verstellung EMR adjustment
Y138 012 10 Magnetveentil Heizung Solenoid valve, heating unit 1A
Y140 008 10 Magnetventil Erreger auf solenoid valve exciter up 0.4 .. 1.2A
Y141 008 11 Magnetventil Erreger ab solenoid valve exciter down 0.4 .. 1.2A
Y142 007 18 Magnetventil Plattenverschieben Links solenoid valve, plate displace left MAX. 1.8A
Y143 007 18 Magnetventil Plattenverschieben rechts solenoidvalve, plate displace right MAX. 1.8A
Y144 007 19 Magnetventil Platten Schwimmstellung solenoidvalve, plate swimmingposition MAX. 1.8A
Y145 007 20 Magnetventil Platten (Prioritt) solenoidvalve, plate (priority) MAX. 1.8A

X38
X37
Gez.: 28.06.2004
Name: Seis
Gepr.: 28.06.2004
Name: Werner
Seite: 1 von: 2
page: 1 from: 2
Ers. f.:
Replaces:
582 700 95
Blatt Nr.: 201
Sheet No.: 201
B57
X36
X1:1 X1:61
X1:79 X1:214
A80
X34:1-19 X32:1-12
bersicht Schaltkasten BW 177...226 DH/BVC-4
overview e-box BW 177...226 DH/BVC-4
K11
K05
K06
K43
K48
K61
K57
K56
K16
K09
A02
Nur bei StvzO
only acc. To StvZO illumination
X1:301
X1:324
Gez.: 28.06.2004
Name: Seis
Gepr.: 28.06.2004
Name: Werner
Seite: 2 von: 2
page: 2 from: 2
Ers. f.:
Replaces:
582 700 95
Blatt Nr.: 201
Sheet No.: 201
A83
Messtechnik Steuerung
CAN 1
CAN 1
CAN 2
CAN 3
EMR + Fahrhebel
BCM
LCD +
Datensammler
+ OPUS 21
X2:47 X2:78
bersicht Schaltkasten-Tr BW 177...226 DH-4/BVC
overview e-box door BW 177...266 DH-4
A34
Fahrsteuerung
Seite 1
WAGO smart DESIGNER 4.0
Copyright WAGO. Technische nderungen vorbehalten.
02.07.2004 09:04:26
Lieferadresse: :
Projekt :
Zeichnung :
Plan :
Ort :
Betriebsmittel :
ausgewhlte Tragschiene :
Artikelnummer :
Bohrungsabmessungen :
Kabelbume DH-4 VErsion
Stahl-Tragschiene 35x7,5 mm, 1 mm dick
210-112
5.20 x 25.00 [mm]
Zeichnungsnummer :
Artikelnummer :
Artikelnummer lang :
Konstrukteur :
geprft :
Projektgruppe : Walzenzge-4 Klemmenleisten Optional1 :
Optional2 :
Optional3 :
Optional4 :
Optional5 :
Optional6 :
Optional7 :
1 05756417
2 3 x 05756540 "R" + 793-501
5 05756539 "R" + 793-501
6 05756537
7 3 x 05756540 "R" + 793-501
10 05756537
11 05756540 "R" + 793-501
12 05756535 "R" + 793-501
13 05756537
14 2 x 05756538 "R" + 793-501
16 2 x 05756539 "R" + 793-501
18 05756537
19 4 x 05756540 "R" + 793-501
23 05756537
24 4 x 05756540 "R" + 793-501
28 2 x 05756539 "R" + 793-501
30 05756537
31 05756540 "R" + 793-501
32 05756539 "R" + 793-501
33 05756537
34 4 x 05756540 "R" + 793-501
38 05756539 "R" + 793-501
39 05756537
40 4 x 05756540 "R" + 793-501
Seite 2
02.07.2004 09:04:26
Lieferadresse: :
Projekt :
Zeichnung :
Plan :
Ort :
Betriebsmittel :
Artikelnummer :
210-112
5.20 x 25.00 [mm]
Zeichnungsnummer :
Artikelnummer :
Konstrukteur :
geprft :
Optional2 :
Optional3 :
Optional4 :
Optional5 :
Optional6 :
Optional7 :
44 05756537
45 05756540 "R" + 793-501
46 05756535 "R" + 793-501
47 05756537
48 05756540 "R" + 793-501
49 05756535 "R" + 793-501
50 05756537
51 05756538 "R" + 793-501
52 2 x 05756540 "R" + 793-501
54 05756539 "R" + 793-501
55 05756537
56 3 x 05756540 "R" + 793-501
59 05756538 "R" + 793-501
60 05756537
61 3 x 05756540 "R" + 793-501
64 05756535 "R" + 793-501
65 05756537
66 2 x 05756540 "R" + 793-501
68 05756539 "R" + 793-501
69 05756537
70 3 x 05756540 "R" + 793-501
73 05756535 "R" + 793-501
74 05756537
75 2 x 05756540 "R" + 793-501
77 05756539 "R" + 793-501
78 05756537
79 05756417
Seite 6
02.07.2004 09:16:28
Lieferadresse: :
Projekt :
Zeichnung :
Plan :
Ort :
Betriebsmittel :
Artikelnummer :
210-112
5.20 x 25.00 [mm]
Zeichnungsnummer :
Artikelnummer :
Konstrukteur :
geprft :
Optional2 :
Optional3 :
Optional4 :
Optional5 :
Optional6 :
Optional7 :
Seite 7
02.07.2004 09:16:28
Lieferadresse: :
Projekt :
Zeichnung :
Plan :
Ort :
Betriebsmittel :
Artikelnummer :
210-112
5.20 x 25.00 [mm]
Zeichnungsnummer :
Artikelnummer :
Konstrukteur :
geprft :
Optional2 :
Optional3 :
Optional4 :
Optional5 :
Optional6 :
Optional7 :
Seite 1
02.07.2004 09:19:48
Lieferadresse: :
Projekt :
Zeichnung :
Plan :
Ort :
Betriebsmittel :
Artikelnummer :
Optionen Beleuchtung
210-112
5.20 x 25.00 [mm]
Zeichnungsnummer :
Artikelnummer :
Konstrukteur :
geprft :
Optional2 :
Optional3 :
Optional4 :
Optional5 :
Optional6 :
Optional7 :
1 05756417
2 4 x 05756540 "R" + 793-501
6 05756537
7 2 x 05756540 "R" + 793-501
9 4 x 05756538 "R" + 793-501
13 2 x 05756539 "R" + 793-501
15 05756537
16 05756417
Seite 2
02.07.2004 09:22:27
Lieferadresse: :
Projekt :
Zeichnung :
Plan :
Ort :
Betriebsmittel :
Artikelnummer :
Optionen Beleuchtung
210-112
5.20 x 25.00 [mm]
Zeichnungsnummer :
Artikelnummer :
Konstrukteur :
geprft :
Optional2 :
Optional3 :
Optional4 :
Optional5 :
Optional6 :
Optional7 :
Seite 1
02.07.2004 09:27:03
Lieferadresse: :
Projekt :
Zeichnung :
Plan :
Ort :
Betriebsmittel :
Artikelnummer :
Klemmenleiste X2 /
210-112
5.20 x 25.00 [mm]
Zeichnungsnummer :
Artikelnummer :
Konstrukteur :
geprft :
Optional2 :
Optional3 :
Optional4 :
Optional5 :
Optional6 :
Optional7 :
1 05756417
2 2 x 05756540 "R" + 793-501
4 05756539 "R" + 793-501
5 05756537
6 05756538 "R" + 793-501
7 2 x 05756540 "R" + 793-501
9 05756539 "R" + 793-501
10 05756537
11 2 x 05756540 "R" + 793-501
13 05756539 "R" + 793-501
14 05756537
15 05756540 "R" + 793-501
16 05756538 "R" + 793-501
17 05756540 "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
Seite 2
02.07.2004 09:29:27
Lieferadresse: :
Projekt :
Zeichnung :
Plan :
Ort :
Betriebsmittel :
Artikelnummer :
Klemmenleiste X2 /
210-112
5.20 x 25.00 [mm]
Zeichnungsnummer :
Artikelnummer :
Konstrukteur :
geprft :
Optional2 :
Optional3 :
Optional4 :
Optional5 :
Optional6 :
Optional7 :
Steckerbersicht BW 177...226 DH/BVC-4
Gez.: 28.06.2004
Name: Seis
Gepr.: 28.06.2004
Name: Werner
Seite: 1 von: 1
page: 1 from: 1
Ers. f.:
Replaces:
582 700 95
Blatt Nr.: 301
Sheet No.: 301
Connector overview BW 177...226 DH/BVC-4
X10
X9
X8
X7 X6
X4 X3
X2
X1
X16 X15
X21
X20
X17
X22
X14
X2
X19
X18
X24
X25
X26
X29
X28
X30
X27
X23
X35
X32 X34
X33
X31
X34
X38
X37
X36
X39
X40 X41
X42 X42 X43
X44 X44
X48
(BVC)
X45
X47
X46
X49
(BVC)
X51
X50
X52
X53 X54
X57
X56
X55
X10
X9
X8
X7 X6
X4 X3
X2
X1
X16 X15
X21
X20
X17
X22
X14
X2
X19
X18
X24
X25
X26
X29
X28
X30
X27
X23
X35
X32 X34
X33
X31
X34 X38
X37
X36
X39
X40
X41
X42 X42
X43
X44 X44
X45
X47
X46
X51
X50
X52
X53
X54
X57
X56
X55
X48 X49
X48 X49
X48
(BVC)
X49
(BVC)
X59
X58
X60
X61
X59
X58
X61
X60
X62
X62
X72
X72
X76
X75 X74
X76
X75 X74

BW177-213-226 Series 4 Service Training

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BW177-213-226 Series 4 Service Training

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Service Training

12/2004 Teile-Nr. 008 099 94

back up alarm buzzer

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