BW177-213-226 Series 4 Service Training [PDF]

Zitiervorschau

Service Training

Variocontrol Single drum roller - 4 BW 177 / 213 / 226 BVC Teile-Nr. 008 099 94

12/2004

Service Training Table of contents Foreword

A1

Documentation

A2

General

B1

Peculiarities

B3

Electric steering

C1

Steering circuit

C2

Steering pump

C4

Steering wheel

C5

Steering valve

C6

Steering angle sensor

C12

Trouble shooting

C15

Compaction measuring system

D1

BEM

D1

BTM plus

D2

BTM prof.

D3

BVC

D4

BVC - System

E1

Exciter system

E4

Gear pump

E5

Valve block

E7

Swashing motor

E9

Acceleration transducer

E 10

MESX-control

E 11

BOP

E 12

Working principle of the system

Variocontrol Single Drum Rollers Series 4

F1

Service Training Repair and adjustments

G1

Replacement of swashing motor

G2

Replacement of potentiometer

G3

Potentiometer adjustment

G4

Trouble shooting

H1

Electrics

I1

Service Training MESX - Service Training Wiring diagram Hydraulic diagrams

Variocontrol Single Drum Rollers Series 4

Service Training 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 BOMAG’s philosophy to design and produce the machines with highest possible reliability. This aspect of simple and easy maintenance was one of the key issues when developing and designing the machine: • the 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 BOMAG’s own service personnel as well as the service personnel of BOMAG Profit Centres and dealers is therefore a general prerequisite for BOMAG’s excellent world-wide service. This program of permanent training is only possible with appropriate and up-to-date training material for trainers as well as persons attending the training courses. This training manual has not only been written as a support for the professional work of the trainer, but also for the trainees attending these training courses. The different levels of product training demand, that the training performed by BOMAG, its Profit Centres or its dealers reflects the high quality of the training conducted at the Training Centre at BOMAG in Boppard. For this reason we invested a lot of time in the preparation of these materials . The structure of this training manual enables us to change or up-date individual chapters in case of alterations to the machine.

Variocontrol Single Drum Rollers Series 4

-A1-

Service Training 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.

Variocontrol Single Drum Rollers Series 4

-A2-

Service Training 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.

Variocontrol Single Drum Rollers Series 4

-B1-

Service Training Part of this new further development is the new display and control element Operation Panel) in connection with the MESX.

BOP (Bomag

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

Variocontrol Single Drum Rollers Series 4

-B2-

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.

Variocontrol Single Drum Rollers Series 4

-B3-

Service Training 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.

Variocontrol Single Drum Rollers Series 4

-C1-

Service Training

Variocontrol Single Drum Rollers Series 4

-C2-

Service Training Hydraulic steering circuit

06

to charging

to emergency steering and Vario control valve

MG

from hydr. tank

Variocontrol Single Drum Rollers Series 4

-C3-

Service Training Pos.

Designation

05 05

one steering cylinder on BW 177 two steering cylinders on BW 213 and 226 Steering valve with 2 proportional solenoids and an integrated accumulator High pressure filter 12µm Steering pump and charge pump additional gear pump 5.5 cm³ on BW 177 BVC additional gear pump 8 cm³ on BW 213 and 226 BVC High pressure line filter for Variocontrol 100 µm Optional emergency steering valve with 2 B/W solenoids

06

07 09 17 17 20 21

Pos. in wiring diagram

Pos. in hydraulic diagram

Measuring values

05 05 Y92 / Y93 Page 006

06

07 09 / MB 17 / MG

200 +/-10 bar 80 bar

17 / MG

120 bar

20 Y112 / Y113 Page 006

21

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.

Variocontrol Single Drum Rollers Series 4

-C4-

Service Training Steering pump with filter

Steering pump

Pressure test port Steering pressure

Filter outlet

High pressure filter Steering circuit 12 µm with Pressure differential switc 3,5 bar

Filter inlet

Variocontrol Single Drum Rollers Series 4

-C5-

Service Training Steering wheel The small steering wheel is located in the left hand armrest of the driver's seat

VCC 8,5 V

Pos.

Designation

Electric steering wheel

Variocontrol Single Drum Rollers Series 4

Pos. in wiring diagram

Pos. in hydraulic diagram

Measuring values

A 45 Page 006

-C6-

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 pump

to the charge system

Variocontrol Single Drum Rollers Series 4

-C7-

Service Training Steering valve

5 3 7

6

8

1

Pos.

Designation

1 2 3 4 5 6

Steering valve port P Steering valve port T Steering valve ports A and B Steering valve, pressure relief valve Steering valve, shock valves Steering valve, accumulator

7 8 9

Steering valve, prop. solenoid Steering valve, prop. solenoid Emergency steering valve B/W solenoid Emergency steering valve B/W solenoid

10

Variocontrol Single Drum Rollers Series 4

4 Pos. in wiring diagram

Pos. in hydraulic diagram

06 06 06 06 06 06 Y 93 Y 92 Y 113

Page 006 Page 006 Page 006

Y 112

Page 006

2 Measuring values

175 + 25 bar 230 bar Accumulator pressure 50bar 0,4 - 1,2 A 0,4 - 1,2 A 0/12 V 0/12 V

-C8-

Service Training Emergency steering valve (option, can only be operated via input code) !!!

9

Variocontrol Single Drum Rollers Series 4

10

-C9-

Service Training BW 177 BVC

2

3

1

Pos.

Designation

Pos. in wiring diagram

Pos. in hydraulic diagram

1 2 3

Steering valve Optional emergency steering valve High pressure line filter 100µm in Vario-circuit

Y92 / Y93 Y112 / Y113

06 21 20

Variocontrol Single Drum Rollers Series 4

Measuring values

- C 10 -

Service Training Piping BW 177

Variocontrol Single Drum Rollers Series 4

- C 11 -

Service Training BW 213 and 226 BVC

5

3

4

2

1

Pos.

Designation

Pos. in wiring diagram

Pos. in hydraulic diagram

1 2 3

Steering valve Optional emergency steering valve Pressure retaining valve, Variocontrol circuit Accumulator for Variocontrol circuit

Y92 / Y93 Y112 / Y113

06 21 22

4 5

High pressure line filter 100µm Vario-circuit

in

Variocontrol Single Drum Rollers Series 4

23

Measuring values

110 / 99 bar Accumulator pressure 85bar

20

- C 12 -

Service Training Piping BW 213 and 226

Variocontrol Single Drum Rollers Series 4

- C 13 -

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

Variocontrol Single Drum Rollers Series 4

- C 14 -

Service Training BW 177 and 213 BVC

Variocontrol Single Drum Rollers Series 4

- C 15 -

Service Training BW 226 BVC

Variocontrol Single Drum Rollers Series 4

- C 16 -

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.

Variocontrol Single Drum Rollers Series 4

- C 17 -

Service Training Procedure: The following trouble shooting chart mainly lists mechanical and hydraulic faults.

SYMPTOME

FEHLERSUCHE elektr.LENKUNG BVC-4 Maschinen

Keine Lenkfunktion Endanschläge werden nicht erreicht Lenkung schwergängig

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.

MÖGLICHE URSACHEN Lenkventil Lenk- Speisepumpe Lenkzylinder Knickgelenk

2 1 3 3

2 1 3 3

1 2 3 2

FEHLERSUCHE Variocontrol Single Drum Rollers Series 4

- C 18 -

Service Training Compaction measuring system for single drum rollers: BEM (Bomag E-vib Meter) for circular exciters

CAN Bus I

BMFSA

E vib 150 50

200

! Beschleunigung VV / VL 15g

D+ Signal

Signale

0

MESX

E VIB 250 MN/mm²

Befehle

Neutral Pos. Bedienfunktionen Beschleunigung VH / VL 15g

Vibrationspumpe Stromsignal

Variocontrol Single Drum Rollers Series 4

-D1-

Service Training BTM prof (Bomag Terrameter) for circular exciters

CAN Bus I RS 232

Drucker BOP

Beschleunigung VV / VL 15g

Drehzahlsensor hinten

D+ Signal

Signale

!

MESX

Neutral Pos. Bedienfunktionen Beschleunigung VH / VL 15g

Vibrationspumpe Stromsignal

Variocontrol Single Drum Rollers Series 4

-D2-

Service Training BTM plus (Bomag Terrameter) for circular exciters

CAN Bus I

BOP

Beschleunigung VV / VL 15g

Drehzahlsensor hinten

D+ Signal

Signale

!

MESX

Neutral Pos. Bedienfunktionen Beschleunigung VH / VL 15g

Vibrationspumpe Stromsignal

Variocontrol Single Drum Rollers Series 4

-D3-

Service Training BVC (Bomag Variocontrol) for Vario exciters

CAN Bus I RS 232

Drucker BOP

Beschleunigung VV / VL 15g

Drehzahlsensor hinten

Signale

!

MESX

Befehle Lageregelung Ventil 2 vorn

D+ Signal

Lageregelung Ventil 1 vorn

Neutral Pos. Bedienfunktionen Beschleunigung VH / VL 15g

Vibrationspumpe Stromsignal

Erreger Position vorn

Variocontrol Single Drum Rollers Series 4

-D4-

Service Training 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 components:

system

consists

of

the

following

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

Variocontrol Single Drum Rollers Series 4

primary

-E1-

Service Training BVC Circuit diagram for BW 177 DH-4 Legend from the hydraulic diagram: front

rear

17) External gear pump 5.5 cm³ 18) Valve block with 80 bar pressure relief valve 19) Swivel drive, variable displacement motor 20) High pressure line filter

Y141

20

Y140

to the tank

from tank to filter to steering system

Variocontrol Single Drum Rollers Series 4

-E2-

Service Training BVC Circuit diagram for BW 213 / 226 DH-4 Legend from the hydraulic diagram: 17) External gear pump 8cm³

front

rear

Y141

Y140

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 Emergency steering

to the tank from tank to filter Steering valve

Variocontrol Single Drum Rollers Series 4

-E3-

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

Variocontrol Single Drum Rollers Series 4

-E4-

Service Training Gear pump with high pressure filter

additional gear pump for Variocontrol system

Test port input Variocontrol system

BW 177 BVC Filter Input

High pressure Line filter

Filter Output

Variocontrol Single Drum Rollers Series 4

-E5-

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.

7

1 2

8 3 9

4 5 6

Pos.

Designation

1 2 3 4 5

22 22 22 22 22

6

P3 Input P5 to valve block T T Pressure retaining valve, opens and closes P6 to accumulator

7 8 9

High pressure line filter T1 P4

22 22 22

Variocontrol Single Drum Rollers Series 4

Pos. in wiring diagram

Pos. in hydraulic diagram

23

Measuring values

110 bar / 99 bar Preload pressure 85bar

-E6-

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

8

1

9

2 3 4

10

5 6

8

7

11 Pos.

Designation

1 1 2 3 4 5 6 7 8 9 10 11

Test port BW 177 Test port BW 213 and 226 P2 A T1 P1 B T2 Shock valves Prop. solenoid Prop. solenoid Pressure relief valve BW 177

Variocontrol Single Drum Rollers Series 4

Pos. in wiring diagram

Y 141 Y 140

Page 008 Page 008

Pos. in hydraulic diagram

Measuring values

18 18 18 18 18 18 18 18 18 18 18 18

80 bar 120 bar

120 bar 0,4 - 1,2 A 0,4 - 1,2 A 80 bar

-E7-

Service Training Pos.

Designation

Pos. in wiring diagram

11

Pressure relief valve BW 213 and 226

Pos. in hydraulic diagram

Measuring values

18

120 bar

Valve block installation front left and protection housing for electric connections

Pressure relief valve

Potentiometer

Variocontrol Single Drum Rollers Series 4

-E8-

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

Variocontrol Single Drum Rollers Series 4

-E9-

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, approx. 6,5 V

Horizontal approx. 4,25 V,

Vertical backward

Swashing motor, principle – cross-sectional view (Pleiger)

Variocontrol Single Drum Rollers Series 4

- E 10 -

Service Training

Variocontrol Single Drum Rollers Series 4

- E 11 -

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

Acceleration transducer

Variocontrol Single Drum Rollers Series 4

- E 12 -

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", Training MESX.

Service

MESX

Variocontrol Single Drum Rollers Series 4

- E 13 -

Service Training BOP Bomag Operation Panel The operation of the BOP is described in detail in the operating and maintenance instructions!

1

EVIB display

11) Rotary switch for mode selection (Automatic/Manual)

2

not used

3

Push button F5 START

4

Push button F6 STOP

5

Push button F7 PRINT

6

Push button F8 DELETE

7

Display of vibration frequency

8

Rotary switch for setpoint adjustment (automatic operation)

9

Push button F14 setpoint increase

12) Push button F12 automatic operation 13) Push button F11 manual operation 14) Rotary switch, manual setting of amplitude direction 15) Push button F10 vertical effective direction 16) Push button F9 horizontal effective direction 17) Travel speed display 18) Amplitude display

19) Optional measuring value printer

10 Push button F13 Setpoint reduction

Variocontrol Single Drum Rollers Series 4

- E 14 -

Service Training 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 überwachen. Die Beschleunigungssignale, die aus der dynamischen Wechselwirkung zwischen dem Walzenkörper und der Unterlage resultieren, werden an die MESX-Steuerung weitergeleitet. Werden bestimmte Grenzzustände bzw. Sollzustände erreicht, wird von der MESX ein Signal auf die Verstelleinheit gegeben und dadurch die Verdichtungsenergie an den neuen Einbauzustand angepaßt. Signalisieren die Beschleunigungsaufnehmer eine geringe Bodensteifigkeit, schwenkt das Erregersystem so weit in Richtung der vertikalen Arbeitsrichtung, bis die maximal mögliche Verdichtungsenergie abgegeben wird. Nimmt die Bodensteifigkeit zu und werden bestimmte Grenzwerte bzw. Sollwerte erreicht, schwenkt das Erregersystem in Richtung der horizontalen Arbeitsrichtung, bis die Sollwerte unterschritten werden. Das Ergebnis dieser Regelung ist, daß das VARIOCONTROL-System die maximal mögliche Verdichtungsenergie automatisch an den jeweiligen Einbauzustand anpaßt. Das System muß dabei sehr schnell auf die Steifigkeitsänderungen reagieren. Die Verstellzeiten von vertikaler zu horizontaler Arbeitsrichtung liegen unter einer Sekunde. Damit kann das System 1. auf Veränderungen der Bodensteifigkeit unmittelbar reagieren 2. und zerstörende Bewegungen der Bandage verhindern.

Variocontrol Single Drum Rollers Series 4

-F1-

Service Training Vibration parameters Für den Verdichtungserfolg ist schon die erste dynamische Überfahrt von entscheidender Bedeutung. Die VARIOCONTROL Walzenzüge sind daher auf besonders hohe Zentrifugalkräfte bzw. Amplituden ausgelegt. Hierdurch wird eine sehr hohe Verdichtung und eine gute Tiefenwirkung erzeugt. Durch die große Amplitude würde die VARIOCONTROL Walzenzüge früher springen als Standardwalzenzüge gleichen Betriebsgewicht. Durch die Automatik wird aber der Vertikalanteil der Amplitude dann automatisch zurückgenommen und so ein Springen der Walze verhindert.

Dichte Hochleistungswalze große Amplitude Standardwalze

0

1

2

3

BW 177

4

5

BW 213

6

7

Übergänge

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

Variocontrol Single Drum Rollers Series 4

-F2-

Service Training Repair and adjustments Replacement of swashing motor and potentiometer

Swashing motor

Potentiometer

Fastening screws Potentiometer

Variocontrol Single Drum Rollers Series 4

-G1-

Service Training

Locking screw vertical reverse

Locking screw horizontal

Variocontrol Single Drum Rollers Series 4

-G2-

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, 076 320 16) with seal ring.

P/N

11. Tighten all fastening screws with the specified torque.

Variocontrol Single Drum Rollers Series 4

-G3-

Service Training

Variocontrol Single Drum Rollers Series 4

-G4-

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.

Variocontrol Single Drum Rollers Series 4

-G5-

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.

Wiring diagram Bl 008, Pf 11, B61 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.

Variocontrol Single Drum Rollers Series 4

-G6-

Service Training Exciter lock in vertical reverse

Exciter lock in horizontal

Variocontrol Single Drum Rollers Series 4

-G7-

Service Training 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“ Red fault light

Button „F5“

Button „?“

For detail info on reading out fault codes please refer to the chapter "Electrics, Training MESX".

Variocontrol Single Drum Rollers Series 4

-H1-

Service Training Electrics MESX

Version 3.00

Status: Author:

06.12.2004 T.Löw / TE

Dateiname:

p:\schulung\wz-4\elektrik\englisch\06_12_04\mesx_schulung_v3.00_berndnick_gb.doc

Page 1 of 48

Service Training MESX

Table cof contents 1 2 3 4

Document updating record ................................................................................................................3 Software updating record ..................................................................................................................4 Known faults ......................................................................................................................................5 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

Status:06.12.2004 Author: T.Löw / TE

Page 2 of 48

Service Training MESX

1 Document updating record Version Date Description of changes 0.00 27.04.2004 Creation of first version 1.00 05.05.2004 ! Block diagrams included ! Description of display module extended ! "Software updating record" included 1.01 23.07.2004 ! Description of BOP display pages added. 2.00 31.08.04 ! Input code 4602 replaced by code 4606 ! Machine type BW219D added 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

Status:06.12.2004 Author: T.Löw / TE

resp. Löw Löw

Löw Löw Löw

Page 3 of 48

Service Training MESX

2 Software updating record Version 1.00 1.01

1.02

1.03

1.04

1.05

2.00 3.00

Date Description of changes 25.03.2004 Creation of version 1.00 05.04.2004 ! Printout modified ! Amplitude limitation Automatic limited to 0,3 mm ! Default settings in Automatic changed to "MAX" 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 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 16.04.2004 ! BW226 BVC Polygon implemented ! Max. swashing angle limited to 80° ! Max valve current for BW177 limited to 1000mA 26.07.2004 ! BW219DH and BW213 BVC Polygon implemented ! Cancellation criterion for while loops added in Evib calculations 31.08.2004 ! Number of machine variants extended to 25 (BW219D) ! Problem with sporadic software crashes eliminated 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)

Status:06.12.2004 Author: T.Löw / TE

resp. Löw Löw

Löw

Löw

Löw

Löw

Löw Löw

Page 4 of 48

Service Training MESX

3 Known faults Despite the fault monitoring of inputs and outputs on the ESX control, the ESX control is not able to detect all faults. The following list contains a selection of known fault reactions of the control, which mostly have a different cause to the one described in this documentation.

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"

Status:06.12.2004 Author: T.Löw / TE

Page 5 of 48

Service Training MESX

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 Acceleration transducer 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.

Status:06.12.2004 Author: T.Löw / TE

Page 6 of 48

Service Training MESX

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 7500 7501 7502 7503

Machine type 177 D 177 DH 177 PDH 177 BVC

Available from version 1.00 1.00 not available at present 1.00

7511 7512

179 DH 179 PDH

not available at present not available at present

7520

211 D

7530 7531 7532 7533 7534 7535

213 D 213 DH 213 PDH 213 BVC 213 BVC Plates 213 BVC Polygon

1.03 1.03 not available at present 1.02 not available at present 1.05

7541 7542

214 DH 214 PDH

not available at present not available at present

7550 7551 7552

216 D 216 DH 216 PDH

not available at present not available at present not available at present

7560 7561 7562

219 D 219 DH 219 PDH

2.00 1.05 not available at present

7571 7572 7573 7575

226 DH 226 PDH 226 BVC 226 BVC Polygon

not available at present not available at present not available at present 1.04

Status:06.12.2004 Author: T.Löw / TE

1.03

Page 7 of 48

Service Training MESX

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.

057 667 72

15/54

Vorzeichen

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.

Status: Author:

06.12.2004 T.Löw / TE

Functions of the ESX control

Page 8 of 48

Service Training MESX

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 .

Status: Author:

06.12.2004 T.Löw / TE

Functions of the ESX control

Page 9 of 48

Service Training MESX

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. Note:

Parameter adjustments can only be performed when the engine is not running.

• Enter code number 7 6 0 0 . This code number activates the function "Invert direction signal“. The display module now permanently shows the code 7 6 0 0 . • 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 not inverted).

(signal inverted), or the code 0 0 0 0

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").

Status: Author:

06.12.2004 T.Löw / TE

Functions of the ESX control

Page 10 of 48

Service Training MESX

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.

Status: Author:

06.12.2004 T.Löw / TE

Functions of the ESX control

Page 11 of 48

Service Training MESX

6 Adjustment/display possibilities on machines with BOP 6.1 Setting the machine type (BOP) The machine type is set in the following sequence: Note:

Parameter adjustments can only be performed when the engine is not running.

•

Press key "?" to call up the screen page "MENU". The following screen appears:

•

Press key "F2" to call up the screen page "Set machine type". The following screen appears:

Status: Author:

06.12.2004 T.Löw / TE

Functions of the ESX control

Page 12 of 48

Service Training MESX

•

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. •

Switch the ignition off and on again.

BOP and MESX are now set to the new machine type.

Status: Author:

06.12.2004 T.Löw / TE

Functions of the ESX control

Page 13 of 48

Service Training MESX

6.2 Inverting the direction signal via the BOP control terminal In dependence on the mounting position the axle sensor used delivers a 12 V output signal during forward or reverse travel. In order to make sure that exciter position (only BVC machines) and printout correspond with the actual travel direction, it may be necessary to invert the direction signal.

Note:

Parameter adjustments can only be performed when the engine is not running.

•

Press key "?" to call up the screen page "MENU". The following screen appears:

•

Press key "F1" to call up the screen page "Invert direction signal". The following screen appears:

Status: Author:

06.12.2004 T.Löw / TE

Functions of the ESX control

Page 14 of 48

Service Training MESX

•

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.

Status: Author:

06.12.2004 T.Löw / TE

Functions of the ESX control

Page 15 of 48

Service Training MESX

6.3 Calling up the diagnostics menu •

Press key "?" to call up the screen page "MENU". The following screen appears:

•

Press key "F5" to call up the screen page "Diagnose1". The following screen appears:

Status: Author:

06.12.2004 T.Löw / TE

Functions of the ESX control

Page 16 of 48

Service Training MESX

In case of a actually existing code the corresponding error code is displayed in the field "Actual Errors". •

Press "ESC" to leave the page.

•

Pressing key "A" brings you to a machine related, extended diagnostics menu (see below).

Status: Author:

06.12.2004 T.Löw / TE

Functions of the ESX control

Page 17 of 48

Service Training MESX

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.

Status: Author:

06.12.2004 T.Löw / TE

Functions of the ESX control

Page 18 of 48

Service Training MESX 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.

Status: Author:

06.12.2004 T.Löw / TE

Functions of the ESX control

Page 19 of 48

Service Training MESX

6.4 Changing the printer language •

Press key "?" to call up the screen page "MENU". The following screen appears:

•

Press key "F6" to call up the screen page "Printer language". The following screen appears:

Status: Author:

06.12.2004 T.Löw / TE

Functions of the ESX control

Page 20 of 48

Service Training MESX

•

The required printer language can be selected by pressing keys "F11" and "F12".

•

After selecting the required language press key "F14" to save the setting. The symbol (F14) lights green for a moment as confirmation.

•

Press "ESC" to leave the page.

Status: Author:

06.12.2004 T.Löw / TE

Functions of the ESX control

Page 21 of 48

Service Training MESX

6.5 Setting the machine serial number •

Press key "?" to call up the screen page "MENU". The following screen appears:

•

Press key "F7" to call up the screen page "Serial number". The following screen appears:

Status: Author:

06.12.2004 T.Löw / TE

Functions of the ESX control

Page 22 of 48

Service Training MESX

•

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.

•

Press "ESC" to leave the page.

Status: Author:

06.12.2004 T.Löw / TE

Functions of the ESX control

Page 23 of 48

Service Training MESX

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 "?" to call up the screen page "MENU". The following screen appears:

•

Press key "F8" to call up the screen page "Distance impulses". The following screen appears:

Status: Author:

06.12.2004 T.Löw / TE

Functions of the ESX control

Page 24 of 48

Service Training MESX

•

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:

•

Press "ESC" to leave the page.

Note:

Status: Author:

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!

06.12.2004 T.Löw / TE

Functions of the ESX control

Page 25 of 48

Service Training MESX

Block diagram

7 Block diagram BEM

Status: Author:

06.12.2004 T. Löw / TE

Block diagram

Page 27 of 48

Service Training MESX

Block diagram

8 Block diagram BTMplus / VARIOCONTROL

Status: Author:

06.12.2004 T. Löw / TE

Block diagram

Page 28 of 48

Service Training MESX

Description of signals

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 X0:1 AGND = Analogue ground: Ground potential for sensors (steering joystick, speed range switch etc.) X0:2

Nominal values (voltage / current) approx. 0 V measured against ground (terminal 31)

X0:3

PWM signal (100Hz): "

X0:4

Output Evib display PWM (max. 2.5 A) Interface RS 232 RxD, is used for printer control.

X0:5

Interface RS 232 TxD, is used for printer control.

Measurement not possible!

Input acceleration transducer VH20g/HR15g

Acceleration signal (measured against AGND)

approx. 0..6 V

Measurement not possible!

X0:6 X0:7

Open-circuit voltage (vibration off):

"

4,2..4,3 V

Analogue input / voltage input 0..8.5 V X0:8 X0:9

Status: Author:

Input exciter position front Analogue input / voltage input 0..8.5 V

06.12.2004 T. Löw / TE

Position exciter front (measured against AGND) Bottom stop " approx. 2,2 V Neutral position " approx. 4,25 V Top stop " approx. 6,6 V

Description of signals

Page 29 of 48

Service Training MESX

Description of signals

ESX terminal Signal description X0:10

Nominal values (voltage / current)

X0:11 X0:12 X0:13 X0:14 X0:15 X0:16 X0:17 X0:18 X0:19

" >6V "approx.0 V " 12 V " 2V " 12 V " 2V " 12 V " 2V " 12 V " 2V

Input vibration 1 On Digital input active high Input "START" button (option) Digital input active high Input "STOP" button (option) Digital input active high Input "PRINT" button (option) Digital input active high Input "CLEAR" button (option) Digital input active high

Vibration on Vibration off: Push button pressed Push button not pressed Push button pressed Push button not pressed Push button pressed Push button not pressed Push button pressed Push button not pressed

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.

X0:20 X0:21 X0:22 X0:23

X0:24

Status: Author:

06.12.2004 T. Löw / TE

Description of signals

Page 30 of 48

Service Training MESX

Description of signals

ESX terminal Signal description X0:25

Nominal values (voltage / current)

X0:26

Interface CAN-Bus1 Wire -, is used to communicate with the BOPoperating panel. Interface CAN-Bus1 Wire +, is used to communicate with the BOPoperating panel.

Measurement not possible!

Control switched on Control switched off

X0:29

Input potential terminal 15 Digital input active high This signal must be present, so that the control can work. Input acceleration transducer VV/VL15g

X0:30

Analogue input / voltage input 0..8.5 V Input acceleration transducer VH/VR15g

X0:31

Analogue input / voltage input 0..8.5 V Input acceleration transducer VV20g/HR15g

X0:27

X0:28

Measurement not possible! " 12 V "approx.2 V

Acceleration signal (measured against AGND) Open-circuit voltage (vibration off):

"

4,2..4,3 V

Acceleration signal (measured against AGND) Open-circuit voltage (vibration off):

"

4,2..4,3 V

Acceleration signal (measured against AGND) Open-circuit voltage (vibration off):

"

4,2..4,3 V

Analogue input / voltage input 0..8.5 V X0:32 X0:33 X0:34

Interface CAN-Bus2 Wire -, is used to communicate with the BCM05.

Measurement not possible!

X0:35

Input distance transducer

Transducer delivers square-wave pulses. Frequency machine type dependent.

Digital input active high

Status: Author:

06.12.2004 T. Löw / TE

Description of signals

Page 31 of 48

Service Training MESX

Description of signals

ESX terminal Signal description X0:36

Nominal values (voltage / current)

X0:37

Input D+ generator Digital input active high Input vibration 2 On Digital input active high

Engine running / engine is started Engine not running Vibration on Vibration off:

Output valve 1 front PWM digital output (max. 4 A) Output valve 2 front PWM digital output (max. 4 A)

permissible current range: approx. 0..1,5 A

X0:38

" 12 V " 0V " >6V "approx.0 V

X0:39 X0:40 X0:41 X0:42 X0:43 X0:44 X0:45 X0:46 X0:47

permissible current range: approx. 0..1,5 A

X0:48 X0:49 X0:50 X0:51 X0:52

Status: Author:

06.12.2004 T. Löw / TE

Description of signals

Page 32 of 48

Service Training MESX

Description of signals

ESX terminal Signal description X0:53 Interface CAN-Bus2 Wire +, is used to communicate with the BCM05. X0:54 Voltage supply for electronics X0:55

Ground connection electronics

Nominal values (voltage / current) Measurement not possible! Emergency stop not actuated " Emergency stop actuated " 0 V measured against ground

X0:56

Voltage supply for outputs

approx. 12 V measured against ground

X0:57

Voltage supply for outputs

approx. 12 V measured against ground

X0:58

Voltage supply for outputs

approx. 12 V measured against ground

X0:59

Voltage supply for outputs

approx. 12 V measured against ground

X0:60

Voltage supply for outputs

approx. 12 V measured against ground

X0:65

Mouse port Baby Boards

approx. 0 V

X0:66

Mouse port Baby Boards

approx. 0 V

X0:67

Mouse port Baby Boards

approx. 0 V

X0:68

Mouse port Baby Boards

approx. 0 V

12 V 0V

X0:61 X0:62 X0:63 X0:64

Status: Author:

06.12.2004 T. Löw / TE

Description of signals

Page 33 of 48

Service Training

Error codes of the ESX control

10 Error codes of the ESX control 10.1 Overview Error code 4501 4540 4601 4620 8000 8250

Status: Author:

Description of error Position controller (exciter potentiometer, valves) Acceleration transducer Internal software error

06.12.2004 T.Löw / TE

Error codes of the ESX control

Page 34 of 48

Service Training MESX

Description of error codes on the ESX control

10.2 Description of error reactions Error reaction 1

2

3

4

5

Note:

Status: Author:

Description of error reaction Warning. Error code is displayed. Signal light in BOP (option) lights in 5 second intervals. Function affected, the emergency function overrides the faulty function. Error code is displayed. Signal light in BOP (option) lights in 5 second intervals. 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. Error code is displayed. Signal light in BOP (option) lights in 5 second intervals. 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. Error code is displayed. Signal light in BOP (option) lights in 1 second intervals. Fatal fault. The function of the control can no longer be guaranteed. Control is switched off. Error code is displayed. Signal light in BOP (option) lights permanently.

Faults with fault reaction 1 are only warnings and are NOT stored in the error log!

06.12.2004 T. Löw / TE

Description of error codes on the ESX control

Page 35 of 48

Service Training MESX

Description of error codes on the ESX control

10.3 Detailed description of fault codes and their possible causes Error code

Description of error

Possible cause

Terminal on ESX

450 1

Input exciter potentiometer front The voltage applied to the input is below the specified range (see signal description).

X0:09

450 2

Input exciter potentiometer front The voltage applied to the input is above 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 " Current path connected to +12 V / +8,5 V " Potentiometer not connected to ground " Potentiometer defective

Status: Author:

06.12.2004 T. Löw / TE

Description of error codes on the ESX control

X0:09

Input Error code for reaction diagnose 5

5

Page 36 of 48

Service Training MESX

Description of error codes on the ESX control

Error code

Description of error

Possible cause

Terminal on ESX

452 1

Output proportional solenoid front Valve exciter up Output current too low.

X0:46

452 2

Output proportional solenoid front Valve exciter up Output current too high.

" Current path has short circuit to voltage supply " Current path has non-permitted connection to another current path " Current path is interrupted " Current path has short circuit to ground " Current path has non-permitted connection to another current path

452 3

Output proportional solenoid front Valve exciter up Fault when calibrating the valve

452 6

Output proportional solenoid front Valve exciter down Output current too low.

452 7

452 8

Status: Author:

Error Input code for reaction diagnose 2

X0:46

2

" Current path is interrupted " Current path has unpermitted connection to another current path / ground

X0:46

2

X0:47

2

Output proportional solenoid front Valve exciter down Output current too high.

" Current path has short circuit to voltage supply " Current path has non-permitted connection to another current path " Current path is interrupted " Current path has short circuit to ground " Current path has non-permitted connection to another current path

X0:47

2

Output proportional solenoid front Valve exciter down Fault when calibrating the valve

" Current path is interrupted " Current path has impermissible connection to another current path / ground

X0:47

2

06.12.2004 T. Löw / TE

Description of error codes on the ESX control

Page 37 of 48

Service Training MESX

Description of error codes on the ESX control Error Input code for reaction diagnose 5000 2

Error code

Description of error

Possible cause

Terminal on ESX

453 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

453 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

5000

2

460 1

Input acceleration transducer 1 The voltage applied to the input is below the specified range (see signal description).

" Current path has no connection to +12 V / +8,5 V " Current path connected to ground " Transducer defective

X0:29, or X0:31

4601

2

460 2

Input acceleration transducer 1 The voltage applied to the input is above the specified range (see signal description).

" Current path connected to +12 V / +8,5 V " Current path not connected to ground " Transducer defective

X0:29, or X0:31

4601

2

460 6

Input acceleration transducer 2 The voltage applied to the input is below the specified range (see signal description).

" Current path has no connection to +12 V / +8,5 V " Current path connected to ground " Transducer defective

X0:30, or X0:07

4606

2

460 7

Input acceleration transducer 2 The voltage applied to the input is above the specified range (see signal description).

" Current path connected to +12 V / +8,5 V " Current path not connected to ground " Transducer defective

X0:30, or X0:07

4606

2

Status: Author:

06.12.2004 T. Löw / TE

Description of error codes on the ESX control

Page 38 of 48

Service Training MESX

Description of error codes on the ESX control

Error code

Description of error

800 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. Error message „severe software fault in control“ This fault cannot be rectified on the machine. The control must be immediately replaced.

800 1 899 9 900 0 999 8

Ct0

Status: Author:

Possible cause

-

Error Input code for reaction diagnose 2

-

-

5

Terminal on ESX

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

Display module has no connection to ESXcontrol.

" 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

-

-

06.12.2004 T. Löw / TE

Description of error codes on the ESX control

Page 39 of 48

Service Training MESX

Description of input codes for the control

11 Input codes for ESX control (only via BEM display module) 11.1 Travel system Input code 1000

Description of display function Travel direction sensor Displays the status of sensor.

Display values 0000 " 0V 0001 " 12 V

1001

Travel direction Displays the travel direction derived from the "Travel direction sensor" by the control.

1000 " 0000 " 000I "

1002

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. Travel speed Displays the actual speed. Parameter "Display distance impulses per 10m" Eeprom parameter is displayed Parameter "Invert travel direction" Eeprom parameter is displayed

Display value = travel distance in 10 cm

1003 1010 1011

Status: Author:

06.12.2004 T. Löw / TE

Forward travel detected Neutral position Reverse travel detected

Display value = speed in km/h Depending on selected machine type, e.g. 5896 at BW177 BVC 0000 " 000I "

Direction signal is not inverted Direction signal is inverted

Description of input codes for the control

Page 40 of 48

Service Training MESX

Description of input codes for the control

11.2 Vibration Input code 3000 3001 3002

Description of display function Vibration status general The status of vibration is displayed. Vibration status low amplitude The status of vibration with low amplitude is displayed. Vibration status high amplitude The status of vibration with high amplitude is displayed.

Display values 0000 " Vibration OFF 0001 " Vibration ON 0000 " Vibration OFF 0001 " Vibration ON 0000 " Vibration OFF 0001 " Vibration ON

Description of display function Input light switch The status of the lighting system is displayed.

Display values 0000 " Light OFF 0001 " Light ON

11.3 Light Input code 3010

Status: Author:

06.12.2004 T. Löw / TE

Description of input codes for the control

Page 41 of 48

Service Training MESX

Description of input codes for the control

11.4 Acceleration transducer Input code 4601 4606

Description of display function Acceleration transducer 1 Displays voltage for transducer 1. Acceleration transducer 2 Displays voltage for transducer 2.

Display values Display value = voltage in V Display value = voltage in V

11.5 Diesel engine Input code 5000

Status: Author:

Description of display function Input MD+ Displays the status of the diesel engine.

06.12.2004 T. Löw / TE

Display values 0000 " Engine OFF 0001 " Engine ON

Description of input codes for the control

Page 42 of 48

Service Training MESX

Description of input codes for the control

11.6 Setting the machine type Input code 7000

Description of display function Displays the set machine type

7010

Switches on function „Set machine type“

7011

Confirms entered machine type

7500..75 99

Preselection of machine type

Status: Author:

06.12.2004 T. Löw / TE

Display values see adjustment instructions (page Fehler! Textmarke nicht definiert.)! see adjustment instructions (page Fehler! Textmarke nicht definiert.)! see adjustment instructions (page Fehler! Textmarke nicht definiert.)! see adjustment instructions (page Fehler! Textmarke nicht definiert.)!

Description of input codes for the control

Page 43 of 48

Service Training MESX

Description of input codes for the control

11.7 Parameter change Input code 7600 7601

Status: Author:

Description of display function Switches on function "Invert travel direction" Inverts the actually set travel direction

06.12.2004 T. Löw / TE

Display values Display value 7 6 0 0 see adjustment instructions (page Fehler! Textmarke nicht definiert.)!

Description of input codes for the control

Page 44 of 48

Service Training MESX

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

Status: Author:

06.12.2004 T.Löw / TE

General terminology

Page 45 of 48

Service Training MESX 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 Ω to 300 Ω; valve 0% to 100% opened (proportional valve)

Status: Author:

06.12.2004 T.Löw / TE

General terminology

Page 46 of 48

Service Training MESX 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 Operating path:

Closed loop control closed (closed loop control circuit) Measurement and Value to be adjusted is comparison of value to measured and compared. be adjusted: Reaction to faults Counteracts to all faults (generally): targeting the system to be controlled. Technical expense: Low expense: Measurement of the value to be controlled, comparison of nominal and actual value, power amplification Performance in For unstable systems closed unstable systems loop controls must be used.

Status: Author:

06.12.2004 T.Löw / TE

Control open (control chain) Values to be controlled are not measured and compared. Does not respond to unknown faults High expense if many faults have to be considered, low expense if not faults occur. In unstable systems controls cannot be used.

General terminology

Page 47 of 48

Service Training MESX Current and voltage measurement

Ohm’s law: U = Voltage R = Resistance I = Current

Plausibility check The control (ESX) runs a plausibility check on all inputs. This means the control checks permanently whether certain state combinations are permitted; e.g. travel lever position forward and reverse will cause an fault message, because this condition is normally not possible. 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: Author:

06.12.2004 T.Löw / TE

General terminology

Page 48 of 48

Service Training Electrics Single Drum Rollers – 4 From -DH Version 1.10

Version 1.03 Status: Author:

06.12.04 Seis / TE

Dateiname:

p:\schulung\wz-4\elektrik\englisch\dez04\esx_schulung_wz4 v1.03_gb.doc

Page 1 of 46

Service Training WZ-4 from version DH

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

Status: Author:

06.12.04 Seis / TE

Dateiname:

p:\schulung\wz-4\elektrik\englisch\dez04\esx_schulung_wz4 v1.03_gb.doc

Page 2 of 46

Service Training WZ-4 from version DH 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

Status: Author:

06.12.04 Seis / TE

Dateiname:

p:\schulung\wz-4\elektrik\englisch\dez04\esx_schulung_wz4 v1.03_gb.doc

Page 3 of 46

Service Training WZ-4 from version DH

1 List of changes No. 1 2 3 4

Date 23.04.2004 06.05.2004 11.05.2004 24.06.2004

Description of changes Creation of version 1.00 Revision, teach functions Revision, supplements to version 1.01 Revision, supplement to version 1.02

Ver. Date Description of changes 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?

Status: Author:

06.12.04 Seis / TE

Dateiname:

p:\schulung\wz-4\elektrik\englisch\dez04\esx_schulung_wz4 v1.03_gb.doc

resp. Werner Fondel Seis Seis resp. Schroeder, Fondel

Page 4 of 46

Service Training WZ-4 from version DH

2 Selected fault reactions of the ESX control Reaktion

Symbol in fault message display

Signal

Warning

Warning

Engine stop

Code output without buzzer

Code output with buzzer

Code output with buzzer

5100 5112

5101 5112

Engine oil pressure (from EMR)

1)

Coolant temperature (from EMR)

5100 5116 1)

Coolant level

Engine air filter

2)

after 10s

5101 5116 2)

after 15s

5024

5025

after 5s

after 10s

5026

5027

after 5s

after 2min 3)

Charge control light

Pre-heating of engine

Brake

ASC

Different fault causes and reaction times. See fault codes Hydraulic oil filter

Water separator on fuel filter

5502

5503

after 5s

after 2min

5028

5029

after 5s

after 2min

Theft warning system (Option)

Seat contact (Option) Fault in air conditioning (Option) 1) 2)

After reaching the warning limit! After reaching the shut-down limit!

3)

Shut-down currently deactivated by parameter

Status: Author:

06.12.04 Seis / TE

Dateiname:

p:\schulung\wz-4\elektrik\englisch\dez04\esx_schulung_wz4 v1.03_gb.doc

Page 5 of 46

Service Training WZ-4 from version DH 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: Display stay dark, no voltage

Cause: PIN in display plug X 28 bent

Status: Author:

06.12.04 Seis / TE

Dateiname:

p:\schulung\wz-4\elektrik\englisch\dez04\esx_schulung_wz4 v1.03_gb.doc

Page 6 of 46

Service Training WZ-4 from version DH

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.

INFO 1 Taste (gelb)

Werte ändern (grün)

INFO 2 Taste (gelb)

Navigieren (blau)

Werte ändern (grün) Navigieren (blau)

To activate the input mode the travel lever must be engaged in the brake lock! Input mode is activated by simultaneous pressing of both INFO – buttons over a period of approx. 3 seconds.

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.

Status: Author:

06.12.04 Seis/ TE

Functions of ESX control

Page 7 of 46

Service Training WZ-4 from version DH

Normalmodus (Fahrhebel in Bremsraste!) Aufruf optionaler Anzeigen über INFO - Taste 1 und INFO - Taste 2

„Eingabe“ - Modus: Betätigen INFO 1 + INFO 2 ca. 3s

Bet. INFO 1 + INFO 2 ca. 3s oder Fahrhebel aus Bremsr.

Umschaltung Displayfunktion Einstellungen Display Plattenverstellung inaktiv!

Eingabe Zugangangscode 9999

„Service“- Modus: Eingabe Diagnosecodes Fehlerspeicher abrufen / löschen Maschinentypen umstellen Plattenverstellung inaktiv!

CODE - Eingabe „0000" oder Zündung aus

Fahrhebel aus Bremsraste: Diagnosemodus im Vordergrund aktiv!

Status: Author:

06.12.04 Seis/ TE

Functions of ESX control

Page 8 of 46

Service Training WZ-4 from version DH

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: 0

1

2

3

4

5

6

7

8

9

0

Default

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

1

BW 216 PDH-4

BW 177 DH-4 (Dozer blade) 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

72XX DH

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:

Note:

7212

Parameter adjustments can only be performed when the engine is not running.

Note:

This function can only be activated / deactivated when the travel lever is in brake lock position. (! ! Input mode) The following method must be used for initial start-up of a control:

Status: Author:

06.12.04 Seis/ TE

Functions of ESX control

Page 9 of 46

Service Training WZ-4 from version DH • 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“. The display module now permanently shows the code 7 2 0 0 . • 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:

Status: Author:

The steering unit can only be changed when the engine is not running!

06.12.04 Seis/ TE

Functions of ESX control

Page 10 of 46

Service Training WZ-4 from version DH

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 9 9 9 9 ). It must be strictly assured that the speed sensor (in front right hand hydraulic motor) is working correctly. For a function test enter code number 1 1 0 6 at the display module. This code can be used to display the number path pulses from the speed sensor. The displayed value must change when the machine is driven. If this value does not change even though the machine is moving, the measurement must not be performed! The state of the speed sensor must first be corrected, as otherwise the movement of the drum will not be detected. (See also: „Resetting the surge currents in the travel system”) Attention! During the measurement the machine will move when the surge current is reached! Do not leave the machine while the measurement is progressing! During the measurement keep an eye on your environment! To stop the machine reset the travel lever to neutral position! The automatic measurement of the travel system surge currents is performed as follows: • The switch for rotary speed preselection must be set to ECO • If necessary enter code number 9 9 9 9 to enter into service mode. • Then enter 1 0 9 0 . This code number activates the function "Automatic detection of surge currents"; the display now shows the value 0 0 0 0 with the first zero flashing. This code number must be entered before the following steps can be performed. From this point the machine can

Status: Author:

06.12.04 Seis/ TE

Functions of ESX control

Page 11 of 46

Service Training WZ-4 from version DH 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. • During the measurement the actual current is displayed (display value = current in mA). • Once this measurement is finished the display will show O K again. • The travel lever must now be returned to brake position. • Once both jump currents have been learned correctly and the travel lever is back in "brake position", the display will show the message "D O N E", the values are saved and the function is finished. Now the machine can be operated again by the travel lever. The new surge current values for the travel system are valid from the next start. • The teach function can at any point be aborted by simply pressing the emergency stop button or via the ignition switch. With software versions 1.07 and 1.08 use the following procedure: The automatic measurement of the travel system surge currents is performed as follows: • The seat must be adjusted for travel direction forward! • The switch for rotary speed preselection must be set to ECO • If necessary enter code number 9 9 9 9 to enter into service mode. • Then enter 1 0 9 0 . This code number activates the function "Automatic detection of surge currents"; the display now shows the value 0 0 0 0 with the first zero flashing. This code number must be entered before the next steps are possible. From this point the machine can no longer be operated with the travel lever! The travel lever will only be in function again after the steering function has been ended or the engine has been restarted. • Both measurements (forward/reverse) must be started by entering a code number. The code numbers for both travel directions are: 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. • During the measurement the actual current is displayed (display value = current in mA). • Teaching must be performed for both travel directions. • When returning the travel lever to neutral after the two measurements, O K is displayed for 3 seconds and the determined values will be memorized. • After both surge currents have been measured the machine can again be driven with the travel lever. The new surge current values for the travel system are valid from the next start. • The teach function can at any point be aborted by simply pressing the emergency stop button or via the ignition switch.

Status: Author:

06.12.04 Seis/ TE

Functions of ESX control

Page 12 of 46

Service Training WZ-4 from version DH

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:

Status: Author:

During the measurement the machine should be parked on level ground. Before the measurement both drums should be steered to straight ahead position.

06.12.04 Seis/ TE

Functions of ESX control

Page 13 of 46

Service Training WZ-4 from version DH

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.

Status: Author:

06.12.04 Seis/ TE

Functions of ESX control

Page 14 of 46

Service Training WZ-4 from version DH

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. Note:

This function can only be activated / deactivated when the travel lever is in brake lock position. (! ! Input mode)

3.10 Showing stored faults This function sequence is only valid from software version 1.10! 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. Note: This function can only be activated / deactivated when the travel lever is in brake lock position. (! Input mode)

3.11 Deleting all stored faults This function sequence is only valid from software version 1.10! Execute the function „Delete all stored faults“: • The engine must not be running! • Enter code number 0 7 1 0 . • Switch the ignition off and on again. All stored function are now deleted.

Note: The stored faults can only be deleted when the engine is not running. Note: This function can only be activated / deactivated when the travel lever is in brake lock position. (! ! Input mode)

Status: Author:

06.12.04 Seis/ TE

Functions of ESX control

Page 15 of 46

Service Training WZ-4 from version DH

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

Status: Author:

06.12.04 Seis/ TE

Functions of ESX control

Page 16 of 46

Service Training WZ-4 from version DH

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.

Status: Author:

06.12.04 Seis/ TE

Functions of ESX control

Page 17 of 46

Service Training WZ – 4

Description of signals on the ESX control

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.

ESX terminal Signal description 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) X35:3 Output warning buzzer Digital output (max. 2.5 A) X35:4 Interface RS 232 RxD, not used for normal operation. X35:5 Interface RS 232 TxD, not used for normal operation. 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)

X35:13 X35:14

Status: Author:

Not used Not used

06.12.04 Seis/ TE

Nominal values (voltage / current) approx. 0 V measured against ground (terminal 31) active, i.e. high amplitude "approx.12 V inactive, i.e. low amplitude " 0V Warning buzzer active "approx.12 V Warning buzzer inactive " 0V Measurement not possible! Measurement not possible! ------------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 XX m/min "approx.XX Hz Machine type: XX m/min "approx.XX Hz XX m/min "approx.XX Hz Machine type: XX m/min "approx.XX Hz XX m/min "approx.XX Hz -----

Description of signals on the ESX control

Page 18 of 46

Service Training WZ – 4

Description of signals on the ESX control

ESX terminal Signal description X35:15 Input seat contact switch Digital input active high X35:16 Not used X35:17 Input BTS brake (from travel lever) Digital input active high X35:18 Input steering sensor (S1/A) Digital input active high X35:19

Input steering sensor (S1/B) Digital input active high

X35:20

Output steering left PWM digital output (max. 4 A) Output steering right PWM digital output (max. 4 A) Output vibration pump for extension plate PWM current output (max. 4 A)

X35:21 X35:22

X35:23

X35:24 X35:25 X35:26 X35:27 X35:28

X35:29

Status: Author:

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). Output Backup alarm Digital output (max. 2.5 A) Not used Interface CAN-Bus 1 Wire -, is used for communication with the MESX, the data collector, the LC-Display and the BOP. Interface CAN-Bus 1 Wire +, is used for communication with the MESX, the data collector, the LC-Display and the BOP. Input potential terminal 15 Digital input active high This signal must be present, so that the control can work. Input steering angle sensor Analogue input / voltage input 0..8.5 V 06.12.04 Seis/ TE

Nominal values (voltage / current) Seat occupied " 0V Seat not occupied " ?V --Release brake "approx.12 V Apply brake " 0V Signal changes between approx. 0V and 12V, when steering wheel is turned. Frequency depends on speed of rotation Signal changes between approx. 0V and 12V, when steering wheel is turned. Frequency depends on speed of rotation Steering left active " 0,4..1,2 A Steering left inactive " 0A Steering right active " 0,4..1,2 A Steering right inactive " 0A permissible current range: approx. 0..0,6 A Vibration pump active " 0,0..2,0 A Vibration pump not active " 0A Nominal voltage = 8,5 V Permissible range: approx. 7,65..9,35 V This voltage must be measured against AGND. Backup alarm inactive Backup alarm active ---

" 0V "approx.12 V

MEASUREMENT NOT POSSIBLE! MEASUREMENT NOT POSSIBLE! Control switched on Control switched off

"approx.12 V "approx.2 V

Position steering angle sensor (measured against AGND) right hand stop " 0,50..1,00 V

Description of signals on the ESX control

Page 19 of 46

Service Training WZ – 4

Description of signals on the ESX control

ESX terminal Signal description

X35:30

Input longitudinal inclination of machine Analogue input / voltage input 0..8.5 V

X35:31

Input hydraulic pressure travel pump circuit Analogue input (current input 4mA..20mA) from pressure sensor on travel pump Not used Interface CAN-Bus 2 Wire -, is used for communication with travel lever and engine EMR.

X35:32 X35:33 X35:34

Input drum speed Frequency input (0....7,5kHz)

X35:35

Input vibration motor Frequency input (0....2,0kHz)

X35:36

Input vibration motor sense of rotation (currently not used)

Status: Author:

06.12.04 Seis/ TE

Nominal values (voltage / current) straight ahead / neutral / middle " .. V left hand stop " 6,80..8,70 V 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 0 bar " approx.4 mA 600 bar " approx.20 mA ---

MEASUREMENT NOT POSSIBLE! 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 XX m/min "approx.XX Hz Machine type: XX m/min "approx.XX Hz XX m/min "approx.XX Hz Machine type: XX m/min "approx.XX Hz XX m/min "approx.XX Hz Frequency at vibration frequency in Hz Machine type: Vib. frequency XX Hz "approx.XX Hz Vib. frequency XX Hz "approx.XX Hz Machine type: Vib. frequency XX Hz "approx.XX Hz Vib. frequency XX Hz "approx.XX Hz Machine type: Vib. frequency XX Hz "approx.XX Hz Vib. frequency XX Hz "approx.XX Hz Sense of rotation forward "approx.12 V Sense of rotation reverse "approx.2 V

Description of signals on the ESX control

Page 20 of 46

Service Training WZ – 4 ESX terminal Signal description Digital input active high X35:37 Input drum sense of rotation Digital input active high X35:38 Input axle sense of rotation Digital input active high X35:39 Not used X35:40 Input steering sensor (S2/A) Digital input active high

Description of signals on the ESX control Nominal values (voltage / current)

X35:41

Input steering sensor (S2/B) Digital input active high

X35:42

Output emergency steering

X35:43 X35:44 X35:45 X35:46

Not used Not used Not used Output drum drive motor PWM current output (max. 4 A)

X35:47

Output axle drive motor PWM current output (max. 4 A)

X35:48

Output vibration pump PWM current output (max. 4 A)

X35:49

Output travel pump forward PWM current output (max. 4 A)

Sense of rotation forward "approx.12 V Sense of rotation reverse "approx.2 V Sense of rotation forward "approx.12 V Sense of rotation reverse "approx.2 V --Signal changes between approx. 0V and 12V, when steering wheel is turned. Frequency depends on speed of rotation Signal changes between approx. 0V and 12V, when steering wheel is turned. Frequency depends on speed of rotation Emergency steering active "approx.12 V Emergency steering inactive " 0V ------permissible current range: approx. 0..0,6 A Drum drive motor active " 0,0..2,0 A Drum drive motor not active " 0A permissible current range: approx. 0..0,6 A Axle motor active " 0,0..2,0 A Axle motor not active " 0A permissible current range: approx. 0..0,6 A Axle motor active " 0,0..2,0 A Axle motor not active " 0A Travel forward active " 0,0..2,0 A Travel forward inactive " 0A

Not used Not used Not used

Sauer components with EDC Travel forward active Travel forward inactive -------

X35:50 X35:51 X35:52

Status: Author:

06.12.04 Seis/ TE

Description of signals on the ESX control

" 18..80 mA " 0 mA

Page 21 of 46

Service Training WZ – 4

Description of signals on the ESX control

ESX terminal Signal description X35:53 Interface CAN-Bus 2 Wire +, is used for communication with travel lever and engine EMR.

Nominal values (voltage / current)

MEASUREMENT NOT POSSIBLE!

X35:54

Voltage supply for electronics (permanent voltage)

X35:55 X35:56 X35:57 X35:58 X35:59 X35:60 X35:61

Ground connection electronics Voltage supply for outputs (permanent voltage) Voltage supply for outputs (permanent voltage) Voltage supply for outputs (permanent voltage) Voltage supply for outputs (permanent voltage) Voltage supply for outputs (permanent voltage) Output brake Digital output (max. 4 A) Output blower coupling stage 2 (currently not used) Digital output (max. 4 A) Output blower coupling stage 3 (currently not used) Digital output (max. 4 A) Output travel pumps reverse PWM current output (max. 4 A)

Control running "approx.12 V Control not running " 0V 0 V (measured against ground) approx. 12 V (measured against ground) approx. 12 V (measured against ground) approx. 12 V (measured against ground) approx. 12 V (measured against ground) approx. 12 V (measured against ground) Open brake "approx.12 V Close brake " 0V Active "approx.12 V Inactive " 0V Active "approx.12 V Inactive " 0V Travel forward active " 0,0..2,0 A Travel forward inactive " 0A

X35:65

Test connection Baby Boards

Sauer components with EDC Travel forward active Travel forward inactive approx. 0 V

X35:66

Test connection Baby Boards

approx. 0 V

X35:67

Test connection Baby Boards

approx. 0 V

X35:68

Test connection Baby Boards

approx. 0 V

X35:62 X35:63 X35:64

Status: Author:

06.12.04 Seis/ TE

Description of signals on the ESX control

" 18..80 mA " 0 mA

Page 22 of 46

Service Training WZ – 4

Description of signals on the data collector

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 under due consideration of voltage drops in the lines.

PIN data collector X26:1 X26:2 X26:3 X26:4 X26:5 X26:6 X26:7 X26:8 X26:9 X26:10 X26:11 X26:12 X27:1 X27:2

X27:3 X27:4 Status: Author:

Signal description

Nominal values (voltage / current)

Input direction indicator right Digital input active high Input direction indicator left Digital input active high Input engine running (D+) Digital input active high Not used Input differential pressure hydraulic oil filter Digital input active low Not used Input air conditioning Digital input active high Input engine air filter Digital input active low Input background illumination Digital input active high Input coolant level Digital input active low Not used Ground connection Not used Input fuel level Analog input

Direction indicator right active Direction indicator left active Direction indicator left active Direction indicator left active Engine running Engine not running --Filter clogged Filter OK --Air conditioning on Air conditioning off Filter clogged Filter OK Illumination on Illumination off Coolant level too low Coolant level sufficient --0V (measured against ground)

Not used Voltage supply for monitoring of the water separation (PIN X27:9) 06.12.04 Seis/ TE

"approx.12 V " 0V "approx.12 V " 0V "approx.12 V " 0V " "

0V ?V

"approx.12 V " 0V " 0V " ?V "approx.12 V " 0V " 0V " ?V

The voltage signals change with the fuel level in the diesel tank Fuel tank empty " ?? V Fuel tank full " ?? V --Voltage supply O.K. "approx.12 V

Description of signals on the data collector

Page 23 of 46

Service Training WZ – 4

Description of signals on the data collector

PIN data collector

Signal description

X27:5 X27:6

Ground connection Interface CAN-Bus 1 Wire +, is used for communication with the MESX, the ESX, the LC-Display and the BOP. Interface CAN-Bus 1 Wire -, is used for communication with the MESX, the ESX, the LC-Display and the BOP. Voltage supply (permanent voltage)

X27:7 X27:8 X27:9

Input water separation Current input

X27:10 X27:11 X27:12

Not used Not used Not used

Status: Author:

06.12.04 Seis/ TE

Nominal values (voltage / current) No voltage supply 0V (measured against ground) Measurement not possible!

"

0V

Measurement not possible! Control running "approx.12 V Control not running " 0V 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 -------

Description of signals on the data collector

Page 24 of 46

Service Training WZ – 4

Description of signals on the travel lever

7 Description of signals on the travel lever Notes: Wherever the value of 12 V is mentioned in the following text it refers to the current battery voltage under due consideration of voltage drops in the lines.

PIN Travel lever X23:1 X23:2 X23:3 X23:4 X23:5

X23:6 X23:7 X23:8

X23:9 X23:10 X23:11

X23:12 X24:1 X24:2

Status: Author:

Signal description

Nominal values (voltage / current)

Voltage supply (permanent voltage)

Electronics working Electronics not working 0V (measured against ground) Brake opens Brake closing

Ground connection Output BTS brake Digital output (max. 4 A) Output BTS (not used) Digital output (max. 4 A) 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. Interface CAN-Bus 2 Wire +, is used for communication with the ESX and the engine EMR. Interface CAN-Bus 2 Wire -, is used for communication with the ESX and the engine EMR. AGND = Analogue ground: Ground potential for additional analog evaluation Relation to PIN X23:5 Node address addressing 1 Node address addressing 2 Input travel speed range switch Analog input Not used Not used Input high amplitude

06.12.04 Seis/ TE

"approx.12 V " 0V "approx.12 V " 0V

Nominal voltage = approx. 5,0 V Permissible range: approx. 4,8..5,2 V This voltage must be measured against AGND. Measurement not possible! Measurement not possible! approx. 0 V measured against ground (terminal 31)

Connection to machine ground (0V) Connection to machine ground (0V) The voltage signal changes with the adjusted travel range Travel stage min. " ?? V Travel stage max. " ?? V ----High amplitude active "approx.12 V

Description of signals on the travel lever

Page 25 of 46

Service Training WZ – 4 PIN Travel lever X24:3 X24:4 X24:5 X24:6 X24:7

X24:8

Status: Author:

Description of signals on the travel lever

Signal description

Nominal values (voltage / current)

Digital input active high Input low amplitude Digital input active high Not used Not used Input left hand armrest (not yet realized) Digital input active high 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. Output voltage supply ground potential This output in connection with PIN X24:7 enables the control of additional components (relay, displays etc.)

High amplitude inactive Low amplitude active Low amplitude inactive -------

" 0V "approx.12 V " 0V

Voltage supply active Voltage supply inactive

"approx.12 V " 0V

06.12.04 Seis/ TE

0V (measured against ground)

Description of signals on the travel lever

Page 26 of 46

Service Training WZ – 4

Description of signals on the LC - display

8 Description of signals on the LC - Display Notes: Wherever the value of 12 V is mentioned in the following text it refers to the current battery voltage under due consideration of voltage drops in the lines.

PIN Display X28:1

Signal description Voltage supply (permanent voltage "ignition on")

X28:2 X28:3

Ground connection Interface CAN-Bus 1 Wire +, is used for communication with the MESX, the ESX, the data collector and the BOP. Interface CAN-Bus 1 Wire -, is used for communication with the MESX, the ESX, the data collector and the BOP. Voltage supply (permanent voltage "Battery +" for RTC)

X28:4 X28:5 X28:6 X29:1 X29:2 X29:3 X29:4 X29:5 X29:6 X29:7

X29:8

Status: Author:

Not used Input frequency adjustment lower Digital input active high Input frequency adjustment higher Digital input active high Input engine speed high idle Digital input active high Input engine speed low idle Digital input active high Not used Not used 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. Not used

06.12.04 Seis/ TE

Nominal values (voltage / current) Electronics working "approx.12 V Electronics not working " 0V 0V (measured against ground) Measurement not possible! Measurement not possible! Electronics working Electronics not working " --Adjustment active Adjustment inactive Adjustment active Adjustment inactive High idle active High idle inactive Low idle active Low idle inactive ----Voltage supply active Voltage supply inactive

"approx.12 V 0V "approx.12 V " 0V "approx.12 V " 0V "approx.12 V " 0V "approx.12 V " 0V

"approx.12 V " 0V

---

Description of signals on the LC - display

Page 27 of 46

Service Training WZ - 4

Description of signals on the DIOS module

9 Description of signals on the DIOS module (only with optional extension plates) DIOS terminal X0:1 X0:2 X0:3 X0:4

Signal description Interface CAN-Bus 1 Wire +, is used to communicate with the ESXcontrol. Interface CAN-Bus 1 Wire -, is used to communicate with the ESXcontrol. Voltage supply for electronics

X0:9

Input Proximity switch plates middle Digital input active high Output plates up Digital output (max. 4 A) Output plates down Digital output (max. 4 A) Output plate left Digital output (max. 4 A) Output plate right Digital output (max. 4 A) Voltage supply for outputs

X0:10

Voltage supply for outputs

X0:11 X0:12

Ground connection Input proximity switch plates middle Digital input active high Output plates floating position Digital output (max. 4 A) Output plates priority Digital output (max. 4 A) Not used Not used

X0:5 X0:6 X0:7 X0:8

X0:13 X0:14 X0:15 X0:16

Status: Author:

06.12.04 Seis / TE

Nominal values (voltage / current) Measurement not possible! Measurement not possible! Ignition ON: Ignition OFF: Plates in middle position Plate outside middle position Lifting active Lifting inactive Lowering active Lowering inactive Offset left active Offset left inactive Offset right active Offset right inactive Ignition ON: Ignition OFF: Ignition ON: Ignition OFF: 0 V measured against ground Plates at top lift point Plates lowered Float position active Lifting inactive Priority active Priority inactive -----

Description of signals on the DIOS module

"approx.12 V " 0V "approx.12 V " 0V "approx.12 V " 0V "approx.12 V " 0V "approx.12 V " 0V "approx.12 V " 0V "approx.12 V " 0V "approx.12 V " 0V "approx.12 V " 0V "approx.12 V " 0V "approx.12 V " 0V

Page 28 of 46

Service Training

Error codes of the ESX control

10 Fault codes of the ESX control 10.1 Overview Fault code 0000 0999 1000 1999 2000 2499 2500 2999 3000 4499 4500 4999 5000 5499 5500 5999 6000 6999 7000 7499 7500 7899 7900 7999 8000 8999 9000 9999

Status: Author:

Fault description General faults / warnings / machine tests Fault in travel system Fault in steering system Fault in remote control Fault of work functions (vibration, rotor, dozer blade, chip spreader) Fault in measuring systems Fault diesel engine Fault hydraulic system Fault anti-theft warning system, locating system, access system, time calculation, etc. Input of machine codes Input of measuring technology codes Operating hours, load spectrum, etc. Severe software fault Fault of external I/O-nodes (joystick, data collector, Dios-module, LCD-display, etc.)

06.12.04 Seis / TE

Error codes of the ESX control

Page 29 of 46

Service Training WZ – 4

Description of input codes of the control

10.2 Description of fault reactions Fault reaction Description of fault reaction 1

Warning. Fault code is displayed.

2

Warning. Fault code is displayed. Audible signal

3

Function affected, the faulty function is replaced by an emergency function. Fault code is displayed. Audible signal

4

Partial function faulty, the partial function cannot be overridden by an emergency function. The machine is stopped if this fault occurs. The machine can still be driven to a limited extent, but must be repaired by the service department as soon as possible. Fault code is displayed. Audible signal

5

Partial function faulty, the partial function cannot be overridden by an emergency function. The machine is no longer able to drive, e.g. because parts of the travel system are defective " the diesel engine is shut down. Fault code is displayed. Audible signal

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:

Status: Author:

Faults with fault reaction 1 and 2 are only warnings and are NOT stored in the error log!

06.12.04 Seis / TE

Description of input codes of the control

Page 30 of 46

Service Training WZ – 4

Description of input codes of the control

10.3 Detailed description of fault codes and their possible causes

Fault Code

Fault description

Possible causes

Terminal on ESX

DH-4

Assignment BVC-4

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

A corresponding input code was entered

X

504

Warning "Anti-Slip Control (ASC) deactivated" The function "Anti-Slup Control (ASC)" is deactivated

A corresponding input code was entered

X

507

Warning "Drum drive deactivated" The test mode "drum drive deactivated" was activated.

A corresponding input code was entered

X

508

Warning "Axle drive deactivated" The test mode "axle drive deactivated" was activated.

A corresponding input code was entered

X

560

Fault "Overvoltage 8,5V" The voltage level of 8,5V range is exceeded in an unacceptable way (see signal description) Fault "Undervoltage 8,5V" The voltage level of 8,5V range is fallen short of in an unacceptable way (see signal description) Fault "Voltage override relay" The voltage level of the 8,5V range is...

Connection of the voltage level to operating voltage, another voltage potential or control defective

X

Connection of the voltage level to ground, another voltage potential or control defective

X

Fault brake valve The required control power cannot be transmitted to the control solenoid. Fault brake valve Signal outside the valid range (see signal description) Fault brake valve Signal outside the valid range (see signal description) Fault BTS brake / travel lever Overheating of the BTS has the effect that the travel lever brake position is not recognized correctly

The connecting line from the output of the control to the control solenoid is interrupted, or the proportional solenoid is defective Cable breakage in ground line, or the connecting cable valve / ground connection has come loose Cable breakage in supply line, or the connecting cable valve / supply has come loose Hardware defect on travel lever

561

562

1001

1002 1003 1004

Status: Author:

06.12.04 Seis / TE

Input code for diagnose

Fault reaction

X

Description of input codes of the control

X

X

X

X

X

X

X

X

Page 31 of 46

Service Training WZ – 4 Fault Code

Fault description

Description of input codes of the control Possible causes

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

1040

Fault travel range switch "ground connection" Signal outside the valid range (see signal description)

1041

Fault travel range switch "supply connection" Signal outside the valid range (see signal description) Fault travel range switch Signal outside the valid range (see signal description)

1042

Cable breakage in ground line, or the connecting cable switch / ground connection has come loose Cable breakage in supply line, or the connecting cable switch / supply has come loose Increased transition resistance values on contacts may have led to a falsification of the signal. The switch needs to be replaced

X

X

X

X

X

X

The connecting line from the output of the control to the proportional solenoid is interrupted, or the proportional solenoid is defective

X

X

X X X

X X X

X

X

X X X

X X X

X

X

X

X

1071 1072 1073

Fault of current regulator forward Fault of current regulator forward Short circuit in the connecting line (control to prop valve) to Fault output "travel pump forward" Supply voltage UB applied at the output to the proportional supply voltage valve. Machine is mechanically blocked Fault when teaching surge current forward Bypass valves in travel system are deadjusted

1080

1081 1082 1083

1084

Fault output "travel pump reverse" The required control power cannot be transmitted to the proportional solenoid. Fault of current regulator reverse Fault of current regulator reverse Fault output "travel pump reverse" Supply voltage UB applied at the output to the proportional valve. Fault when teaching surge current reverse

1088

Informative message! Surge currents of travel pump NOT YET learned. See 3.6

1100

Fault output "front travel motor" The required control power cannot be transmitted to the proportional solenoid.

Status: Author:

06.12.04 Seis / TE

Assignment BVC-4 X

Fault output "travel pump forward" The required control power cannot be transmitted to the proportional solenoid.

The connecting line from the output of the control to the proportional solenoid is interrupted, or the proportional solenoid is defective

Short circuit in the connecting line (control to prop valve) to supply voltage Machine is mechanically blocked Bypass valves in travel system are deadjusted Function "Learning of pump surge currents" for travel pump not yet executed. -> New machine/control change The connecting line from the output of the control to the proportional solenoid is interrupted, or the proportional solenoid is defective

Description of input codes of the control

X35:17

DH-4

X

1070

1074

Terminal on ESX

Input code for diagnose

Fault reaction

Note

Page 32 of 46

Service Training WZ – 4 Fault Code

Fault description

Description of input codes of the control Possible causes

Terminal on ESX

DH-4

Assignment BVC-4

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"

Check connecting lines and plugs to the wheel speed sensor or replace the speed sensor, if necessary

X

X

1107

Short circuit in the connecting line (control to prop valve) to Fault output "front travel motor" Supply voltage UB applied at the output to the proportional supply voltage valve.

X

X

1110

Fault output "rear travel motor" The required control power cannot be transmitted to the 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

1115

Fault rear 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

1116

Fault rear travel motor "speed sensor" Faulty or non-existent signal "direction"

Check connecting lines and plugs to the wheel speed sensor or replace the speed sensor, if necessary

X

X

1117

Short circuit in the connecting line (control to prop valve) to Fault output "rear travel motor" Supply voltage UB applied at the output to the proportional supply voltage valve.

X

X

1140

Fault pressure switch travel system "signal" The current signal is not transmitted (see signal specification) Fault pressure switch travel system "signal range" The current signal is outside the permissible range (see signal specification) Fault pressure switch travel system "no pressure" The current signal indicates that no permanent travel pressure is built up.

The connecting line from the output of the control to the pressure sensor is interrupted, or The pressure sensor is defective The pressure sensor is defective

X

X

X

X

No pressure connection on sensor, of supply line clogged or no travel pressure is built up

X

X

Fault inclination sensor "supply connection" Signal outside the valid range (see signal description) Fault inclination sensor "ground connection" Signal outside the valid range (see signal description)

Cable breakage in supply line, or the connecting cable sensor / voltage supply has come loose Cable breakage in ground line, or the connecting cable sensor / ground connection has come loose

X

X

X

X

1141

1142

1145 1146

Status: Author:

06.12.04 Seis / TE

Description of input codes of the control

Input code for diagnose

Fault reaction

Page 33 of 46

Service Training WZ – 4 Fault Code

Fault description

Description of input codes of the control Possible causes

1300

Seat contact switch not occupied

1500

Warning "dangerous situation ASC"

2060

Fault output "steering valve right" The required control power cannot be transmitted to the proportional solenoid. Fault output "steering valve left" The required control power cannot be transmitted to the proportional solenoid.

The connecting line from the output of the control to the proportional solenoid is interrupted, or the proportional solenoid is defective The connecting line from the output of the control to the proportional solenoid is interrupted, or the proportional solenoid is defective

2065

Fault learning the surge current right hand valve

2066

Fault learning the surge current left hand valve

2068

Informative message! Surge currents of steering pump NOT YET learned. See 3.7 (Only machines with electric steering)

Drum was not moved, maximum current reached, steering is blocked (e.g. articulation lock applied) Drum was not moved, maximum current reached, steering is blocked (e.g. articulation lock applied) Function "Learning of pump surge currents" for steering pump not yet executed. -> New machine/control change

2170 2171

2174 2175 2176

Fault steering wheel "change of direction" Fault steering wheel "impulse coverage" Measuring value of sensor 1 and 2 difference too strong Fault steering wheel "sensor 1 pulse range" The detected steering pulses on steering sensor 1 are outside the valid range (see signal description) Fault steering sensor "sensor 2 pulse range" The detected steering pulses on steering sensor 2 are outside the valid range (see signal description) Fault steering wheel "sensor 1" Fault steering wheel "sensor 2" Fault steering wheel "sensor 1 cable damage"

2177

Fault steering wheel "sensor 2 cable damage"

2190

Fault steering "steering angle sensor... initialization" Fault when initializing the steering angle sensor Fault steering "steering angle sensor—ADC" Fault steering "steering angle sensor—cable damage supply" Fault steering "steering angle sensor—cable damage

2061

2172

2173

2191 2192 2193

Status: Author:

06.12.04 Seis / TE

Cable breakage in signal line, or driver's seat not occupied (driver not seated!)

Terminal on ESX

DH-4

Assignment BVC-4

X

X

X

X

Fault reaction

X

X

(X)

Wiring fault or steering sensor in left hand arm rest defective Steering sensor in left hand arm rest defective.

X X

Check connecting line to steering sensor – sensor 1, if necessary change the steering sensor in the left hand arm rest

X

Check the connecting lines to the steering sensor – sensor 2, or replace the steering sensor in the left hand arm rest.

X

Steering sensor in left hand arm rest defective. Steering sensor in left hand arm rest defective. Check the connecting lines to the steering sensor – sensor 1, or replace the steering sensor in the left hand arm rest. Check the connecting lines to the steering sensor – sensor 2, or replace the steering sensor in the left hand arm rest.

X X X

Steering angle sensor on articulated joint defective

X

Steering angle sensor on articulated joint defective Voltage supply line to steering angle sensor interrupted or Steering angle sensor on articulated joint defective Ground supply line to steering angle sensor interrupted or

X X

Description of input codes of the control

Input code for diagnose

Note

X

X

Page 34 of 46

Service Training WZ – 4 Fault Code

Fault description

Description of input codes of the control Possible causes

Terminal on ESX

DH-4

Assignment BVC-4

ground" Informative message! Steering stops of the electric steering NOT YET learned. See 3.8 (Only machines with electric steering)

Steering angle sensor on articulated joint defective Function "Learning of steering stops" for electric steering not yet executed. -> New machine/control change

2300

Fault "driver's seat armrest lifted"

2301 2302

Fault "driver's seat armrest" Signal outside the valid range (see signal description) Fault "driver's seat armrest cable damage supply"

2303

Fault "driver's seat armrest cable damage ground"

Arm rest is raised or magnetic switch under left hand arm rest defective Cable breakage in signal line, or magnetic switch under left hand arm rest defective Voltage supply line to magnetic switch interrupted or magnetic switch under left hand arm rest defective Ground supply line to magnet switch interrupted or magnetic switch under left hand arm rest defective

3000

Fault vibration sensor "no signal" The sensor in the vibration motor does not detect any pulses.

3001

Fault vibration pump "valve for low amplitude" The required control power cannot be transmitted to the proportional solenoid.

3002

Fault vib. pump valve low amplitude "hysteresis" The...

3003

Fault vib. pump valve low amplitude "current range" The current signal is outside the permissible range (see signal specification)

3004

Fault vibration pump "valve for high amplitude" The required control power cannot be transmitted to the proportional solenoid.

3005

Fault vib. pump valve high amplitude "hysteresis" The...

3006

Fault vib. pump valve high amplitude "current range" The current signal is outside the permissible range (see signal specification)

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

2198

Status: Author:

06.12.04 Seis / TE

(X)

Fault reaction

Note

X X X X

X

X

X

X

X

X

Fault in connecting line or connection to another potential (e.g.: operating voltage)

X

X

The connecting line from the output of the control to the proportional solenoid is interrupted, or the proportional solenoid is defective, or the change-over relay / bridge is missing

X

Check connecting lines and plugs to the vibration sensor or replace the sensor in the vibration motor, if necessary The connecting line from the output of the control to the proportional solenoid is interrupted, or the proportional solenoid is defective, or the changeover relay / bridge is missing

Input code for diagnose

X

Description of input codes of the control

X

Page 35 of 46

Service Training WZ – 4 Fault Code

Fault description

Description of input codes of the control Possible causes

Terminal on ESX

DH-4

Assignment BVC-4

5025 5026 5027 5028 5029

Fault diesel engine shut-down "coolant filling level" Fault diesel engine warning "air filter" Fault diesel engine shut-down "air filter" Warning water separator Shut-down caused by water separator

Coolant level too low or sensor defective Air filter soiled or sensor defective Air filter soiled or sensor defective Water or other dirt in fuel filter Water or other dirt in fuel filter

X X X X X

X X X X X

5100

Fault diesel engine EMR "warning lamp"

X

X

5101

Fault diesel engine EMR "red stop light"

Collective warning " see other fault codes for exact fault diagnose Collective fault engine shut-down " see other fault codes for exact fault diagnose

X

X

5110

Fault diesel engine EMR "nominal speed value"

X

X

5112 5113 5114 5116 5117 5118

Fault diesel engine EMR "oil pressure" Fault diesel engine EMR "charge air pressure" Fault diesel engine EMR "temperature intake pipe" Fault diesel engine EMR "coolant temperature" Fault diesel engine EMR "fuel temperature" Fault diesel engine EMR "engine speed"

X X X X X X

X X X X X X

5122

Fault diesel engine EMR "nominal speed value"

5123 5124 5125

Fault CAN communication Fault CAN communication Fault CAN communication

" 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 " Engine oil pressure too low " Charge air pressure too low " Charge air temperature too high " Coolant temperature too high " Fuel temperature too high " Speed sensor 1 or 2 defective " Connection between EMR and speed sensor 1 or 2 interrupted " 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 " CAN communication between EMR and ESX " CAN communication between EMR and ESX " CAN communication between EMR and ESX

X X X

X X X

5130

Fault diesel engine EMR "oil pressure sensor"

X

X

5131

Fault diesel engine EMR "charge air pressure sensor"

X

X

5132

Fault diesel engine EMR "charge air temperature"

X

X

Status: Author:

06.12.04 Seis / TE

" sensor defective " Wire breakage in current path " Current path has short circuit to ground " sensor defective " Wire breakage in current path " Current path has short circuit to ground " sensor defective " Wire breakage in current path " Current path has short circuit to ground

Description of input codes of the control

Input code for diagnose

Fault reaction

Page 36 of 46

Service Training WZ – 4 Fault Code

Fault description

Description of input codes of the control Possible causes

Terminal on ESX

DH-4

Assignment BVC-4

5134

Fault diesel engine EMR "coolant temperature sensor" " sensor defective " Wire breakage in current path " Current path has short circuit to ground " Speed sensor 1 or 2 defective Fault diesel engine EMR "speed sensor"

5140

Fault diesel engine EMR "unknown fault"

Fault diagnose only with DEUTZ diagnose tool (SERDIA)

X

X

5502 5503 5504 5005

Fault warning "hydraulic oil filter" Fault shut down "hydraulic oil filter" Fault warning "oil temperature" Fault shut down "oil temperature"

Hydraulic oil filter soiled or sensor defective Hydraulic oil filter soiled or sensor defective Hydraulic oil temperature too high or sensor defective Hydraulic oil temperature too high or sensor defective

X X X X

X X X X

7011

Fault warning "change of machine type" This warning appears when the machine type has been changed. Fault "conflict machine type" This fault message is displayed if the set machines do not comply with the basic parameters of the machine.

Only change the machine type after appropriate measures have been applied; e.g. conversion from D to PD (different rolling circumference of drum) 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

X

X

5133

7012

Status: Author:

06.12.04 Seis / TE

Description of input codes of the control

X

X

X

X

Input code for diagnose

Fault reaction

Page 37 of 46

Service Training WZ – 4

Description of input codes of the control

11 Input codes for ESX control 11.1 General Input code 0500

Description of display function Activation of function "Driving against closed brake"

0501 0555

Deactivation of function "Driving against closed brake" Display of "software version"

Display values 500 and brake control light stays on when shifting the travel lever out of the neutral gate O K for 3sec. then back to 0000 e.g.: „109" for software version 1.09

0700 0701 0710 0720

Activation of function "Show stored faults" Deactivation of function "Show stored faults" Delete stored faults Display of "machine code"

Fault codes are successively displayed 0000 once the error log is deleted the display will return to 0000 The machine code is displayed (72xx) (see chapter 3.6)

Description of display function Display of output voltage on output of control "brake valve"

Display values Display in V (e.g. 126 corresponds with 12,6V)

11.2 Brake Input code 1001

Status: Author:

06.12.04 Seis / TE

Description of input codes of the control

Page 38 of 46

Service Training WZ – 4

Description of input codes of the control

11.3 Travel lever / driving Input code 1025

Description of display function Display "travel lever direction"

1026

Display "movement direction"

1027

Display "travel lever enable"

1040 1041

Display "speed range / gear" Display "voltage value for speed range / gear"

1042

Display "voltage value for speed range / gear standardized"

1044

Display "speed range / gear" end value

1070 1071

Display "nominal current travel pump forward“ Display "Actual current travel pump forward“

Status: Author:

06.12.04 Seis / TE

Display values 100 = forward 0 = neutral 1 = reverse 0 = neutral 1 = forward 2 = reverse 1 The display shows the travel range switch position from 1...24 Stages 0...4 = 4 Stages 5...9 = 3 Stages 10...14 = 2 Stages 15...19 = 1 Stages 20...24 = 0 Stage 1 ≈ 956 Stage 2 ≈ 916 Stage 3 ≈ 875 Stage 4 ≈ 835 Stage 5 ≈ 795 Stage 6 ≈ 756 Stage 7 ≈ 716 Stage 8 ≈ 675 Stage 9 ≈ 637 Stage 10 ≈ 597 Stage 11 ≈ 557 Stage 12 ≈ 517 Stage 13 ≈ 478 Stage 14 ≈ 436 Stage 15 ≈ 396 Stage 16 ≈ 357 Stage 17 ≈ 318 Stage 18 ≈ 279 Stage 19 ≈ 238 Stage 20 ≈ 200 Stage 21 ≈ 160 Stage 22 ≈ 120 Stage 23 ≈ 80 Stage 24 ≈ 40 Stage 1 = 417 Stage 2 = 833 Stage 3 = 1'250 Stage 4 = 1'667 Stage 5 = 2'089 Stage 6 = 2'500 Stage 7 = 2'917 Stage 8 = 3'333 Stage 9 = 3'750 Stage 10 = 4'167 Stage 11 = 4'583 Stage 12 = 5'000 Stage 13 = 5'417 Stage 14 = 5'833 Stage 15 = 6'250 Stage 16 = 6'667 Stage 17 = 7'500 Stage 18 = 8'333 Stage 19 = 9'167 Stage 20 = 10'000 Stage 21 = 13'334 Stage 22 = 16'667 Stage 23 = 20'000 Stage 24 = 23'333 0 – 1200 mA Display in mA

Description of input codes of the control

Page 39 of 46

Service Training WZ – 4

Description of input codes of the control

Input code

Description of display function

Display values

1080 1081

Display "nominal current travel pump reverse“ Display "actual current travel pump reverse“

0 – 1200mA Display in mA

1090

see chapter "Teach travel system surge currents"

1091 1092

Activates Function "detect surge currents in travel system automatically" Function "Determine surge current forward" (only vers.1.07 and 1.08) Function "Determine surge current reverse" (only vers.1.07 and 1.08)

1106 1107

Display "speed sensor travel motor front / pulses" Display "speed sensor travel motor front / direction signal"

1108

Display "sense of rotation front drive"

1116 1117

Display "speed sensor travel motor rear / pulses" Display "speed sensor travel motor rear / direction signal"

1118

display "sense of rotation rear drive"

1140

Display "travel pressure"

Display in bar

1145 1146

Display "inclination sensor" standardized Display "inclination sensor" sensor input voltage

1147 1148

Display "inclination sensor" standardized sensor voltage Display "inclination sensor" initialization

Incloination display as standardized value (65540 → 0%) Display in mV 0% ≅ 2550mV Inclination display in mV 1 corresponds with OK

Status: Author:

06.12.04 Seis / TE

see chapter "Teach travel system surge currents" see chapter "Teach travel system surge currents" Counts the pulses up to 99'999 and then starts at 0 again 2 = forward 1 = standstill and reverse 1 = forward 0 = standstill 2 = reverse Counts the pulses up to 99'999 and then starts at 0 again 2 = forward 1 = standstill and reverse 1 = forward 0 = standstill 2 = reverse

Description of input codes of the control

Page 40 of 46

Service Training WZ – 4

Description of input codes of the control

11.4 Steering Input code 1300 1301 1302

Description of display function Function status arm rest contact Voltage of arm rest contact Travel operation status by arm rest contact

Display values 1= arm rest up; 2=arm rest down Display in mV 1=travel enabled; 2= travel disabled

2000 2001 2010 2011 2012 2013

activates Function "teach steering start current" Function "teach steering start current" activates Function "teach steering potentiometer limits" Deactivates Function "teach steering potentiometer limits" Function "teach steering potentiometer right hand limit" Function "teach steering potentiometer left hand limit"

see chapter "Determine steering system surge currents" see chapter "Determine steering system surge currents" see chapter "Determine steering system end stops" 0000 see chapter "Determine steering system end stops" see chapter "Determine steering system end stops"

2060 2061 2062

Activates function „Change steering unit“ Activation of electric steering unit Activation of hydraulic steering unit

see chapter "Changing the steering unit“ see chapter 3.6 see chapter "Changing the steering unit“

2100 2101 2102 2103

Display "Nominal current value steering valve right“ Display "Actual current value steering valve left“ Display "Nominal current value steering valve left“ Display "Actual current value steering valve left“

0 – 1200mA Display in mA 0 – 1200mA Display in mA

2110 2112 2120

Display of voltage value from steering angle sensor on articulated joint Steering angle actual position Steering angle nominal position

0...8,5VDC -1000...0...1000 -1000...0...1000

2130 2131 2132 2133

Steering wheel sensor 1 track 1 absolute pulses Steering wheel sensor 1 track 2 absolute pulses

Number of total pulses Number of total pulses

Steering wheel sensor 1 direction

2140 2141 2142 2143

Steering wheel sensor 2 track 1 absolute pulses Steering wheel sensor 2 track 1 absolute pulses

1=steering wheel steers to the right; 2=steering wheel steers to the left Number of total pulses Number of total pulses

Steering wheel sensor 2 direction

1=steering wheel steers to the right; 2=steering wheel steers to

Status: Author:

06.12.04 Seis / TE

Description of input codes of the control

Page 41 of 46

Service Training WZ – 4 Input code

Description of input codes of the control

Description of display function

Display values the left

11.5 Vibration Input code 3000

Description of display function Display "switch vibration mode"

3001

Display "Status of vibration relay"

3002

Display "Vibration pump valve current" The actual pump current is displayed.

Display values Off = 0 On = 1 0 = Relay K43 not switched 1= Relay K43 switched Display value = mA

11.6 Engine Input code 5024 5026 5028

Description of display function Display "Status engine coolant level" Display "Status engine air filter" Display "Status water separator"

Display values 0= coolant level OK; 1= coolant level too low 0= air filter OK; 1= air filter soiled 0= water separator OK; 1= water or dirt in fuel filter

11.7 Hydraulics Input code 5002

Description of display function Display "Status hydraulic oil – filter"

Display values 0= hydraulic oil filter OK; 1= hydraulic oil filter soiled

11.8 Changing the machine code Input code 7010

Status: Author:

Description of display function Change "machine code"

06.12.04 Seis / TE

Display values see chapter "Changing the machine code“

Description of input codes of the control

Page 42 of 46

Service Training WZ – 4

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

Status: Author:

06.12.04 Seis / TE

General terminology

Page 43 of 46

Service Training WZ – 4 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 Ω to 300 Ω; valve 0% to 100% opened (proportional valve)

Status: Author:

06.12.04 Seis / TE

General terminology

Page 44 of 46

Service Training WZ – 4 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 Operating path:

Closed loop control closed (closed loop control circuit) Measurement and Value to be adjusted is comparison of value to measured and compared. be adjusted: Reaction to faults Counteracts to all faults (generally): targeting the system to be controlled. Technical expense: Low expense: Measurement of the value to be controlled, comparison of nominal and actual value, power amplification Performance in For unstable systems closed unstable systems loop controls must be used.

Status: Author:

06.12.04 Seis / TE

Control open (control chain) Values to be controlled are not measured and compared. Does not respond to unknown faults High expense if many faults have to be considered, low expense if not faults occur. In unstable systems controls cannot be used.

General terminology

Page 45 of 46

Service Training WZ – 4 Current and voltage measurement

Ohm’s law: U = Voltage R = Resistance I = Current

U =R∗I U I= R U R= I

Plausibility check The control (ESX) runs a plausibility check on all inputs. This means the control checks permanently whether certain state combinations are permitted; e.g. travel lever position forward and reverse will cause an fault message, because this condition is normally not possible.

GND - AGND Besides the "normal" battery ground (terminal 31) in the vehicle there is an additional analogue ground, which is only to be used for sensors. (see description of the signals on the ESX-control) 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: Author:

06.12.04 Seis / TE

General terminology

Page 46 of 46

Inhaltsverzeichnis: table of contents: Blatt Nr.: sheet no.: 001 002 003 004 005 006 007 008 009 010 011 012 101

BW177..226DH−4

Zeichnungsnummer drawing − no. 582 700 95 582 700 95 582 700 95 582 700 95 582 700 95 582 700 95 582 700 95 582 700 95 582 700 95 582 700 95 582 700 95 582 700 95 582 700 95

Funktionsgruppe

function unit

Stromlaufplan Versorgung, Starten, Hupe Motor Deutz EMR II Fahrantrieb, Neigungssensor, Sitzkontakt Datensammler, LC−Display Lenkung, Vibration Fahrhebel, Vibrationsplatten Variocontrol, Messtechnik Bomag Compaction Management BCM Beleuchtung und StvZO Kabinenausrüstung, Beleuchtung, Radio, Tachograph Kabinenheizung, Klimaanlage, Zusatzheizung Bauteilliste

Circuit Diagram supply, starting unit, signal horn engine Deutz EMR II driving system, slope sensor, seat contakt switch data−collector, LC−display steering, vibration joystick, vibration−plates Variocontrol, measurement equipm. Bomag Compaction Management BCM illumination and StvZO cabin−equipment, headlights, radio, tachograph cabin−heater, air conditioning, add. heater component listing

28.06.2004 Seis 28.06.2004 Werner

Stromlaufplan circuit diagram

001

001

582 700 95 001

30 K11 2:10

15A

X36:B

X1:15A X36:A

1

F05

2

125A

Startschalter starting swwitch

2

G03

+

X1:3

19 17

NOT−Aus Emerg.−Stop

50a

K61

K61

K32:86

S01:22 3:1 F05:2 5:8

−

D+

5:2

B+

2:11

87a

8:2

X1:1

167A

B+

D+ K09

X1:7

30

86

K11

85

85 31 EMR 3:5

X1:8

86

Taster Hupe push button, horn

X38:A

23

14

24

X1:97

X1:98

X1:101

X1:102

50 B11

M01

2 B−

13

2:6 B+

G02 2

87a

S03

+

S30

K05 30

30

87

85

11:1

X1:155

2:6

2

1

X1:4

7:3 87

X1:109

R19

54 58

1

86

1

−

1

15

X34:P

125mA

V01

D+ MESX G01

X3:3

X1:152

125A

1

1

2

2

V02

1

B11 XS 12V

M −

2

V03

1

1

2

+ −

W X1:110

X1:168

X1:103

X1:123

X1:104

31

31 2:8

Trennschalter Batter break switch battery Heizflansch heating−flange

2

X1:30A

22 12 32 42 52 62

Anzugsw.:50A / Haltew.:10A

F00

15A

21 11 31 41 51 61

X37:B

2

1

F39

2

S01

nur bei Klimaanlage only acc.to air conditioning

F48

15A

X1:28A

X1:151

30

2 x 10qmm

3

1

F23

2

X1:27A

X37:A

Hauptsicherung main fuse

3:19

1

X1:79

Sicherung Heizflansh heating−flange

K14

15A

X1:16A

S00

5

F95

2

X1:30E

X1:28E

4:9

30A

K11:87 5:1 X1:27E

X1:16E 1

F13

87

6:17

X1:15E

X1:10

X1:9

K30 11:1 30 4:1

Batterie battery

Batterie battery

28.06.2004 Seis 28.06.2004 Werner

12:7

2:16

Starter starter

Signalhörer warning horns

3:1 Steckdose socket

Nur bei Geländer/ROPS/SD only at hand−rail/ROPS/sun−roof

Generator generator

Versorgung, Starten, Hupe supply, starting unit, signal horn

1

1

582 700 95 002

2:17 S01:22

S01:22 6:1 X1:95 1 K14 Relais Heizflansch relay heating−flange

2

X1:179

X1:96

B114

B130

Y137

5

2

1

2

B115

X33:8

X33:4

X33:1

X33:6

X33:5

X31:7

X31:2

X31:3

X31:1

X31:6

X57:6

3

X57:1

4

X31:5

X31:8

X31:9 AGND

X31:4 Signal

X57:16

X31:25

1

B113

X34:N

X1:182 X1:186

2:4

B88

RF MESS

X57:19

ESX Fahrst.

X57:18

RF REF

RF−

1

X31:24

X31:23

X31:19

X31:18

X31:16

X57:8

6

X57:9

2

Signal Temperatur

7

X57:4

2

+5V

1

X57:25

X57:17

2

Signal Druck

X57:15

1

X57:24

X57:14

AGND

STG+

X57:11

3

X57:23

STG−

X57:10

X31:17

X31:15

AGND

Signal

X57:13

X31:14

X31:11

AGND

Signal

X57:12

X31:10

X31:13

+5V

X57:22

X31:12

X31:22

X31:21

X31:20 Signal

X57:21

X30:2 AGND

X57:20

X30:1

X30:13

Ubat −

2

EMR Stellglied EMR commander

X32:B

X32:G

X32:K

X1:184

CAN2− 4:11 CAN2+ 4:11

X32:H

1

X1:181

X1:180

CAN high

CAN low

X30:12

X30:14

A48 Motorsteuerung EMR2 engine−controller EMR2

X30:11

X30:10 L

K

X1:183 X32:L

X32:A 31

X33:3

8−polig PNEUTRON

Diagnosestecker EMR diagnosis interface EMR

2:20

X33:2

max 7A

X33:7

X1:185 Steckerschnittstelle Deutz connector interface Deutz

31 EMR 31 4:1 2:2 Motordrehzahlsensor sender engine rpm 2 Motordrehzahlsensor sender engine rpm 1 EMR Motoröldruck EMR engine oil pressure

28.06.2004 Seis 28.06.2004 Werner

EMR Kühlmitteltemperatur EMR coolant temperature Ladeluftdruck + Temp charging air pressure + temperature

Motor Deutz EMR II engine Deutz EMR II

1

1

582 700 95 003

2:14

30

30 5:1 F24:2 5:3

X1:2 EMR Deutz

X1:145

3:4 3:4

CAN2+

CAN2+ 7:6 CAN2− 7:6 CAN1+ 5:8

CAN2−

X1:42 31 X1:119

Fahrhebel

LC−Display, OPUS 21

CAN1− 5:8

X1:120

X1:146 32

1

F84 10A

X34:G

X34:H

X34:C

X1:174 3:20 31

Sensor Achse sender axle

X35:68

X35:67

X35:66

X35:65

X35:55 Gehäuse housing

X35:47

X35:26

CAN1−

X1:50

X1:49

X1:48 X35:27 X35:46

Achsmotor

8:2

6:4

X9:2

X16:2

X1:149

X1:117

X1:123

2

X15:2

1

Y30 2

Y31 2

X1:123

X1:144

2

X1:144

PITCH MESX

Neigungssensor slope sensor

X1:143

X14:A

1

Y16

X1:143

X1:55

−

X1:46

X15:1 1

Y17

X1:142

sw

S

X16:1 1

+ H14 −

X1:142

S06

X1:124

+

400 ... 1.200mA

X9:1

X14:B

400 ... 1.200mA

2,5V

−

31 5:1

Sitzkontaktschalter switch, seat contact

Prop.−Pumpe Vorw. prop.−pump forwards

Rückfahrwarnsummer back up alarm buzzer 28.06.2004 Seis 28.06.2004 Werner

X1:47

Bandagenmotor

X1:141

4V

Sensor Bandage sender drum

CAN1+

Fahrpumpe rückw.

X1:143

1V

−

X1:178

X1:54

X35:53 X35:49 Fahrpumpe vorw.

X1:122

X1:82

8:2 SPEED MESX

X35:33

CAN2+

RxD

X35:4 Rückfahrwarnsum.

X35:24

X35:15 Sitzkontakt

X1:121

400 ... 1.200mA

B57

dir.

11:6 SPEED TAC

R21

X1:114

speed 8:2 DIR MESX

R23

X1:158

0,46A

br

+

B59

120 OHM 1 2

−45_G=0,5V

bl

X1:172

sw

−

dir.

speed

ws

br

+ B60

Diagnosestecker Fahrzeug diagnosis interface equipment

X34:B

120 OHM 1 2

400 ... 1.200mA

X1:175

X35:5

TxD

Elektronik Neigung

X35:30

X35:54

X35:60

X35:59

X35:57

X35:58

X35:34 speed

X1:176 bl

X35:37 Richtung

X1:177 ws

X35:12

X35:56

X35:31

X35:28 speed

X1:44

X35:38 Richtung

X1:45

+45_G=4,5V

X1:173

X1:171

Leistung

Drucksensor

8:2

+

X34:A

2

X1:34A X1:34A

A34

X34:D

X35:64

2

X1:17A

Fahr−Steuerung driving controller

R20

X1:53

1

15A

Drucksensor Fahrpumpe pressure sensor drive pump

R22 X1:34E

F67

B112

120 OHM 1 2

CAN2−

X1:17E

120 OHM 1 2

X1:52

sw

X1:51

rt

X52:2

X52:1

S01 2:16

Fahrantrieb, Neigungssensor, Sitzkontakt driving system, slope sensor, seat contakt switch

Prop.−Ventil Bandagenmotor prop.−Valve drum motor

Prop.−Pumpe Rückw. prop−pump backwards

Prop.−Ventil Achsmotor prop.−Valve axle motor

1

1 1

582 700 95 004

4:20 2:20

30

30 8:1 K11:87 7:14 F24:2 6:15

K11:87 F24:2

4:3

2:17 F05:2 4:17 CAN1+ 4:17 CAN1−

X1:29E 1

F24 15A

ESX Fahrsteuerung

2

F05:2 2:17 CAN1+ 7:14 CAN1− 7:14

DIOS Platten

X1:29A

X1:80

X1:86

X1:41

X1:40

X1:39

X1:87 X1:88

Ub out

not connected

not connected

Ub "15"

Ub "30"

CAN1 low

CAN1 high

CAN1 low

VCC

CAN1 high

X34:R

D+

P

X1:117

X1:94

X1:94

28.06.2004 Seis 28.06.2004 Werner

DIN6

X29:6

X29:7

X29:8

X28:6 DIN5

X29:5

X28:1

X29:4 DIN4

X29:3 DIN3

X29:1 DIN1

X28:4 X29:2 DIN2

GND

X28:2

X26:12 GND

X27:5 GND

X27:3 GND/UIN3

AIN1

AIN2

X27:1

X28:3

X27:7 X27:12

X27:11 UIN2

X27:10 UIN3

X26:11 DIN11

X26:4 DIN4

X26:6 DIN6

X26:2 DIN2

X26:9

X26:1 DIN1

DIN7

DIN9

X26:7

X27:2 UIN1

X27:9 Sepa2

Füllstand Diesel fuel−level

Wasserabscheider water−seperator

Q X8:2

ECO Low High

BL 10:17 BR 10:17 BEL 10:4 KLIMA 12:6

23

down

13

up

23

13

S120 24

14

S139

24

14

X10:2

2 X21:2

31

X8:1 B124

1 B55

A81 LC−Display LC−display

X1:105

R03 P 2

4:20

X1:108

X10:3 X1:117

0 .. 67 OHM

2:6

1 B03

X1:107

Kühlmittelvorrat coolant stock level X21:1

B21

Sepa1

DIN10

DIN8

X1:112

Luftfilter air cleaner

Hydraulikölfilter hydraulic oil filter

X1:111

X27:4

X26:10

connector−colour: X26−grey; X27−black

X26:8

X26:5 DIN5

X26:3 DIN3

X1:106

X27:6

Steckerfarbe: X26−grau; X27−schwarz

A80 Datensammler data−collector

X28:5

X27:8

Schalter Motordrehzahl switch engine−rpm mode X1:154

X1:149

Datensammler, LC−Display data−collector, LC−display

switch frequency−control Schalter Frequenzverstellung

X1:82

31 6:1

1

1

582 700 95 005

S01:22

S01:22

X1:148

Lenkwinkelsensor steering angle sensor

7:1

F24:2 X1:41 X1:187

Lenkeinheit steering unit

S1 A

X39:3

X35:18

A34 Fahr−Steuerung driving controller

X35:23

X35:29

X35:1

X1:42

8,5V

X1:207

X1:55

4:6

VIB

11:6

BTS BREMSE 7:2

X35:35

1

X22:3

X22:4 X1:189

0V

sw ws

BTS Bremse

A

X41:6

0V

X35:19

X39:4

bl

B16

X41:8

X41:2

X40:3

S2

− X22:2

X1:206

X1:162

2

B

X40:2

X35:41

X41:4 X40:4

X39:2

X41:7

X1:159

S1 B

X1:208

X41:3 X40:1 VCC

X35:40

X41:1 X39:1 VCC

X41:5

1

X1:161 X1:160

+

br

X1:205

1

2

X1:56 FM1 X1:57

2

X1:58 FM2 X1:59

X1:60 FM5 X1:61

X1:203

AGND

X34:J nur BVC only BVC

Sig.

−

87a

X1:196

X1:195

Y112 1

1 Y93

2 X1:149

2

X1:200

X1:197

KA MESX

X1:38 7:14

GA MESX

K56

1

86

K57

86

K43

2

85

86

85

85

X6:1 Y08

1

X1:197

31 6:4

6:3

6:14

12

X7:1 Y07 1

X1:150 X1:113

+

H07

8:2 BRAKE MESX

Y04 1

2

−

2

X7:2 X1:82

Anbau 177DH: h.r.

Anbau 177DH: h.l.

Anbau 213DH: oben

Anbau 213DH: unten

X1:117

X1:190 31

7:1

Magnetventil Bremse solenoid valve brake

Prop−Ventil Vibration groß prop. valve vibration big

Prop. Ventil lenken links prop. valve steering left

28.06.2004 Seis 28.06.2004 TS022 Werner

S01 2:16

Prop.−Ventil Vibration klein prop. valve vibration small

Notlenkung rechts emrg. valve steering right

11

8:2

X1:115

2 X6:2 X1:118

5:20

Notlenkung links emerg. valve steering left

X35:61

8:2

X1:37 X1:116

Bremse

Warnsummer

X35:3

X35:48 Prop. out

X35:2 X35:22

7:2 87a

Y92 2

X1:200

6:2

X35:16

X1:89

6:12 87a

max.1.8A

Y113 1

X1:198

K43 87

30 K48 87 X1:147

150mA

6:9

X1:199

400 ... 1.200mA

X35:16

400 ... 1.200mA

X1:154

30

400 ... 1.200mA

87a

Umsch. Amplitude

6:8 87

X35:22

X35:16

K56 30

Pumpe Vib.−Platten

6:9 87

Armlehne

X51:2

X51:3

K57 30

X35:25

X35:21

X43:1 X35:20

Schalter Armlehne armrest−switch

B132

−

Aufnehmer Vibrationsmotor sensor vibration motor

X22:1

Lenkwink.

X1:55 X1:202

S

X35:17

A45

X1:188

X1:201 B65 +

X51:1

X43:2

F24:2

Vib.− Frequenz

X23:1

5:20

Vib.− Richtung

3:20

Warnsummer Störung warning buzzer, failure

Prop. Ventil lenken rechts prop. valve steering right

Lenkung, Vibration steering, vibration

1

1

582 700 95 006

CAN2+

5:14 5:14

LC−Display

CAN2−

5:20

CAN1+

CAN1+ 8:16 CAN1− 8:16 K11:87 8:1

CAN1− K11:87

Taster 1 = Platten rechts push button 1 = plates right

X1:31E

Taster 2 = Platten heben push button 2 = lift plates

Taster 4 = Platten links push button 4 = plates left

Taster 7 = Infotaste 1 push button 7 = info button 1 Taster 8 = Infotaste 2 push button 8 = Info button 2

BTS BREMSE 3

2

Näherungssch. Platten Mitte sensor plates centered

X1:156

X1:157

Taster 5 = platten senken push button 5 = lower plates

6:18

1 F145

Näherungssch. Platten oben sensor plates up

Taster 3 = Vibration EIN/AUS push button 3 = vibration ON/OFF

15A

X1:31A X1:209

B135 + −

B134 + −

X1:214

4:17 4:17

ESX Fahrst.

X1:213

6:2 X23:1

2

Fahrstufenschalter speed range selector

7

1

4

8

5

S

S

Add1 Add2

8

0V (Ref PIN5)

9 10

11 12

AK Ext1

X35:22

X62:1

X62:9 X62:10

X62:3

X62:2

X62:14

2

6:11

+5V out

X62:13

0V in

CAN+

X62:8

BTS zus.

CAN−

S55 Fahrhebel travel lever

X62:7

X1:153

7 6 5

1 3 4

X62:12 A54 Platten Steuerung plate−controller

X62:6

BTS Bremse

X62:11

Bremse auf = Ub

X25:3

Ub in

Bremse zu = 0V

X25:4 X25:2

+ − S

X62:5

X62:4

S42

AK Ext2

Stecker X23

400 .. 1.200 mA

X50:1

X50:2

X50:3

Ub out

8 OV out

7 DK Ext6

DK Ext5

DK Ext3

DK Ext1

DK Ext4

Stecker X24 3 4 5 6

2 DK Ext2

1

X1:210 S − + S35 K0G K48

86

K05

13

23

S09

13

S64

13 S36

13

S139

86

Y123 1 2 Y98

14

14

14

6:20 6:17

85

2

2

1

Y122 1

Y142 1

Y144 1

2

2

2

2

X72:2

X1:149

31

Y145 1

14

24 85

Y143 1

X72:1

X1:211

X1:212 8:1 31

2:12 nicht bei BVC not at BVC Schalter Amplitude switch amplitudes

28.06.2004 Seis 28.06.2004 TS022 Werner

Nur bei BVC Only at BVC

Schalter Schwimmstellung Platten sw. swimming pos. plates Frequenzverstellung Platten freq. adjust plates

Schalter Vibration Ein/Aus switch vibration on/off

Schalter Betriebsart Platten modesw. plates

Fahrhebel, Vibrationsplatten joystick, vibration−plates

Prop−Pumpe Platten prop.−valve plates

MV Platten heben MV Platten rechts plates up plates right MV Platten senken MV Platten Schwimmst plates down plates float−pos. MV Platten links MV Platten Priorität plates left plates priority

1

1

582 700 95 007

BTM

Beschleunigungssensoren acc. sensor front

Drucker printer

Aufnehmer Verstellmotor sens. adjust. motor

Display Messtechnik BOP display measurem. BOP

Bedieneinheit BEM control−unit BEM

GND

30 10:1 X2:48 + X2:66

X48:2

X48:1

X49:2

X49:1

X2:78

B62

X2:67

X2:68

X47:A

X47:B

AGND MESX

CAN−

X42:4

X74:4

CAN+

X4:E

X74:5

DIOS Platten

X4:C

X4:D

X74:3 X74:1

X74:2

X4:A

X4:B

X2:64

X2:65

120 OHM R21 1 2 120 OHM

10:4

2 X2:76

0..6VDC

CAN3−

X1:85

1

9:15 +

CAN3−

P07 E VIB

CAN3+

X2:60

9:15

−

2 X2:74

X2:63

8:19

CAN1−

X2:66

31.1

v.l.

BEL MESX

X2:51

X44:27 X44:3

X44:53

X44:5

X44:4 X44:68

X44:67

X44:66

CAN1+

v.r.

Y141

X42:3

1 R20 2

TxD

EVIB

400 .. 1.200mA

1

X2:73

X42:5

CAN1+

X2:50

GND

Y140

BRAKE MESX D+ MESX

Prop.

PITCH MESX

400 .. 1.200mA

X2:75

7:20

CAN1−

7:20

RxD

X44:46

X44:23 X44:47

6:15

Prop.

KA MESX GA MESX SPEED MESX DIR MESX

2:6

X2:69

P33

CAN3+

6:15

6:17

nur bei BTM prof only at BTM prof

−/sw

+/sw 20g/br

X44:41

X44:37

X44:31

X44:29

Elektronik

X44:60

X47:C

7:20

P11

X44:1

X2:59

X44:65

X2:58

X44:55

X2:55

S/ws

X44:9

X2:54

+/rt

8.5V

X49:4

B61

X44:7

X49:3 Aufn. vorne 20g

X48:4 Aufn. vorne 15g

X48:3

X44:54 X44:36

X44:59 X44:32

X44:14

X44:57 X44:35

X44:58

Leistung

X44:15

X44:38

X44:56

Pot. 15

X44:28

15g/bl

20g/br

15g/bl

−/gg

Aufn. hinten 20g

B62

9:15

X2:57

4:3 4:3 4:8

F2

X2:71

2

−/gg

A83 Messtechnik−Rechner measurement calc. unit

F1

nur bei BTM+/BTM prof only at BTM+/BTM prof

FM4

X42:8

X2:57

8:20

X2:60

X44:26

X2:53

X44:33

X2:56 2

X1:35A F148:2

P16 1

Erregerpos.

15A

2

X1:32A

X2:70

X2:77 1

Aufn. hinten 15g

10A

F146

X44:30

F148

+/sw

1

X2:49

− nur bei BEM only at BEM

X1:35E

X1:32E

31.1

Pot 15

X2:47

Pot 30

K11:87 10:1

X42:7

7:20

K11:87

X42:1

30

X42:2

5:20

X42:6

4:9

Beschleunigungssensoren acc. sensor rear

X1:34A

X1:82

31

31 9:1 Prop−Ventil Erreger auf solenoid−valve exciter up

EVIB−Meter EVIB−meter

Prop−Ventil Erreger ab solenoid valve exciter down

28.06.2004 Seis 28.06.2004 TS022 Werner

Variocontrol, Messtechnik Variocontrol, measurement equipm.

1

1

582 700 95 008

8:4

8:18

F148:2

CAN3−

8:18 CAN3+

1 R242

CAN3+

CAN3−

120 OHM X2:61

X2:62 R25 1 2 120 OHM

X4:N

X4:M

X75:7

X75:2

A87 USB−CAN Schnittst. USB−CAN Interface BCM X2:70 X76:1 P15

X4:G

X76:2 X4:F X2:63

BCM 05 BCM 05 nur bei BCM only at BCM 8:20

31

31 10:1

28.06.2004 Seis 28.06.2004 TS022 Werner

Bomag Compaction Management BCM Bomag Compaction Management BCM

1

1

582 700 95 009

K11:87 30

K06

X1:26A X1:83

12

87a

Anschluß Arbeitsschein− werfer ohne StvZO X1:21E

15A

X1:302

X1:21A E

30

24

10:10

85

− X3:1

X61:1

E09 1

E10 1

E11 1

2

2

2

2

Anschluß Arbeitsscheinwerfer bei ROPS/SD Aufbau Connection head lights acc.to ROPS/SD

11:1 31

Bel. Warnbinkschalter illumination, switch hazard light Blinkleuchte VL indicator front, LH Blinkleuchte HL indicator rear, LH

Blinkleuchte HR indicator rear, RH

Blinkleuchte VR indicator front, RH

Schlußleuchte rechts tail light, RH 28.06.2004 Seis 28.06.2004 Werner

X1:314 X59:2

E08 1 + H06

X1:321

24

1,75A

Warnblinkschalter switch, hazard light

X60:1

14

X1:313

23

X1:323 X60:2

2

13 01

X58:2

2

01 S14

1,75A

2

BR

X1:315 X58:6

2

4,6A

E25 1

BL

X1:304

Arbeitsscheinwerfer vorne rechts working head lights, front rh.

Arbeitsscheinwerfer vorne links working head lights, front lh.

Arbeitsscheinwerfer hinten rechts working head lights, rear rh.

E23 1

4,6A

86

E28 1

4,6A

K16

10:2 Schlußleuchte links tail light, LH Parkleuchte links parking light, LH Parkleuchte rechts parking light, RH

Scheinwerfer rechts head light RH

Arbeitsscheinwerfer hinten links working head lights, rear lh.

X1:320 X61:3 X1:324 X61:4

2

0,42A

X1:316 X59:6

2

0,42A

2

E27 1

4,6A

X1:312 X59:3

X1:303

X1:311 X58:3 2

0,42A

85

0,125A

X1:319 X60:3

Anschluß Arbeitsschein− werfer ohne StvZO connection working head lights without StvZO

86

X1:315 X58:6

4,6A

X1:316 X59:6

K06

E13 1 E12 1 E14 1 E15 1

X1:323 X60:4

X1:43

31 Scheinwerfer links head light LH

5:9 5:9

0,42A

8:7 0,125A

X1:310 X59:5

X1:84

R

X1:24A

13

BEL MESX

L

15A

X1:23A

S16 14

49R

49L

A02

BEL 5:9

2

4,6A

14

Anschluß Arbeitsscheinwerfer D bei Kabine Connection head lights with cabin STV1 11:17 STV2 11:17

F10

15A

Schalter Arbeitsbele switch, working head lights

X1:309 X58:5

87a

2 X1:315 X58:6

Schalter Blinker switch indicator

31 82

E16 1 E17 1

9:20

X3:5

X1:24E

F09

10:9 87

X1:22A

X3:4

X1:23E

4

F19

15A

23

L0R

S37

X1:22E 5

F22

24

K16 30

13

L0R

connection working head lights without StvZO

S15

X1:25A X1:305

X1:322

23

15A

X1:19A

10:4 87

11

32

30

1,75A

31

F08

15A

Schalter StvZO switch, StvZO 012

X1:25E

F07

X1:324 X61:2

X1:18A

X1:19E

1,75A

10A

X1:2

X1:316 X59:6

15A

X1:301

F18

X1:307

X1:26E

F11

X1:306

8:3 K11:87 8:19 30 X1:18E

Beleuchtung und StvZO illumination and StvZO

1

1

582 700 95 010

X3:6

K30

2:14

K32:87

12:2

X3:7 K32

X3:8

30

STV2 10:13 10:13 STV1

11:1 87 G

F143 15A

10A

7

87a

H

F42

A

F43 15A

8

B

F44 15A

1

C

F130 10A

2

F42 12:8 F130 11:14

E

F41

F

10A

3

6

5

11:9 F130

F144 15A

F130 12:7

1

VIB X3:18 5

B4

3

C3

E27

4,6A

2

P09

0,83A

X56:1

B3

X56:3

1

X56:4

A1

1

2

1 E28

1 E23

1 E25

1

2

2

2

2

XS 12V

+ −

Steckdose socket

7,8,9

A2+A3 6

5

4

4,6A

5

4,6A

S20

4,6A

4

6:18

+

K32 M

M05

M 2,9A

− 85

+ M04

M − M06

X56:2

I

15

E32

K141

M

− M07

X55:2

3 S158

4

31

+

5A

3,8A

A5+A6

−

3 min

+

5

S38

1 E72

4,7A

S86

S163 5

Abfallverzögert

Innenleuchte inside light, cabin

X3:17 4 4:3 SPEED TAC A16

−

1

E70

Tachographenmodul module, tachograph

A01

TK

2

2 S21

Radio radio

+

S45

01W 7 01

− − 31

Schalter Innenleuche switches interior lights

max. 13A

2

Kontrolleuchte indicator

E71 1

2

Nachtleuchte night illumination

− −

2

2 Heizung Heckscheibe heating rear screen

01W 7 01

3,8A

87a

R80

86

15 + + B51

E29

2:19 1

30

X55:1

11:16 87

K32:86

B51 + +

1

X55:3

30

X55:4

K141

1,75A

A12

ZA option 12:18 KABINE 31

Schalter Nachtleuchte switch, night illumination

Tachograph tachograph X3:2

Türkontaktschalter door switch

X3:1

Relais Kabine relais cabin

Schalterbel. switch illum.

10:20 31

31 12:1 Wascher hinten washer rear

11:6

Wischer hinten windscreen wiper, rear

28.06.2004 Seis 28.06.2004 Werner

Wascher vorn washer front Wischer vorne windscreen wiper, rear

Kabinenausrüstung, Beleuchtung, Radio, Tachograph cabin−equipment, headlights, radio, tachograph

Arbeitsscheinwerfer vorn working head lights, front

11:2

Arbeitsscheinwerfer hinten working head lights, rear

1

Rundumkennleuchte rotary beacon

1

582 700 95 011

11:17 F130 F42 Potential 15 aus Kabine 11:9

D

F31 20A

Potential 30 aus Kabine

F40 20A

4

Bedienteil Kabinenheizung/Klimaanlage X53:B

X54:4

0123

X54:3

3 A72 Steuergerät control unit 6 11 12

Schalter Kabinenlüfter switch blower cabin

X54:11

X54:6

K09

X54:12

5 1 X54:1

E30 Zusatzheizung add. heater

S28

Kleine Stufe = 0,67A mittleter Stufe = 1,0A große Stufe = 1.9A

6 2 1 3

X3:14

X18:1

X1:169 X19:1

B131

B103

1 2

X19:2 X20:1

rt

or

M

5:9

br

br

Stufe 1: 3.0A pro Lüfter Stufe 2: 4.5A pro Lüfter

X20:2 Y15

Stufe 3: 11.5A pro Lüfter

8

7

4

15

1

11:19

Y14 2

KABINE 31 2

2

2

X1:168 1 31

Klimakompressor air conditioning compr.

Kabinenlüfter cab ventilator

Y138 1 V06

V04 3,5A

X1:164

6

2

X18:2

1

X17:4

5

1

_t

HP

10 9

1A

_t

X20:4

ge

X1:167

Thermofühler Heizung temperature sensor heating unit

87a

KLIMA

11:20 31

0123

Regel aus = 0,4A

30

87

X1:170 Stromaufnahme Lüfter / current blower

12 11 13 14 16

2:8

X20:3 Überwachung Kühlmitt monitoring coolant pressure

Thermofühler Klimaan temperature sensor air conditioning

X17:2 X1:165

X3:12

X3:11

X53:H

X53:M X3:10

X53:L X3:9 X17:1 X1:163

X17:3 X1:166 or

M09

M

1

Anlaufstrom beim Start = 8,3A

B104 P LP 3

M09

3

Power Stufe = 2,8A

4

rt

2

A

2

X3:13

ge

5A

X54:2

4

S44

F15

8

1

control−unit cab−heater /air conditioning

X53:C

H

Schalter Kabinenzusatzheizung switch, cab add.−heater

11:19 K32:87 Potential 15 aus Kabine

Magnetventil Heizung solenoid valve, heating unit

Kraftstoffpumpe fuel pump heating unit

Kabinenlüfter cab ventilator

28.06.2004 Seis 28.06.2004 Werner

Kabinenheizung, Klimaanlage, Zusatzheizung cabin−heater, air conditioning, add. heater

1

1

582 700 95 012

Name

28.06.2004 Seis 28.06.2004 Werner

Bauteilliste component listing 1 9 101

582 700 95

Bl. 010 011 011 004 006 006 003 007 012 005 005 008 009

Pf. 17 5 6 6 5 9 3 17 11 3 18 6 15

Benennung

A02 A12 A16 A34 A34 A45 A48 A54 A72 A80 A81 A83 A87

Blinkrelais Radio Elektronik Tachograph Prozessorplatine Prozessorplatine Lenkrad Elektronische Motorsteuerung Modul Pumpenansteuerung Steuergeraet Klimaanlage, Heizung Modul Datensammler Anzeigeeinheit Elektronik Messtechnik USB−CAN Schnittstelle BCM

indicator relay Radio Electronic system, tachograph Prozessing circuit board Prozessing circuit board Steering wheel Electronic engine management Modul pump control Control unit,air conditioning,heating modul data−collector Display−Unit electronic measurement−equipment USB−CAN Interface BCM

title

TYP

B03 B11 B11 B16 B21 B51 B51 B55 B57 B59 B60 B61 B62 B62 B65 B88 B103 B104 B112 B113 B114 B115 B124 B126 B130 B131 B132 B134 B135

005 002 002 006 005 011 011 005 004 004 004 008 008 008 006 003 012 012 004 003 003 003 005 003 003 012 006 007 007

3 16 18 16 2 4 6 4 6 4 2 12 8 10 4 6 7 7 3 13 7 11 5 14 8 10 2 17 16

Unterdruckschalter Luftfilter Signalhorn Signalhorn Aufnehmer Vibrationsfrequenz vorne Differenzdruckschalter Hydr.−Oelfilter Lautsprecher Radio Lautsprecher Radio Kuehlmittelstand Ausgleichsbehaelter Neigungssensor Stufenumschaltung Aufnehmer Bandagengeschwindigkeit Aufnehmer Achsgeschwindigkeit Aufnehmer Verstellzylinder Beschleunigungsaufnehmer Beschleunigungsaufnehmer Sensor, Lenkwinkel vorn Druckgeber Motoroel Temperaturschalter Klimaanlage Druckschalter Klimaanlage Druckgeber Fahrpumpe EMR Temperaturgeber Kuehlmittel EMR Aufnehmer, Motordrehzahl 1 Geber Ladeluftdruck Geber Wasserstandsabscheider Diesel EMR Temperaturgeber Kraftstoff EMR Aufnehmer, Motordrehzahl 2 Temperaturschalter Heizung Inititator Armlehne links Näherungsschalter Platten oben Näherungsschalter Platten mitte

Vacuum switch, air cleaner Warning horn Warning horn Transducer, vibration frequency, front Pressure diff. switch, hydr. oil filter Speaker radio Speaker radio Coolant charge expansion tank Slope sensor, speed range selection Sensor, drum speed Sensor, axle speed Sensor, ajustable zylinder Acceleration sensor Acceleration sensor Sensor, angularity steering, front Sender, engine oil pressure Temperature switch, air conditioning Pressure switch, air conditioning pressure sender, driving pump EMR Temperature switch, collant EMR Trancducer, engine speed 1 Sender, charging air pressure Sender, water separator fuel EMR fuel temperature sender EMR Trancducer, engine speed 2 Temperature switch, heating proximity switch left arm rest proximity switch, plate up proximity switch, plate middle

E08 E09 E10 E11 E12 E13 E14 E15 E16 E17 E23 E23 E25 E25 E27 E27 E28 E28 E29 E30 E32 E70 E71 E72

010 010 010 010 010 010 010 010 010 010 010 011 010 011 010 011 010 011 011 012 011 011 011 011

17 18 19 19 7 6 7 8 2 2 11 18 12 19 10 17 11 17 3 13 19 15 3 16

Blinkleuchte vorne links Blinkleuchte hinten links Blinkleuchte vorne rechts Blinkleuchte hinten rechts Parkleuchte links Schlussleuchte links Parkleuchte rechts Schlussleuchte rechts Scheinwerfer links Scheinwerfer rechts Arbeitsscheinwerfer vorne links Arbeitsscheinwerfer vorne links Arbeitsscheinwerfer vorne rechts Arbeitsscheinwerfer vorne rechts Arbeitsscheinwerfer hinten links Arbeitsscheinwerfer hinten links Arbeitsscheinwerfer hinten rechts Arbeitsscheinwerfer hinten rechts Innenleuchte Kabine Heizgeraet Kennleuchte Nachtleuchte Kontrolleuchte Schalter Heckscheibenheizung Beleuchtung Bedienschalter

Indicator, front, lh. Indicator, rear, lh. Indicator, front, rh. Indicator, rear, rh. Parking light, lh. Tail light, lh. Parking light, rh. Tail light, rh. Head light, lh. Head light, rh. Working head light, front, lh. Working head light, front, lh. Working head light, front, rh. Working head light, front, rh. Working head light, rear, lh. Working head light, rear, lh. Working head light, rear, rh. Working head light, rear, rh. Inside light, cabin Heating unit Warning light Night lamp indicator light switch rear screen illum. Switches

MAX. 1,75A MAX. 1,75A MAX. 1,75A MAX. 1,75A MAX. 0,42A MAX. 0,42A MAX. 0,42A MAX. 0,42A MAX. 4,6A MAX. 4,6A MAX. 4,6A 4,6A MAX. 4,6A 4,6A MAX. 4,6A 4,6A MAX. 4,6A 4,6A 1,75A

F00 F05 F07 F08 F09 F10 F11 F13 F15 F18 F19 F22 F23 F24 F31 F39 F40 F41 F42 F43 F44 F48 F67 F84 F95 FM1 FM2 FM4 FM5 F130

002 002 010 010 010 010 010 002 012 010 010 010 002 005 012 002 012 011 011 011 011 002 004 004 002 006 006 008 006 011

4 14 15 18 6 8 2 10 18 5 12 10 18 2 3 19 13 19 3 10 13 3 7 9 16 6 5 11 5 15

Hauptsicherung Batterie Sicherung Steckdose Sicherung Warnblinker Sicherung Blinker u. Arbeitsscheinw. Sicherung Park− u. Schlussl. links Sicherung Park− u. Schlussl. rechts Sicherung Scheinwerfer links Sicherung Startschalter Sicherung Heizgeraet Vorsicherung Arbeitsscheinw. vorne Sicherung Arbeitsscheinw. vorne li. Sicherung Arbeitsscheinwerfer hinten Sicherung Signalhorn Sicherung Ueberwachungsmodul Sicherung Kabinenluefter Hauptsicherung Kabine Sicherung Kabinenheizung Sicherung Rundumkennleuchte Sicherung Kabineninnenleuchte Sicherung Wischermotor hinten Sicherung Wischermotor vorn Sicherung Gluehanlage Sicherung Steuerung (Potential 30) Sicherung Steuerung (Klemme 54) Sicherung Motormanagement intern Platinensicherung Platinensicherung Platinensicherung Platinensicherung Sicherung Nachtleuchte

Fuse, main, battery Fuse, socket Fuse, hazard light Fuse, indicators a. work. head light Fuse, parking and tail light, lh. Fuse, parking and tail light, rh. Fuse, head light, lh. Fuse, starter switch Fuse, heating unit Primary fuse, work. head light, fr. Fuse, working head light, front, lh. Fuse, working head lights, rear Fuse, warning horn Fuse, monitoring module Fuse, cabin ventilator Main fuse, cab Fuse, heating unit cab Fuse, rotary beacon Fuse, inside light cab Fuse, wipermotor rear Fuse, wipermotor front Fuse, glow plug system Fuse, controller (pot.30) Fuse, controller (Pin 54) Fuse, engine controller (internal) Multifuse Multifuse Multifuse Multifuse Fuse, night lamp

125A 15A 15A 15A 10A 10A 15A 30A 5A 30A 30A 30A 15A 15A 20A 15A 20A 10A 10A 15A 15A 125A 15A 10A 15A MULTIFUSE MULTIFUSE MULTIFUSE MULTIFUSE 10A

5A 0,83A 1,75A

Name F143 F144 F145 F146 F148

Bl. 011 011 007 008 008

G01 G02 G03

Pf. 2 20 18 5 2

Benennung

title

TYP

28.06.2004 Seis 28.06.2004 Werner

Bauteilliste component listing 2 9 102

582 700 95

Sicherung Heckscheibenheizung Sicherung Kabinensteckdose Sicherung Anhängeplatten Sicherung Steuerung MESX (Potential 30) Sicherung Steuerung MESX (Potential 15)

fuse rear screen heating unit Fuse cabin−socket fuse vibration plates Fuse Controller (Pot. 30) Fuse Controller (Pot. 15)

15A 15A 15A 15A 10A

002 3 002 5 002 4

Batterie Generator Batterie

Battery Generator Battery

103A

H06 H07 H14

010 15 006 16 004 11

Meldeleuchte Warnblinker Warnsummer Betriebsstoerung Warnsummer Rueckwaertsfahrt

Indicator light, hazard light Warning buzzer, breakdown Back−up alarm buzzer

LED ROT 0.15A MAX O,46A

K05 K06 K09 K11 K14 K16 K32 K43 K48 K56 K57 K61 K141

007 010 002 002 003 010 011 006 007 006 006 002 011

3 4 8 10 19 9 1 12 2 8 9 6 16

Relais Startstrom Relais Scheinwerfer hinten Relais Klimageraet Relais Klemme 30 auf 15 Relais Vorgluehen Relais Scheinwerfer vorne Relais Kabine Relais Vibration Relais Fahrhebel 0−Stellung Relais Lenkung Relais Lenkung Relais Ladekontrolle Relais Heckscheibenheizung

Relay, starting current Relay, head lights, rear Relay, air conditioning Relay, terminal 30 to 15 Relay, glow plug system Relay, head lights, front Relay, cabin Relay, vibration Relay, travel lever 0−position Relay, steering system Relay, steering system Relay, charge control relay, heating rear screen

BOSCHW BOSCHW BOSCHW BOSCHL TYCOX BOSCHW BOSCHW BOSCHW BOSCHW BOSCHW BOSCHW BOSCHW BOSCHW

M01 M04 M05 M06 M07 M09 M09

002 011 011 011 011 012 012

11 12 10 13 11 3 4

Starter Scheibenwischermotor vorne Scheibenwischermotor hinten Scheibenwaschermotor vorne Scheibenwaschermotor hinten Kabinenluefter Kabinenluefter

Starter Windscreen wiper motor, front Windscreen wiper motor, rear Windscreen washer motor, front Windscreen washer motor, rear Cabin ventilator Cabin ventilator

2.3 KW 4,7A 2,9A MAX. 3,8A MAX. 3,8A

P07 P09 P11 P15 P16 P33

008 011 008 009 008 008

15 8 14 16 16 18

Omegameter Frequenz− und Geschwindigkeitsanzeige Drucker BCM 03 Bildschirm Diagnose, Variomatic Opus 21

Omegameter Frequency− and Speedometer Printer BCM 03 terminal Diagnostics, varimatic Opus 21

R03 R19 R20 R20 R21 R21 R22 R23 R24 R25 R80

005 002 004 008 004 008 004 004 009 009 011

6 2 15 17 15 17 12 12 15 15 2

Geber Tankanzeige Heizflansch Widerstand Widerstand Widerstand Widerstand Widerstand Widerstand Widerstand Widerstand Heizung Heckscheibe

Sender, level gauge heater flange Resistor Resistor Resistor Resistor Resistor Resistor Resistor Resistor heating rear screen

S00 S01 S03 S06 S09 S14 S15 S16 S20 S21 S28 S30 S35 S36 S37 S38 S42 S44 S45 S55 S64 S86 S120 S139 S139 S158 S163

002 002 002 004 007 010 010 010 011 011 012 002 007 007 010 011 007 012 011 007 007 011 005 005 007 011 011

10 16 18 10 8 15 4 4 13 10 18 3 7 11 18 19 11 3 3 6 10 3 17 19 13 15 16

Startschalter Schalter NOT AUS Taster Signalhorn Sitzkontaktschalter links Vibrationsschalter vorne Warnblinkschalter Beleuchtungsschalter StVZO Schalter Arbeitsbeleuchtung vorne Schalter Scheibenwischer vorne Schalter Scheibenwischer hinten Schalter Kabinenheizung Batterietrennschalter Vibrationsschalter klein/gross Vibrationsschalter Schalter Blinker Schalter Kennleuchte Stufenumschalter schnell−langsam Schalter Kabinenluefter Schalter Kabineninnenleuchte Schalter Fahrhebel Schalter Schwimmstellung Schalter Tuer, links Schalter Motordrehzahl Schalter Frequenzverstellung Schalter Frequenzverstellung Schalter Nachtbeleuchtung Schalter Heckscheibenheizung

Starter switch Switch, emergency off Push button, warning horn Switch, seat contact, lh. Switch, vibration, front Switch, hazard light Switch, lighting StVZO Switch, working head lights, front Switch, windscreen wiper, front Switch, windscreen wiper, rear Switch, cabin heating Switch, battery disconnect Switch, vibration low/high Switch, vibration Switch, indicator Switch, warning light Speed range selector, fast−slow Switch, cabin ventilator Switch, cabin inside light Switch, travel control lever Switch, float position Switch door, lh. Switch, engine speed Switch, frequency control Switch, frequency control Switch, cabin night lamp switch rear screen heating unit

V01 V02 V03 V04 V06

002 002 002 012 012

7 17 18 8 9

Diode Diode Diode Diode Diode

Diode Diode Diode Diode Diode

X1:1 X1:2 X1:2 X1:3 X1:4 X1:7 X1:8 X1:9 X1:10 X1:37

002 004 010 002 002 002 002 002 002 006

6 9 10 10 10 12 12 5 5 15

WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK

WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX

103A

0 .. 67 OHM 167A 120 OHM 120 OHM 120 OHM 120 OHM 120 OHM 120 OHM 120 OHM 120 OHM MAX. 13A

NOTAUSH

FE5B FE5B FE5B FE5B

Name

28.06.2004 Seis 28.06.2004 Werner

Bauteilliste component listing 3 9 103

582 700 95

X1:38 X1:39 X1:40 X1:41 X1:41 X1:42 X1:42 X1:43 X1:44 X1:45 X1:46 X1:47 X1:48 X1:49 X1:50 X1:51 X1:52 X1:53 X1:54 X1:55 X1:56 X1:57 X1:58 X1:59 X1:60 X1:61 X1:79 X1:80 X1:82 X1:82 X1:82 X1:82 X1:83 X1:84 X1:85 X1:86 X1:87 X1:88 X1:89 X1:94 X1:94 X1:95 X1:96 X1:97 X1:98 X1:101 X1:102 X1:103 X1:104 X1:105 X1:106 X1:107 X1:108 X1:109 X1:110 X1:111 X1:112 X1:113 X1:114 X1:115 X1:116 X1:117 X1:117 X1:117 X1:117 X1:118 X1:119 X1:120 X1:121 X1:122 X1:123 X1:123 X1:123 X1:124 X1:141 X1:142 X1:142 X1:143 X1:143 X1:143 X1:144 X1:144 X1:145 X1:146 X1:147 X1:148 X1:149 X1:149 X1:149 X1:149 X1:150 X1:151 X1:152 X1:153 X1:154 X1:154 X1:155 X1:156 X1:157

Bl. 006 005 005 005 006 004 006 010 004 004 004 004 004 004 004 004 004 004 004 006 006 006 006 006 006 006 002 005 004 005 006 008 010 010 008 005 005 005 006 005 005 003 003 002 002 002 002 002 002 005 005 005 005 002 002 005 005 006 004 006 006 004 005 005 006 006 004 004 004 004 002 004 004 004 004 004 004 004 004 004 004 004 004 004 006 006 004 005 006 007 006 002 002 007 005 006 002 007 007

Pf. 15 2 2 3 16 2 17 4 3 2 8 14 15 16 16 12 12 13 13 4 6 6 5 5 5 5 10 16 17 13 16 15 5 4 15 16 13 14 16 3 4 19 19 16 18 16 18 16 18 6 2 5 5 6 6 3 4 17 11 15 14 11 2 6 17 14 2 4 12 13 10 12 13 18 16 18 19 15 19 19 15 16 9 9 17 2 10 12 2 3 17 16 16 3 11 10 18 9 9

Benennung WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK

title WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX

TYP

Name

28.06.2004 Seis 28.06.2004 Werner

Bauteilliste component listing 4 9 104

582 700 95

X1:158 X1:159 X1:15A X1:15E X1:160 X1:161 X1:162 X1:163 X1:164 X1:165 X1:166 X1:167 X1:168 X1:168 X1:169 X1:16A X1:16E X1:170 X1:171 X1:172 X1:173 X1:174 X1:175 X1:176 X1:177 X1:178 X1:179 X1:17A X1:17E X1:180 X1:181 X1:182 X1:183 X1:184 X1:185 X1:186 X1:187 X1:188 X1:189 X1:18A X1:18E X1:190 X1:195 X1:196 X1:197 X1:197 X1:198 X1:199 X1:19A X1:19E X1:200 X1:200 X1:201 X1:202 X1:203 X1:205 X1:206 X1:207 X1:208 X1:209 X1:210 X1:211 X1:212 X1:213 X1:214 X1:21A X1:21E X1:22A X1:22E X1:23A X1:23E X1:24A X1:24E X1:25A X1:25E X1:26A X1:26E X1:27A X1:27E X1:28A X1:28E X1:29A X1:29E X1:301 X1:302 X1:303 X1:304 X1:305 X1:306 X1:307 X1:309 X1:30A X1:30E X1:310 X1:311 X1:312 X1:313 X1:314 X1:315

Bl. 004 006 002 002 006 006 006 012 012 012 012 012 002 012 012 002 002 012 004 004 004 004 004 004 004 004 003 004 004 003 003 003 003 003 003 003 006 006 006 010 010 006 006 006 006 006 006 006 010 010 006 006 006 006 006 006 006 006 006 007 007 007 007 007 007 010 010 010 010 010 010 010 010 010 010 010 010 002 002 002 002 005 005 010 010 010 010 010 010 010 010 002 002 010 010 010 010 010 010

Pf. 10 7 10 10 7 7 7 3 5 3 4 10 8 10 7 14 14 7 2 2 2 2 4 5 5 4 2 7 7 3 3 5 2 2 19 4 16 17 16 2 2 19 7 6 6 7 4 3 15 15 3 4 4 4 4 11 11 11 11 18 14 14 16 19 19 10 10 12 12 6 6 8 8 18 18 5 5 16 16 18 18 2 2 5 5 9 15 18 18 18 2 19 19 2 7 7 17 19 2

Benennung WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK

title WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX

TYP

Name

28.06.2004 Seis 28.06.2004 Werner

Bauteilliste component listing 5 9 105

582 700 95

X1:315 X1:315 X1:316 X1:316 X1:316 X1:319 X1:31A X1:31E X1:320 X1:321 X1:322 X1:323 X1:323 X1:324 X1:324 X1:32A X1:32E X1:34A X1:34E X1:35A X1:35E X2:47 X2:48 X2:49 X2:50 X2:51 X2:53 X2:54 X2:55 X2:56 X2:57 X2:57 X2:58 X2:59 X2:60 X2:60 X2:61 X2:62 X2:63 X2:63 X2:64 X2:65 X2:66 X2:66 X2:67 X2:68 X2:69 X2:70 X2:70 X2:71 X2:73 X2:74 X2:75 X2:76 X2:77 X2:78 X3:1 X3:1 X3:2 X3:3 X3:4 X3:5 X3:6 X3:7 X3:8 X3:9 X3:10 X3:11 X3:12 X3:13 X3:14 X3:17 X3:18 X4:A X4:B X4:C X4:D X4:E X4:F X4:G X4:M X4:N X6:1 X6:2 X7:1 X7:2 X8:1 X8:2 X9:1 X9:2 XS XS X10:2 X10:3 X14:A X14:B X15:1 X15:2 X16:1

Bl. 010 010 010 010 010 010 007 007 010 010 010 010 010 010 010 008 008 004 004 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 009 009 008 009 008 008 008 008 008 008 008 008 009 008 008 008 008 008 008 008 010 011 011 002 010 010 011 011 011 012 012 012 012 012 012 011 011 008 008 008 008 008 009 009 009 009 006 006 006 006 005 005 004 004 002 011 005 005 004 004 004 004 004

Pf. 7 17 2 7 19 6 18 18 8 18 19 6 18 8 19 2 2 9 9 5 5 18 18 19 17 18 8 7 8 7 2 10 9 10 9 13 15 16 13 18 14 14 14 14 11 12 12 15 18 13 11 11 10 10 11 11 11 10 10 19 10 12 2 2 2 3 3 4 4 7 10 6 6 14 14 14 14 15 18 18 16 15 13 14 15 14 5 5 11 11 19 20 6 6 10 10 13 13 12

Benennung WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO ZENTRALELEKTRIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK WAGO−MESSTECHNIK STECKER ROPS/SD STECKER KABINE/ROPS STECKER KABINE/ROPS SETCKER KABINE/ROPS STECKER ROPS/SD STECKER ROPS/SD STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS STECKER KABINE/ROPS KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. KABINENST. MESST. STECKER VIBRATION GRO STECKER VIBRATION GRO STECKER VIBRATION KLE STECKER VIBRATION KLE STECKER WASSERABSCHEI STECKER WASSERABSCHEI STECKER RÜCKFAHRALARM STECKER RÜCKFAHRALARM Steckdose Steckdose STECKER TAUCHROHRGEBE STECKER TAUCHROHRGEBE STECKER SITZKONTAKT STECKER SITZKONTAKT STECKER FAHRPUMPE RÜC STECKER FAHRPUMPE RÜC STECKER FAHRPUMPE VOR

title WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX WAGO E−BOX Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. Wago−measurement equip. conn. ROPS/SR conn. cabin/ROPS conn. cabin/ROPS Con cabin/ROPS conn. ROPS/SR conn. ROPS/SR conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS conn. cabin/ROPS con. measurem.equipm. con. measurem.equipm. con. measurem.equipm. con. measurem.equipm. con. measurem.equipm. con. measurem.equipm. con. measurem.equipm. con. measurem.equipm. con. measurem.equipm. conn. vibration big conn. vibration big conn. vibration small conn. vibration small connector water separator connector water separator conn. backupalarm conn. backupalarm Socket Socket connector fuel level sensor connector fuel level sensor connector seat contact switch connector seat contact switch connectoe driving pump back connectoe driving pump back connector driving pump front

TYP

Name

28.06.2004 Seis 28.06.2004 Werner

Bauteilliste component listing 6 9 106

582 700 95

X16:2 X17:1 X17:2 X17:3 X17:4 X18:1 X18:2 X19:1 X19:2 X20:1 X20:2 X20:3 X20:4 X21:1 X21:2 X22:1 X22:2 X22:3 X22:4 X25:2 X25:3 X25:4 X26:1 X26:2 X26:3 X26:4 X26:5 X26:6 X26:7 X26:8 X26:9 X26:10 X26:11 X26:12 X27:1 X27:2 X27:3 X27:4 X27:5 X27:6 X27:7 X27:8 X27:9 X27:10 X27:11 X27:12 X28:1 X28:2 X28:3 X28:4 X28:5 X28:6 X29:1 X29:2 X29:3 X29:4 X29:5 X29:6 X29:7 X29:8 X30:1 X30:2 X30:3 X30:4 X30:5 X30:10 X30:11 X30:12 X30:13 X30:14 X30:15 X30:17 X30:22 X30:23 X30:24 X30:25 X31:1 X31:2 X31:3 X31:4 X31:5 X31:6 X31:7 X31:8 X31:9 X31:10 X31:11 X31:12 X31:13 X31:14 X31:15 X31:16 X31:17 X31:18 X31:19 X31:20 X31:21 X31:22 X31:23

Bl. 004 012 012 012 012 012 012 012 012 012 012 012 012 005 005 006 006 006 006 007 007 007 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 005 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003

Pf. 12 3 3 4 5 10 10 7 7 7 7 7 7 4 4 16 17 17 16 11 11 10 8 8 2 9 2 9 7 3 7 4 9 12 11 6 10 5 11 9 10 2 5 10 10 10 16 13 13 14 16 17 14 14 15 15 17 17 18 17 5 5 8 7 7 2 2 3 3 2 7 6 5 6 6 6 16 17 17 12 14 15 17 13 13 8 8 7 7 9 9 11 10 10 10 6 6 6 11

Benennung STECKER FAHRPUMPE VOR STECKER LÜFTER HKL STECKER LÜFTER HKL STECKER LÜFTER HKL STECKER LÜFTER HKL STECKER THERMOFÜHLER STECKER THERMOFÜHLER STECKER EISSCHUTZ HKL STECKER EISSCHUTZ HKL STECKER DRUCKSCH. KLI STECKER DRUCKSCH. KLI STECKER DRUCKSCH. KLI STECKER DRUCKSCH. KLI STECKER KÜHLMITTEL STECKER KÜHLMITTEL ST. VIBRATIONSAUFNEHM ST. VIBRATIONSAUFNEHM ST. VIBRATIONSAUFNEHM ST. VIBRATIONSAUFNEHM ST. FAHRSTUFENSCHALTE ST. FAHRSTUFENSCHALTE ST. FAHRSTUFENSCHALTE STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER DATENSAMMLER STECKER LC−DISPLAY 1 STECKER LC−DISPLAY 1 STECKER LC−DISPLAY 1 STECKER LC−DISPLAY 1 STECKER LC−DISPLAY 1 STECKER LC−DISPLAY 1 STECKER LC−DISPLAY 2 STECKER LC−DISPLAY 2 STECKER LC−DISPLAY 2 STECKER LC−DISPLAY 2 STECKER LC−DISPLAY 2 STECKER LC−DISPLAY 2 STECKER LC−DISPLAY 2 STECKER LC−DISPLAY 2 EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Fahrzeug EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor EMR−Stecker Motor

title connector driving pump front conn. blower conn. blower conn. blower conn. blower conn. sender temp. conn. sender temp. conn. anti−ice air−cond. conn. anti−ice air−cond. conn. pressuresitch air−cond. conn. pressuresitch air−cond. conn. pressuresitch air−cond. conn. pressuresitch air−cond. connector coolant sensor connector coolant sensor connector vibration sensor connector vibration sensor connector vibration sensor connector vibration sensor connector switch speed ranges connector switch speed ranges connector switch speed ranges connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector data collector connector LC−display 1 connector LC−display 1 connector LC−display 1 connector LC−display 1 connector LC−display 1 connector LC−display 1 connector LC−display 2 connector LC−display 2 connector LC−display 2 connector LC−display 2 connector LC−display 2 connector LC−display 2 connector LC−display 2 connector LC−display 2 EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector compactor EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine EMR−connector engine

TYP

Name

28.06.2004 Seis 28.06.2004 Werner

Bauteilliste component listing 7 9 107

582 700 95

X31:24 X31:25 X32:A X32:B X32:G X32:H X32:K X32:L X33:1 X33:2 X33:3 X33:4 X33:5 X33:6 X33:7 X33:8 X34:A X34:B X34:C X34:D X34:G X34:H X34:J X34:N X34:P X34:R X35:1 X35:2 X35:3 X35:4 X35:5 X35:12 X35:15 X35:16 X35:17 X35:18 X35:19 X35:20 X35:21 X35:22 X35:23 X35:24 X35:25 X35:26 X35:27 X35:28 X35:29 X35:30 X35:31 X35:33 X35:34 X35:35 X35:37 X35:38 X35:40 X35:41 X35:46 X35:47 X35:48 X35:49 X35:53 X35:54 X35:55 X35:56 X35:57 X35:58 X35:59 X35:60 X35:61 X35:64 X35:65 X35:66 X35:67 X35:68 X36:A X36:B X37:A X37:B X38:A X39:1 X39:2 X39:3 X39:4 X40:1 X40:2 X40:3 X40:4 X41:1 X41:2 X41:3 X41:4 X41:5 X41:6 X41:7 X41:8 X42:1 X42:2 X42:3 X42:4

Bl. 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 004 004 004 004 004 004 006 003 002 005 006 006 006 004 004 004 004 006 006 006 006 006 006 006 006 004 006 004 004 004 006 004 004 004 004 006 004 004 006 006 004 004 006 004 004 004 004 004 004 004 004 004 006 004 004 004 004 004 002 002 002 002 002 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 006 008 008 008 008

Pf. 11 12 2 3 3 3 2 2 19 18 18 19 18 19 17 20 14 16 12 13 10 11 3 5 14 2 4 12 16 11 10 3 10 10 18 11 11 4 3 10 5 11 8 16 15 2 4 9 5 13 5 17 5 2 11 11 15 16 14 12 12 9 18 7 7 8 8 8 17 13 18 19 19 19 4 5 10 12 12 9 10 10 9 9 10 10 9 8 8 8 8 11 11 11 11 18 18 19 18

Benennung EMR−Stecker Motor EMR−Stecker Motor EMR − Diagnose EMR − Diagnose EMR − Diagnose EMR − Diagnose EMR − Diagnose EMR − Diagnose Trennstelle EMR II Trennstelle EMR II Trennstelle EMR II Trennstelle EMR II Trennstelle EMR II Trennstelle EMR II Trennstelle EMR II Trennstelle EMR II DIAGNOSESTECKER ESX DIAGNOSESTECKER ESX DIAGNOSESTECKER ESX DIAGNOSESTECKER ESX DIAGNOSESTECKER ESX DIAGNOSESTECKER ESX DIAGNOSESTECKER ESX DIAGNOSESTECKER ESX DIAGNOSESTECKER ESX DIAGNOSESTECKER ESX ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER ESX STECKER EINSPEISUNG SCHALTKAS EINSPEISUNG SCHALTKAS ST. ZÜNDSCHLOSS E−KAS ST. ZÜNDSCHLOSS E−KAS STECKER STARTER E−KAS STECKER 1 LENKRAD STECKER 1 LENKRAD STECKER 1 LENKRAD STECKER 1 LENKRAD STECKER 2 LENKRAD STECKER 2 LENKRAD STECKER 2 LENKRAD STECKER 2 LENKRAD ST. LENKRADKABELBAUM ST. LENKRADKABELBAUM ST. LENKRADKABELBAUM ST. LENKRADKABELBAUM ST. LENKRADKABELBAUM ST. LENKRADKABELBAUM ST. LENKRADKABELBAUM ST. LENKRADKABELBAUM STECKER OPUS21 STECKER OPUS21 STECKER OPUS21 STECKER OPUS21

title EMR−connector engine EMR−connector engine EMR−diagnosis EMR−diagnosis EMR−diagnosis EMR−diagnosis EMR−diagnosis EMR−diagnosis conector EMR II conector EMR II conector EMR II conector EMR II conector EMR II conector EMR II conector EMR II conector EMR II connector diagnosis ESX connector diagnosis ESX connector diagnosis ESX connector diagnosis ESX connector diagnosis ESX connector diagnosis ESX connector diagnosis ESX connector diagnosis ESX connector diagnosis ESX connector diagnosis ESX esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector esx connector supply e−box supply e−box connector ignition switch, e−box connector ignition switch, e−box connector starter, e−Box connector 1 steering unit connector 1 steering unit connector 1 steering unit connector 1 steering unit connector 2 steering unit connector 2 steering unit connector 2 steering unit connector 2 steering unit conn. steer. wire harn. conn. steer. wire harn. conn. steer. wire harn. conn. steer. wire harn. conn. steer. wire harn. conn. steer. wire harn. conn. steer. wire harn. conn. steer. wire harn. conn. OPUS21 conn. OPUS21 conn. OPUS21 conn. OPUS21

TYP

Name

28.06.2004 Seis 28.06.2004 Werner

Bauteilliste component listing 8 9 108

582 700 95

X42:5 X42:6 X42:7 X42:8 X43:1 X43:2 X44:1 X44:3 X44:4 X44:5 X44:7 X44:9 X44:14 X44:15 X44:23 X44:26 X44:27 X44:28 X44:29 X44:30 X44:31 X44:32 X44:33 X44:35 X44:36 X44:37 X44:38 X44:41 X44:46 X44:47 X44:53 X44:54 X44:55 X44:56 X44:57 X44:58 X44:59 X44:60 X44:65 X44:66 X44:67 X44:68 X47:A X47:B X47:C X48:1 X48:2 X48:3 X48:4 X49:1 X49:2 X49:3 X49:4 X50:1 X50:2 X50:3 X51:1 X51:2 X51:3 X52:1 X52:2 X53:B X53:C X53:H X53:L X53:M X54:1 X54:2 X54:3 X54:4 X54:6 X54:11 X54:12 X55:1 X55:2 X55:3 X55:4 X56:1 X56:2 X56:3 X56:4 X57:1 X57:2 X57:3 X57:4 X57:5 X57:6 X57:8 X57:9 X57:10 X57:11 X57:12 X57:13 X57:14 X57:15 X57:16 X57:17 X57:18 X57:19

Bl. 008 008 008 008 006 006 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 008 007 007 007 006 006 006 004 004 012 012 012 012 012 012 012 012 012 012 012 012 011 011 011 011 011 011 011 011 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003 003

Pf. 19 18 19 19 2 1 13 15 14 14 10 12 5 4 11 18 17 2 7 9 8 5 18 5 6 6 4 7 11 10 17 6 13 4 5 5 5 6 13 13 14 14 11 12 12 8 7 7 8 10 9 9 10 13 13 13 2 1 2 3 3 3 4 4 3 3 11 11 10 10 7 10 11 11 10 10 10 14 13 13 12 15 13 14 12 14 15 13 13 8 8 7 7 9 9 11 10 10 10

Benennung STECKER OPUS21 STECKER OPUS21 STECKER OPUS21 STECKER OPUS21 STECKER SCHALTER ARML STECKER SCHALTER ARML MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER MESX STECKER STECKER AUFN. PLEIGER STECKER AUFN. PLEIGER STECKER AUFN. PLEIGER STECKER AUFN. VORNE STECKER AUFN. VORNE STECKER AUFN. VORNE STECKER AUFN. VORNE STECKER AUFN. HINTEN STECKER AUFN. HINTEN STECKER AUFN. HINTEN STECKER AUFN. HINTEN ST. PLATTENFREQ. ST. PLATTENFREQ. ST. PLATTENFREQ. ST. 1 LENKRADKABELBAU ST. 1 LENKRADKABELBAU ST. 1 LENKRADKABELBAU STECKER DRUCKSENSOR STECKER DRUCKSENSOR STECKER LÜFTERSCHALTE STECKER LÜFTERSCHALTE STECKER LÜFTERSCHALTE STECKER LÜFTERSCHALTE STECKER LÜFTERSCHALTE STECKER HEIZSTEUERUNG STECKER HEIZSTEUERUNG STECKER HEIZSTEUERUNG STECKER HEIZSTEUERUNG STECKER HEIZSTEUERUNG STECKER HEIZSTEUERUNG STECKER HEIZSTEUERUNG STECKER WISCHER HINTE STECKER WISCHER HINTE STECKER WISCHER HINTE STECKER WISCHER HINTE STECKER WISCHER VORNE STECKER WISCHER VORNE STECKER WISCHER VORNE STECKER WISCHER VORNE Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor

title conn. OPUS21 conn. OPUS21 conn. OPUS21 conn. OPUS21 connector switch arm rest connector switch arm rest MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker MESX Stecker conn. sender PLEIGER conn. sender PLEIGER conn. sender PLEIGER conn. sender front conn. sender front conn. sender front conn. sender front conn. sender rear conn. sender rear conn. sender rear conn. sender rear conn. plate−freq. conn. plate−freq. conn. plate−freq. connector 1 steering wiring connector 1 steering wiring connector 1 steering wiring connector pressure sensor connector pressure sensor conn. blowerswitch conn. blowerswitch conn. blowerswitch conn. blowerswitch conn. blowerswitch conn. heating controller conn. heating controller conn. heating controller conn. heating controller conn. heating controller conn. heating controller conn. heating controller connector wiper rear connector wiper rear connector wiper rear connector wiper rear conn. wiper front conn. wiper front conn. wiper front conn. wiper front connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine connector engine

TYP

Name

28.06.2004 Seis 28.06.2004 Werner

Bauteilliste component listing

Bl. 003 003 003 003 003 003 010 010 010 010 010 010 010 010 010 010 010 010 010 010 010 010 010 010 010 010 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 007 008 008 008 008 008 009 009 009 009

Pf. 6 6 6 11 11 12 17 7 2 2 7 17 19 7 2 2 7 19 18 18 6 6 19 19 8 8 19 19 18 16 16 17 18 18 18 18 16 17 19 20 14 14 14 14 14 15 14 16 15 17 17

Benennung

X57:20 X57:21 X57:22 X57:23 X57:24 X57:25 X58:2 X58:3 X58:5 X58:6 X58:6 X58:6 X59:2 X59:3 X59:5 X59:6 X59:6 X59:6 X60:1 X60:2 X60:3 X60:4 X61:1 X61:2 X61:3 X61:4 X62:1 X62:2 X62:3 X62:4 X62:5 X62:6 X62:7 X62:8 X62:9 X62:10 X62:11 X62:12 X62:13 X62:14 X72:1 X72:2 X74:1 X74:2 X74:3 X74:4 X74:5 X75:2 X75:7 X76:1 X76:2

Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor Stecker Motor STECKER STVZO VL STECKER STVZO VL STECKER STVZO VL STECKER STVZO VL STECKER STVZO VL STECKER STVZO VL STECKER STVZO VR STECKER STVZO VR STECKER STVZO VR STECKER STVZO VR STECKER STVZO VR STECKER STVZO VR STECKER STVZO HL STECKER STVZO HL STECKER STVZO HL STECKER STVZO HL STECKER STVZO HR STECKER STVZO HR STECKER STVZO HR STECKER STVZO HR STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN STECKER DIOS PLATTEN ST. PROP.−PUMPE PLATT ST. PROP.−PUMPE PLATT STECKER DRUCKER STECKER DRUCKER STECKER DRUCKER STECKER DRUCKER STECKER DRUCKER SUB−D STECKER BCM INT SUB−D STECKER BCM INT STECKER VERS. BCM STECKER VERS. BCM

connector engine connector engine connector engine connector engine connector engine connector engine Con. STVZO FL Con. STVZO FL Con. STVZO FL Con. STVZO FL Con. STVZO FL Con. STVZO FL Con. STVZO FR Con. STVZO FR Con. STVZO FR Con. STVZO FR Con. STVZO FR Con. STVZO FR Con. STVZO BL Con. STVZO BL Con. STVZO BL Con. STVZO BL Con. STVZO BR Con. STVZO BR Con. STVZO BR Con. STVZO BR con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. DIOS−plates con. plate−pump con. plate−pump con. printer con. printer con. printer con. printer con. printer con. SUB−D BCM con. SUB−D BCM con. Power−sup. BCM con. Power−sup. BCM

title

Y04 Y07 Y08 Y14 Y15 Y16 Y17 Y30 Y31 Y92 Y93 Y98 Y112 Y113 Y122 Y123 Y137 Y138 Y140 Y141 Y142 Y143 Y144 Y145

006 006 006 012 012 004 004 004 004 006 006 007 006 006 007 007 003 012 008 008 007 007 007 007

17 15 13 14 7 13 12 15 16 7 6 14 4 3 16 17 10 10 10 11 18 18 19 20

Magnetventil Bremse Magnetventil Vibration vorne gross Magnetventil Vibration vorne klein Kraftstoffpumpe Heizgeraet Magnetkupplung Klimakompressor Magnetventil Fahrtrichtung vorwaerts Magnetventil Fahrtrichtung rueckwaerts Magnetventil Stufenumschaltung vorn Magnetventil Stufenumschaltung hinten Magnetventil Lenkung vorne rechts Magnetventil Lenkung vorne links Magnetventil Vibrationsfrequenz, hinten Magnetventil Lenkung (Y1) Magnetventil Lenkung (Y2) Magnetventil Platten heben Magnetventil Platten senken EMR Verstellung Magnetveentil Heizung Magnetventil Erreger auf Magnetventil Erreger ab Magnetventil Plattenverschieben Links Magnetventil Plattenverschieben rechts Magnetventil Platten Schwimmstellung Magnetventil Platten (Priorität)

Solenoid valve, brake Solenoid valve, vibration, front, high Solenoid valve, vibration, front, low Fuel pump, heating unit Magnetic clutch, air conditioning compr. Solenoid valve, travel direction forw. Solenoid valve, travel direction backw. Solenoid valve, speed range sel., front Solenoid valve, speed range sel., rear Solenoid valve, steering, front rh. Solenoid valve, steering, front lh. Solenoid valve, vibrat.freq.,rear Solenoid valve, steering (Y1) Solenoid valve, steering (Y2) Solenoid valve, lift plates Solenoid valve, let down plates EMR adjustment Solenoid valve, heating unit solenoid valve exciter up solenoid valve exciter down solenoid valve, plate displace left solenoid−valve, plate displace right solenoid−valve, plate swimming−position solenoid−valve, plate (priority)

TYP

MAX. 1.8A 0.4 .. 1.2A 0.4 .. 1.2A 3,5A 0.4 .. 1.2A 0.4 .. 1.2A 0.4 .. 1.2A 0.4 .. 1.2A 0.4 .. 1.2A 0.4 .. 1.2A 0.4 .. 1.2A MAX. 1.8A MAX. 1.8A MAX. 1.8A MAX. 1.8A 1A 0.4 .. 1.2A 0.4 .. 1.2A MAX. 1.8A MAX. 1.8A MAX. 1.8A MAX. 1.8A

9 9 109

582 700 95

X36 X37

X38 X1:301… X1:324 X1:79 … X1:214

A80

X1:1 … X1:61

Nur bei StvzO only acc. To StvZO illumination

A02

K11

K05

K16

K06

K09

K43 K48 K61

B57

K57 K56

X32:1-12

Gez.: 28.06.2004 Name: Seis Gepr.: 28.06.2004 Name: Werner

X34:1-19

Übersicht Schaltkasten BW 177...226 DH/BVC-4

Seite: 1

von: 2

page: 1

from: 2

overview e-box BW 177...226 DH/BVC-4

Ers. f.:

Blatt Nr.: 201

Replaces:

Sheet No.: 201

582 700 95

X2:47 … X2:78

CAN 1 A34 Fahrsteuerung

CAN 2

EMR + Fahrhebel

CAN 1

LCD + Datensammler + OPUS 21

A83 Messtechnik Steuerung

CAN 3

Gez.: 28.06.2004 Name: Seis Gepr.: 28.06.2004 Name: Werner

BCM

Übersicht Schaltkasten-Tür BW 177...226 DH-4/BVC

Seite: 2

von: 2

page: 2

from: 2

overview e-box door BW 177...266 DH-4

Ers. f.:

Blatt Nr.: 201

Replaces:

Sheet No.: 201

582 700 95

WAGO smart DESIGNER 4.0 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 19

05756537 4 x 05756540 "R" + 793-501

23

05756537

24

4 x 05756540 "R" + 793-501

28

2 x 05756539 "R" + 793-501

30 31

05756537 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

Optional1 :

Projektgruppe :

Optional2 :

Projekt :

Optional3 :

Zeichnung : Plan : Ort :

Optional4 :

Betriebsmittel :

Walzenzüge-4 Klemmenleisten

Artikelnummer : Artikelnummer lang : Konstrukteur : geprüft : Kabelbäume DH-4 VErsion

Optional5 :

ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick

Optional6 :

Artikelnummer : Bohrungsabmessungen :

Optional7 :

Zeichnungsnummer :

Lieferadresse: :

210-112 5.20 x 25.00 [mm]

Copyright WAGO. Technische Änderungen vorbehalten. 02.07.2004 09:04:26

Seite 1

WAGO smart DESIGNER 4.0

44

05756537

45

05756540 "R" + 793-501

46

05756535 "R" + 793-501

47 48

05756537 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 75

05756537 2 x 05756540 "R" + 793-501

77

05756539 "R" + 793-501

78 79

05756537 05756417

Optional1 :

Projektgruppe :

Optional2 :

Projekt :

Optional3 :

Zeichnung : Plan : Ort :

Optional4 :

Betriebsmittel :

Walzenzüge-4 Klemmenleisten

Artikelnummer : Artikelnummer lang : Konstrukteur : geprüft : Kabelbäume DH-4 VErsion

Optional5 :

ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick

Optional6 :

Artikelnummer : Bohrungsabmessungen :

Optional7 :

Zeichnungsnummer :

Lieferadresse: :

210-112 5.20 x 25.00 [mm]

Copyright WAGO. Technische Änderungen vorbehalten. 02.07.2004 09:04:26

Seite 2

WAGO smart DESIGNER 4.0

Optional1 :

Projektgruppe :

Optional2 :

Projekt :

Optional3 :

Zeichnung : Plan : Ort :

Optional4 :

Betriebsmittel :

Walzenzüge-4 Klemmenleisten

Artikelnummer : Artikelnummer lang : Konstrukteur : geprüft : Kabelbäume DH-4 VErsion

Optional5 :

ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick

Optional6 :

Artikelnummer : Bohrungsabmessungen :

Optional7 :

Zeichnungsnummer :

Lieferadresse: :

210-112 5.20 x 25.00 [mm]

Copyright WAGO. Technische Änderungen vorbehalten. 02.07.2004 09:16:28

Seite 6

WAGO smart DESIGNER 4.0

Optional1 :

Projektgruppe :

Optional2 :

Projekt :

Optional3 :

Zeichnung : Plan : Ort :

Optional4 :

Betriebsmittel :

Walzenzüge-4 Klemmenleisten

Artikelnummer : Artikelnummer lang : Konstrukteur : geprüft : Kabelbäume DH-4 VErsion

Optional5 :

ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick

Optional6 :

Artikelnummer : Bohrungsabmessungen :

Optional7 :

Zeichnungsnummer :

Lieferadresse: :

210-112 5.20 x 25.00 [mm]

Copyright WAGO. Technische Änderungen vorbehalten. 02.07.2004 09:16:28

Seite 7

WAGO smart DESIGNER 4.0 1

05756417

2

4 x 05756540 "R" + 793-501

6 7

05756537 2 x 05756540 "R" + 793-501

9

4 x 05756538 "R" + 793-501

13

2 x 05756539 "R" + 793-501

15

05756537

16

05756417

Optional1 :

Projektgruppe :

Optional2 :

Projekt :

Optional3 :

Zeichnung : Plan : Ort :

Optional4 :

Betriebsmittel :

Walzenzüge-4 Klemmenleisten

Artikelnummer : Artikelnummer lang : Konstrukteur : geprüft : Optionen Beleuchtung

Optional5 :

ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick

Optional6 :

Artikelnummer : Bohrungsabmessungen :

Optional7 :

Zeichnungsnummer :

Lieferadresse: :

210-112 5.20 x 25.00 [mm]

Copyright WAGO. Technische Änderungen vorbehalten. 02.07.2004 09:19:48

Seite 1

WAGO smart DESIGNER 4.0

Optional1 :

Projektgruppe :

Optional2 :

Projekt :

Optional3 :

Zeichnung : Plan : Ort :

Optional4 :

Betriebsmittel :

Walzenzüge-4 Klemmenleisten

Artikelnummer : Artikelnummer lang : Konstrukteur : geprüft : Optionen Beleuchtung

Optional5 :

ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick

Optional6 :

Artikelnummer : Bohrungsabmessungen :

Optional7 :

Zeichnungsnummer :

Lieferadresse: :

210-112 5.20 x 25.00 [mm]

Copyright WAGO. Technische Änderungen vorbehalten. 02.07.2004 09:22:27

Seite 2

WAGO smart DESIGNER 4.0 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 22

05756537 2 x 05756438 "R" + 793-501

24 25

05756421 05756417

Optional1 :

Projektgruppe :

Optional2 :

Projekt :

Optional3 :

Zeichnung : Plan : Ort :

Optional4 :

Betriebsmittel :

Walzenzüge-4 Klemmenleisten

Artikelnummer : Artikelnummer lang : Konstrukteur : geprüft : Klemmenleiste X2 /

Optional5 :

ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick

Optional6 :

Artikelnummer : Bohrungsabmessungen :

Optional7 :

Zeichnungsnummer :

Lieferadresse: :

210-112 5.20 x 25.00 [mm]

Copyright WAGO. Technische Änderungen vorbehalten. 02.07.2004 09:27:03

Seite 1

WAGO smart DESIGNER 4.0

Optional1 :

Projektgruppe :

Optional2 :

Projekt :

Optional3 :

Zeichnung : Plan : Ort :

Optional4 :

Betriebsmittel :

Walzenzüge-4 Klemmenleisten

Artikelnummer : Artikelnummer lang : Konstrukteur : geprüft : Klemmenleiste X2 /

Optional5 :

ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick

Optional6 :

Artikelnummer : Bohrungsabmessungen :

Optional7 :

Zeichnungsnummer :

Lieferadresse: :

210-112 5.20 x 25.00 [mm]

Copyright WAGO. Technische Änderungen vorbehalten. 02.07.2004 09:29:27

Seite 2

X74 X75 X55 X76

X56

X53 X54

X29 X28

X21

X39 X23 X24 X50

X59

X40 X25 X41

X58

X42

X51 X43

X18 X45 X46

X47 X48 X49

X19

X22

X17

X52

X30 X31

X48 X49

(BVC) (BVC)

X57

X20

X14

X72

X33

X4 X3

X36

X26

X37 X1

X27

X6 X7 X8 X10

X15 X16 X60 X61 X62

X38 X2

X9

X44 X35 X32 X34

X61 X9 X21 X59

X74 X75

X72

X76 X55

X42 X23 X24 X50

X57

X25 X41 X51 X53

X29 X18 X28 X19

X20 X14

X17

X56

X54

X45 X46

X47 X48 X49 (BVC) (BVC)

X52

X30 X31

X6 X7 X15 X16

X39 X40 X58

X62 X8 X10

X43

X33

X4 X3

X36 X35 X1

X26

X37 X44 X2

X27

X38 X32 X34

X60

X48 X49 X22

Gez.: 28.06.2004 Name: Seis Gepr.: 28.06.2004 Name: Werner

Steckerübersicht BW 177...226 DH/BVC-4

Seite: 1

von: 1

page: 1

from: 1

Connector overview BW 177...226 DH/BVC-4

Ers. f.:

Blatt Nr.: 301

Replaces:

Sheet No.: 301

582 700 95