Training 214
Training 214
Training 214
New developments A5
Maintenance C1
Maintenance chart C2
Travel system E1
Travel pump E3
Control E7
Charge pressure relief valve E8
High pressure relief valve E9
Pressure override E11
Axle drive motor E14
Drum drive motor E17
Test and adjustment points, travel system E19
Trouble shooting travel system E27
Vibration F1
Vibration pump F3
High pressure relief valves F6
Control F7
Vibration motor F8
Drum F11
Test and adjustment points, vibration system F13
Trouble shooting vibration F15
Steering G1
Charge pump G2
Steering pump G3
Steering valve G5
Articulated joint G7
Measuring and adjustment points G9
Trouble shooting steering G10
Electric - Training
Wiring diagram
Hydraulic diagram
• for the customer/user it is a basis for an exact calculation of utilization periods and the completion of
projects as scheduled.
• in the rental business it means that the equipment can be reliably used and planned without having
to stock a large number of stand-by machines.
• for the manufacturer it means that customers are satisfied, provides him with a good image and gives
him a feeling of confidence.
It is BOMAG’s philosophy to design and produce the machines with highest possible reliability. This
aspect of simple and easy maintenance was one of the key issues when developing and designing the
machine:
• the high quality standard of BOMAG is the basis for the considerable extension of the service and
maintenance intervals.
• the After Sales Service of BOMAG, including excellent operating and maintenance instruction
manuals, high quality training courses and on-site machine demonstrations helps the customer to
maintain their machines in good condition over a long period of time.
Permanent training of BOMAG’s own service personnel as well as the service personnel of BOMAG
Profit Centres and dealers is therefore a general prerequisite for BOMAG’s excellent world-wide service.
This program of permanent training is only possible with appropriate and up-to-date training material for
trainers as well as persons attending the training courses.
This training manual has not only been written as a support for the professional work of the trainer, but
also for the trainees attending these training courses.
The different levels of product training demand, that the training performed by BOMAG, its Profit Centres
or its dealers reflects the high quality of the training conducted at the Training Centre at BOMAG in
Boppard. For this reason we invested a lot of time in the preparation of these materials .
The structure of this training manual enables us to change or up-date individual chapters in case of
alterations to the machine.
BW 213 DH-4
BW 214 DH-4
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.
These machines have been successfully and reliably used for years on construction sites all over the
world, especially in earth construction and on sanitary landfill sites.
High compaction power and excellent traction are characteristics, which are of utmost importance for
this type of machine.
All components installed in these machines are manufactured in series production and are subjected to
stringent quality tests. This guarantees a high level of reliability and safety.
As with many other BOMAG products, and here especially with the large single drum rollers of the new
generation, we have decided to use the same successful drive concept with diesel engine (water cooled)
and hydrostatic drives also for these machines. The hydrostatic drives transfer the output power of the
engine directly to drum, drive wheels and steering.
The drive wheels are driven by fast rotating hydraulic motors and axle, whereas the drum is driven by
slow running radial piston motors.
On construction machines the work place of the operator is of utmost importance. Under such working
conditions the health and safety of the operator must be the greatest concern.
The cabin is very spacious and clearly arranged. The driver’s seat is very comfortable and can be
individually adjusted for every operator, even for his weight.
All control elements and gauges are within the reach and in the sight of the operator.
A monitoring display with light emitting diodes and clear pictograms informs the operator about any
operating faults. The operator is therefore always informed about the present condition of the machine.
The generously glazed cabin with windscreen wiper and washer systems for front and rear windscreens,
as well as a heated rear windscreen, offers clear vision to all sides.
• disc brakes in axle and drum drive motor serve as parking and emergency brakes
• high stability due to low centre of gravity and the use of an articulated joint
• operating safety due to the use of monitoring boards for all important system data
• automatic engine shut-down at too engine temperature, too low hydraulic oil level (when reaching the
lowest permissible level the engine will be shut down after 20 seconds) and too low engine oil
pressure.
The new single drum roller serie -4 are well designed down to the smallest detail, so that they can meet
the toughest demands on large scale construction sites all over the world.
Attention!
The currently valid technical data and adjustment values can be taken from the BOMAG Intranet
or Extranet (BOMAG Secured Area) in accordance with the serial number of the machine.
Status: 2005-01-28
Engine:
Manufacturer: Deutz
Type: BF4M1013EC EMR
Combustion principle: 4-stroke-Diesel
Cooling: Water
Number of cylinders: 4
Power acc. to ISO 9249: 114 kW
Power data at nominal speed of: 2200 1/min
Low idle speed: 900+/-10 1/min
High idle speed: 2200 +/-10 1/min
Spec. fuel consumption: 235 g/kWh
Valve clearance, inlet: 0,3 mm
Valve clearance, outlet: 0,5 mm
Opening pressure, injection valves: 275 bar
Starter voltage: 12 V
Starter power: 3,1 kW
Travel pump:
Manufacturer: Sauer-Danfoss
Type: 90R 075 (EP)
System: Axial piston-swash plate
Max. displacement: 75 cm3 /U
Max. flow ratio: 165,0 l/min
High pressure limitation: 400 bar
Charge pressure, high idle: 25+/-1 bar
Drum drive:
Manufacturer: Sauer-Danfoss
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BOMAG Central Service Seite 2 von 3
Vibration pump:
Manufacturer: Sauer-Danfoss
Type: 90R 075 (EP)
System: Axial piston-swash plate
Max. displacement: 75 cm3 /U
Starting pressure: 365+/-65 bar
Operating pressure, soil dependent: ca.100 bar
Vibration motor:
Manufacturer: Bosch-Rexroth
Type: A2FM 56 HDD
System: Axial piston-bent axle
Displacement: 56 cm3 /U
Frequency: 30-40 Hz
Amplitude: 2,0/0,9 mm
Steering valve:
Manufacturer: Sauer-Danfoss
Type: OSPC 500 ON
System: Rotary valve
DBV - Einstellung (?): 175 bar
Schockventile (?): 240 bar
Rear axle:
Manufacturer: Dana
Type: CHC 193/66LD
Differential: No-Spin
Degree of locking: 100 %
Reduction ratio: 65,08
Filling capacities:
Engine coolant: 16 l (50% Water, 50% Anti-freeze agent on
Ethane-diol-basis)
Engine oil: 13 l (SAE 15W-40, API CG-4 (for details see
maintenance manual))
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BOMAG Central Service Seite 3 von 3
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Service Training
Maintenance
Single drum rollers are heavy-duty construction machines for extremely difficult tasks in earth
construction. To be able to meet these demands the machines must always be ready to be loaded up
to their limits. Furthermore, all safety installations, protections and guards must always be in place and
fully functional.
Thorough maintenance of the machine is therefore mandatory. This not only guarantees a remarkably
higher functional safety, but also prolongs the lifetime of the machine and of important components.
The time required for thorough maintenance is only minor when being compared with the malfunctions
and faults that may occur if these instructions are not observed.
The maintenance intervals are given in operating hours. It is quite obvious that with each maintenance
interval all the work for shorter preceding intervals must also be performed. During the 2000 hours
interval you must also perform the work described for the service intervals after 50, 250 and 500 hours.
During maintenance work you must only use the fuels and lubricants mentioned in the table of fuels and
lubricants (oils, fuels, grease etc.).
The designation specified under No: in the first column of the maintenance chart refers to the
corresponding number of the service work to be performed, as specified in the operating and
maintenance instructions. This also helps to find detailed information on the individual maintenance
tasks.
Crankcase and cylinders of this engine are made of alloyed cast iron. This provides strength and
ensures high wear resistance.
The engine is equipped with wet cylinder liners, which can be easily changed in case of a repair.
The forged steel conrods are fitted with compensation weights near the conrod bearing seats. These
weights compensate manufacturing tolerances with respect to weight and centre of gravity.
The pistons are made of an aluminium alloy. The combustion chamber recess is slightly offset from the
middle at its side walls are inclined for 10° towards the inside. All pistons are fitted with three piston rings
and a cast iron ring carrier for the first ring. The pistons are lubricated by an oil mist.
The block-type cylinder head is made of cast steel. Each cylinder is fitted with one intake and one
exhaust valve. The valve guides are shrunk into the cylinder head. The valve seat rings are made of
high-grade steel and are also shrink fitted.
3 4
2
5
6
14
9 8
13 12 11 10
3
1
1 Flywheel
2 Ground cable
3 Starter
4 Turbo charger
5 Generator
6 Coolant temperature switch
2 1 22 21 20 19 18 17 16
3 1
5 4
1 Cooler
2 To cooler
3 From cooler
4 Coolant pump
5 Lubrication oil cooler
6 Cylinder cooling
7 Cylinder head cooling
8 Ventilation connection between cylinder head and heat exchanger
1a
1b
1c
Fuel tank
1d
1
2
1) Hand pump
2) Breather valve
3 Filter element
4) Water and dirt collecting bowl
5 Drain valve
6 Electric connection for water level sensor
• the dirt / water sediment bowl with water level warning sensor
The water resistant filter element retains remaining smaller dirt and water particles.
Once the water level reaches the height of the warning connections, the warning light in the dashboard
lights up.
If the filter element is clogged before a service is due (indicated by e.g. a power drop), the filter may be
regenerated as follows to keep up operation of the engine:
• Open the bleeding screw (this applies atmospheric pressure to the filter element and releases bigger
dirt particles from the bottom side of the filter, which will then sink down.
• Open the drain valve and let approx. 0.5 l of fuel run out. The fuel above the filter element presses
through the filter element and cleans the underside of the filter element from dirt.
Bleed the system with the manual fuel pump and then tighten the bleeding screw.
Attention!
The main fuel filter is subjected to approx. 10 bar fuel pre-pressure from the fuel lift pump. This
pressure is considerably higher than on other engines. For this reason only original filter
elements must be used. Filter elements of similar design or with adequate dimensions are not
necessarily pressure resistant!
A filter element of insufficient pressure resistance will be damaged by the high pressure and will
disintegrate. This causes severe damage to the injection system!
The Deutz engines in single drum roller BW 213 / 214 DH-4 are equipped with an electronic engine
management (Deutz EMR II).
• shorter response times compared with mechanically controlled engines, i.e. the response times are
significantly better. This improvement is achieved without increasing the acceleration fumes or the
fuel consumption.
• no mechanical throttle control (light moving, maintenance free, less susceptible for faults)
• in comparison with the first version of the Deutz-EMR this system has the essential advantage that
faults can be indicated directly by the fault indicator light on the machine in form of a flashing code,
with the necessity of additional software.
The EMR-injection system is based on the approved Deutz-injection system of series 1012/1013 with
individual injection pumps for each cylinder. However, the fuel quantity per stroke is not regulated
mechanically via a throttle cable, but is controlled by the EMR II-system by means of an electromagnetic
actuator acting on the governor rod.
The essential components of the EMR II-system for engine speed control are:
• EMR II control unit [A48] at the left under the operator's stand.
• displacement measuring system in the EMR actuator [Y 137] (current position of the injection pump
control rod)
• the engine oil pressure sensor [B 88] on the oil filter housing
• the charge air pressure and charge air temperature sensor [B 115] connected to the intake manifold
• The cold start device (heating flange) is additionally triggered by the EMR II in dependence on the
coolant temperature
In ECO-mode (position "AUTO") the travel lever determines the engine speed setpoint. The control unit
compares this nominal value with the actual speed value detected by the engine speed sensor. If the
nominal value corresponds with the actual value, the signal to the EMR actuator will remain unchanged.
However, if the nominal speed deviates from the actual speed (e.g. when changing the travel lever
position or under higher load), the control unit uses the current turbo charger pressure and the coolant
temperature to determine the necessary change in fuel quantity to achieve the nominal speed value.
The control unit then sends a signal to the EMR actuator to change the control rod position and thereby
the engine speed.
Control unit
EMR II
Connecting cable
Engine wiring harness
Control unit EMR II
- D 13 -
Service Training
The EMR control unit is located above the central electrics under the operator's stand in the access
area. This is the computer unit of the EMR and it processes the input signals from the sensors to output
signals for the EMR actuator (governor rod).
1
3
2
The EMR actuator is directly connected with the governor rod of the injection pump and moves this rod
by being excited by the signal currents from the EMR control unit. At the same time the actual position
of the actuator is fed back to the EMR control unit. This component is generally a proportional magnet
with integrated path measuring system.
In case of a fault in the path measuring system the engine is shut down and a fault code displayed.
2 Stg+
7
3 RF -
1 Stg+
9
4 RFMeß 6
5 RF Ref
Pin assignment of EMR-actuator looking towards actuator (plug pins mirror inverted)
EMR-actuator
The EMR coolant temperature sensor is mounted to the flywheel end of the engine. The EMR sensor
is the bottom sensor.
The coolant temperature influences the calculated injection quantity of the EMR.
The EMR sensor value is not only used for the EMR itself, but also for the high coolant temperature
control light in the display.
In case of a too high temperature the EMR shuts down the engine and a fault code is displayed.
The sensors for camshaft and crankshaft speeds are installed in the side of the engine block.
These sensors deliver the actual engine speed value for the EMR control unit.
If the engine speed is too high (pushing operation) the governor rod is returned to zero position, until the
speed has dropped to the permissible range.
In case of a sensor failure the engine is shut down and the fault code appears in the display.
With a missing rotary speed signal from standstill the engine will not start, however, no fault message
will be displayed, because the EMR assumes that the engine is at standstill and does therefore not
release any fuel.
The EMR speed sensor has a fixed stop and does not need to be adjusted after installation.
The engine oil pressure sensor is mounted on the engine oil filter housing. The oil pressure is
permanently monitored by the EMR.
With a too low engine oil pressure the display shows a fault code.
In case of a too low pressure the EMR shuts down the engine and a fault code is displayed.
In case of a sensor failure the engine keeps on running and the display shows a fault code.
Pin 2 (Signal)
Pin 1 (AGND)
Ventilation
The Deutz engine BF4M1013EC (EMR) is fitted with a combination sensor for charge air pressure and
charge air temperature. This sensor measures the pressure and temperature in the intake manifold. The
sensor itself is located on the intake manifold. Charge air pressure and charge air temperature inform
the EMR about the actual load state of the engine.
Instead of glow plugs this engine is fitted with a heating flange before the intake air manifold, which
heats up the passing air with resistance heated wires when the engine is cold. This system is electrically
supplied via high current relay K14, located to the left next to the engine. This high current relay is
triggered by the EMR-control unit (ground triggering) in dependence on the coolant temperature.
2
1
For a detailed description of how to read out fault codes and the display
please refer to the page on "Electrics" (Service Training Electrics)
with fault code 5140: a fault diagnose is only possible via SERDIA
SERDIA is a software program from Deutz which can be used in connection with a laptop computer to
perform more detailed fault analyses, especially reading out of the error log.
• Nature of fault (e.g. ’fallen short of bottom limit value’, ’sporadic fault’)
• Environmental data / operating data (speed and operating hours at the time of the last fault
occurrence)
• Frequency of fault
Fault messages for non-present / rectified faults can be deleted with SERDIA.
• Function test: With the engine shut down the control outputs and the travel of the governor rod can
be activated.
• Representation of measuring values: There are a lot of measuring values available which can be
used if no EMR II fault is present (starting performance, engine sawing, lack of power).
Connection of SERDIA
with fault code 5140: a fault diagnose is only possible via SERDIA
SERDIA is a software program from Deutz which can be used in connection with a laptop computer to
perform more detailed fault analyses, especially reading out of the error log.
• Nature of fault (e.g. ’fallen short of bottom limit value’, ’sporadic fault’)
• Environmental data / operating data (speed and operating hours at the time of the last fault
occurrence)
• Frequency of fault
Fault messages for non-present / rectified faults can be deleted with SERDIA.
• Function test: With the engine shut down the control outputs and the travel of the governor rod can
be activated.
• Representation of measuring values: There are a lot of measuring values available which can be
used if no EMR II fault is present (starting performance, engine sawing, lack of power).
Replacement of system
components
Note: The Deutz part-number specified on the EMR-control unit is the part number without software
specific for the engine. The correct part number can be found in the spare parts catalogue.
Excessive or insufficient valve clearance can cause failure of the engine as a result of mechanical and
thermal overloads. The valve clearance must therefore be checked and, if necessary, adjusted at the
intervals specified in the operating and maintenance instructions.
Note: The valve clearance must be checked and adjusted when the engine is cold.
• Turn the crankshaft until both valves on cylinder 1 are overlapping (the exhaust valve is not yet
closed, the intake valve starts to open).
Flywheel
side
1 2 3 4
• Check and adjust the valve clearance by following the black marking in the adjustment schematics.
For control purposes mark the respective rocker arm with chalk.
Flywheel
side
1 2 3 4
During the following work the following pictograms are used for the reason of simplicity:
Deutz diesel engines of product range 2012 are equipped with plug-in injection pumps of series PF 33
from Bosch.
The concept of the plug-in fuel injection pumps enables the realization of high injection pressures in
connection with extremely short injection lines, which contributes to a high hydraulic stiffness of the
injection system. This in turn provides the prerequisite for low exhaust emission values (soot) in
combination with a low fuel consumption.
• Stroke 12 mm
• Diameter 9 mm
Cavitation in the injection lines and injection overrun, which is normally associated with high pressures,
is prevented by a return flow nozzle arranged after the pressure valve
The constant volume relief is 50 mm³.
• the power
of the engine.
On engines of series 2012 the start of delivery is adjusted without tolerance. The start of delivery is
entered in degree of crank angle measured from the top dead centre of the piston and depends on
application, power and speed setting of the engine.
The plug-in injection pump is in position of start of delivery when the plunger just closes the fuel supply
bore in the plunger sleeve.
The injection pump cams on engines of series 2012 are arranged on the camshaft of the engine. For
this reason the conventional adjustment method for the start of delivery cannot be used.
The start of delivery of the injection pump must be adjusted using the new method.
For this the conventional adjustment method is subdivided into length measurements of individual
engine parts and calculations.
• cylinder crankcase,
• camshaft,
• plunger
However, in cases of interest for BOMAG engineers the engine will not be overhauled completely, but
individual injection pumps will be replaced.
This results in a certain installation measurement for the engine drive, which is stamped on the engine
type plate.
Note:
If an injection pump and/or nozzle is replaced, the respective high pressure line between pump and
nozzle must also be replaced..
Fig. 4:
Fig. 5:
Note:
Fig. 6:
Note:
View on flywheel
Fig. 7:
Fig. 8:
Fig. 9:
Determination of the compensation shim thickness when replacing plug-in fuel injection pumps
295
The EP-code is used to determine the installation measurement to be corrected „Ek“ from table 1.
EK EP EK EP EK EP EK EP
(mm) code (mm) code (mm) code (mm) code
119,250 230 119,850 254 120,450 278 121,050 302
119,275 231 119,875 255 120,475 279 121,075 303
119,300 232 119,900 256 120,500 280 121,100 304
119,325 233 119,925 257 120,525 281 121,125 305
Ek (mm) = corrected injection pump measurement, determined by EP-code on type plate and from
table 1.
Measurement "A" in 1/100 mm has been written on the pump with an electric marker.
64
A=XXX
Lo
A = XX
A/100
Ek Lo+A/100
Z
Ts
The plug-in fuel injection pump is now positively connected with the drive, which has been set to start
of delivery by inserting a compensation shim "Z" of calibrated thickness..
there is a gap „Ts“ between injection pump plunger foot and roller plunger. This gap has to be
compensated with a compensation shim "Z" of appropriate (calculated) thickness.
For the determination of the theoretical shim thickness „Ts“ it is also necessary to determine
measurement Lo + A/100 of the new fuel injection pump, which must then be subtracted from the
corrected injection pump measurement Ek.
The real compensation shim thickness „Ss“ is determined with the help of table 2.
• see table 1
• Ts = Ek - (Lo + A/100)
Ts = 120,875 mm - (117,5 + 42/100 mm)
Ts = 2.995 mm
Ts = 3,0 mm
Fig. 16:
Fig. 17:
Fig. 18:
Note:
Fig. 19:
Fig. 20:
Fig. 21:
Fig. 22:
Note:
Fig. 23:
Note:
Fig. 24:
19. Slightly oil the O-ring of the crankcase ventilation. Reassemble the crankcase ventilation. Tightening
torque 9 +/- 1Nm
During the following work the following pictograms are used for the reason of simplicity:
The following tools can be ordered from the respective supplier (in brackets) under the stated part-
number.
For tools from Hazet and Bosch you should consult your nearest representative, orders to Wilbär should
be addressed to:
Co. Wilbär
P.O. box 140580
D - 42826 Remscheid
Fig. 1
1
3
15
The travel system of the single drum rollers is a closed hydraulic circuit and consists
mainly of:
• hydraulic lines.
Travel pump and vibration pump are connected to a tandem pump unit. The charge pump is an integral
part of the vibration pump. The travel pump is the first pump section, flanged directly to the flywheel side
of the diesel engine.
The pump delivers the hydraulic oil to the travel motors for drum and axle drives. The multi-function
valves in the pump limit the pressure in the closed circuit to 425 bar (∆p = 400 bar between low and high
pressure sides).
A flushing valve in the axle drive motor (and in the Sauer drum drive motor 51 C 110) flushes a certain
oil quantity out of the closed circuit when the machine is driving (∆p between the two sides of the closed
circuit). Leakage in the individual components of the circuit are replaced by the charge circuit through
the boost check valves in the travel pump.
The charge pump inside the vibration pump draws hydraulic oil out of the tank and delivers it through
the hydraulic oil filter to the boost check valves in travel and vibration pump. The return flow from the
steering system also flows through the hydraulic oil filter and is then available for the closed circuit
charging system. The charge circuit also provides the oil for the control functions in the closed circuits
for travel and vibration drive and to release the parking brakes.
Both travel motors and the travel and vibration pumps are electrically proportionately controlled.
The travel pump is a swash plate operated axial piston pump with variable displacement, most suitable
for applications in hydrostatic drives with closed circuit.
4
1 2
Charging
7 1
6 5
Fig. 1: Travel pump
With the servo control the swashing angle can be infinitely adjusted from neutral position (0) to both
maximum displacement positions.
When altering the swash plate position through the neutral position, the oil flow will be reversed and the
machine will drive to the opposite direction.
All valves as well as the safety and control elements needed for operation in a closed circuit, are
integrated in the pump.
2
4
5
1 3
9
10
8
11
4 3
5
1 Working pistons
2 Slipper pad
3 Pre-tensioning spring
4 Cylinder block
5 Drive shaft
2 3 4 5 6
1
8 6 7
The drive shaft (1) is directly driven by the diesel engine via an elastic coupling. the shaft turns the tightly
connected cylinder block (5).
With the rotation of the drive shaft (1) the cylinder block (5) moves the working pistons (4). The slipper
pads of the working pistons abut against the swash plate (3).
The slipper pads are hydrostatically balanced and are retained on the sliding face of the swashing cradle
by a retaining device.
During a full rotation of the cylinder block each working piston will move through the bottom and top dead
centre back to the initial position. During this movement each piston performs a complete stroke.
During the piston stroke each piston draws in a certain quantity of oil from the low pressure side of the
hydraulic circuit and presses it out into the high pressure side.
38
Thermostat
housing
The servo control (mechanical – hydraulic displacement control) converts the mechanical input signal
from the proportional valve into a position controlling output signal. This position controlling signal
determines the swashing angle of the swash plate (the displacement of the pump), as well as the
swashing direction (flow direction of the pressure fluid).
The flow quantity delivered by the variable displacement pump is proportional to the value of the input
signal from the proportional valve. A mechanical feedback device ensures the fixed correlation between
the proportional valve input signal and the swashing angle of the swash plate (displacement of pump).
Servo cylinder
Control piston
Sliding block
Servo arm
Since the control is spring centred, the swash plate will automatically return to neutral position under the
following conditions, thereby interrupting the oil flow and braking the machine:
Pumps of series 90 are equipped with a follower valve, which activates a pressure override and a
pressure relief valve, one after the other.
1 2
3
A
6 5
B
4
If the adjusted pressure is reached, the pressure override will move the swash plate quickly back
towards neutral position, thereby limiting the system pressure. The average response time is less than
90 ms.
2 3
4
5
1
6
9 7
8
10
11
Pressure override and high pressure relief valve are both parts of the multi-function valve, which is
screwed into the pump.
With its possibility to swash the swash plate inside the pump back within a period of 90 ms, the pressure
override makes sure that the high pressure relief valves will only respond in exceptional cases. This
protects the hydraulic circuit against overheating and reduces the load on the diesel engine.
Note:
The multi function valves must be tightened with a torque of 89 Nm!
The charge pressure relief valve is a direct acting valve with fixed adjustment and is part of the safety
elements in a closed hydraulic circuit. This valve limits the pressure in the charge circuit to the adjusted
value (26 bar).
The charge circuit compensates leaks and flushing quantities in the closed travel and vibration circuits
and provides the necessary pressure to control the travel and vibration pumps, the speed range
selection and to operate the multi-disc brakes in the travel drives.
Since feeding of cool and filtered oil is only possible in the low pressure side of the closed circuit, the
pressure in the low pressure side is almost identical with the pressure in the charge circuit.
When parking the machine on level ground with the engine running, the pressures in both
The axle drive motor is a swash plate controlled Sauer-Danfoss axial piston motor of series 51 D 110
with an electrical proportional control for variable displacement.
HD-Pump Brake valve
Charge pressure
5
4
2
Leak
oil
HD-Pump
1 Motor drive
2 Control piston
3 Proportional control with proportional solenoid
4 Flushing valve with flushing pressure limitation valve
5 Axle with brake
6) Rotary speed sensor (flange sensor)
5 7 8
6
9
11
10
4
2
The motor is connected with the travel pump via the high pressure ports A and B. The hydraulic oil flows
under high pressure through the corresponding port to the back of the working pistons. Since the
working pistons are arranged under an angle to the output shaft, the pressurized pistons will perform a
stroke movement, thereby causing a rotation of the output shaft.
Once the respective piston has passed its dead centre (max. extended position), it will change to the
low pressure side. As the rotation progresses, the piston will move back into the cylinder bore. Oil is
thereby displaced out of the cylinder chamber through the low pressure side back to the pump.
The synchronizing shaft with roller surfaces ensures uniform rotation of output shaft and cylinder block.
The ball joints of the pistons run in journal bearings, which are pressed into the outer shaft. For the
connection between output shaft and pistons no other parts are required. The output shaft runs in two
tapered roller bearings.
Control
The motor can be adjusted to two fixed displacements. This is accomplished by changing the angle
between cylinder block and output shaft.
With a large angle position the motor works with maximum displacement, slow speed and high torque.
When changing the swash plate position to minimal angle the motor works with minimum displacement,
high speed and low torque.
The displacement is changed by a control piston, which is tightly connected with the valve segment.
The front travel motor (drum drive) also is an axial travel motor 51C110
from Sauer-Danfoss.
1 Flushing spool
2 Flushing pressure relief valve
The flushing valves are integrated in the axle drive motor, or on DH/PDH machines, also in the drum
drive motor. In case of a pressure increase in one of the two sides of the closed circuit the flushing valves
have the function to flush a certain quantity of oil out of the low pressure side.
The valve is operated by the pressure difference between the two sides of the closed circuit (A and B).
If the pressure in one side is higher than in the other, this pressure will move the valve out of neutral
position against the neutral setting spring. Oil can now flow out of the low pressure side. This oil flows
through a thermostat valve back to the tank. The flushed out oil quantity is immediately replaced by oil
entering from the charge circuit through the corresponding boost check valve (part of the multi-function
valve).
In this way the closed travel circuit is permanently supplied with cool and filtered oil and the temperature
household of the hydraulic system is maintained at a permissible level.
For manual releasing of the brakes on the rear axle you should proceed as follows:
• Slacken the counter nut (Fig. 14, Pos. 1) and back it off by approx. 8 mm.
• To release the brake tighten the screw for max. 1 complete turn.
Attention!
The drums on the DH-4 and PDH-4 versions are driven by a swash plate operated Sauer axial piston
motor 51C110. This motor is almost identical with the rear axle motor. Another detailed description at
this point is therefore not necessary.
2
3 4
1
10 8
9
This motor is a fast rotating hydraulic motor. Since the output speed of this motor is much too high to
drive the drum, a reduction gear reduces the output speed to the actually required drum drive speed.
During operation the closed hydrostatic travel circuit has the function of a service brake. When moving
the travel lever from full forward or reverse position towards neutral, the travel pump will follow towards
zero position relative to the movement of the travel lever. The oil flow is thereby reduced and the
machine is hydraulically braked. When moving the travel lever to neutral position, the pump will also
return to neutral, the supply of oil is interrupted and the hydraulic circuit brakes the machine to standstill.
However, since minor leaks cannot be avoided in any hydraulic circuit and such minor leaks will cause
creeping of the machine when it is parked on a slope with the engine running, the machine is additionally
equipped with multi-disc brakes in drum drive and both wheel drives. When engaging the travel lever in
neutral position the multi-disc brakes will close and the machine can be parked on slopes with the
engine running and without the risk of creeping.
However, these parking brakes can also be operated via a 3/2-way solenoid valve. In de-energized
condition the multi-disc brakes in the travel drives are unloaded. The charge pressure to the brakes is
interrupted and the oil from the brake housings flows as leak oil back into the tank.
If the brake solenoid valve is supplied with current while the engine is running and the brake is open,
the connection of the brake line to the tank is interrupted and oil from the charge circuit is guided to the
brake pistons. The oil pressure works against the spring force of the brake spring and relieves the brake
discs.
For manual brake release both screws on the drum drive reduction gear (marked with arrow) must be
turned in uniformly, until the drum is able to rotate freely.
2
9
Travel lever
forward
3
8
4
7 5
n
6 ti o
ec 1 Travel pump
dir
el 2 Vibration pump
av
Tr 3 Hydraulic oil filter
4 Rear axle
High pressure 5 Axle drive motor
6 Reduction gear
Low pressure
7 Drum drive motor
Charge pressure 8 Hydraulic oil tank
Leak oil 9 Travel lever
Brake valve
Charge pressure
Brake releasing pressure
Leak oil
2
2
3
1
1
3 4
5
2 1
3
2
4 1
2
1
3
5
3 4
1
For a detailed description of how to read out fault codes and the display
please refer to the page on "Electrics" (Service Training Electrics)
The following trouble shooting chart contains a small selection of possible faults, which may occur
during operation of the machine. The fault list is by no means complete, however, the fault table is based
on the experience of the central service department, i.e. the list covers almost all faults that have
occurred in the past.
The following trouble shooting table contains both electrical as well as mechanical and hydraulic faults.
The number specified in the table indicate the probability of the fault cause and thereby the
recommended trouble shooting sequence, based on our latest field experience.
SYMPTOME
MÖGLICHE URSACHEN
Bremsventil (elektrisch/mechanisch/hydraulisch) 1
Bremse Achse/Bandagenmotor (mechanisch/hydraulisch) 2 2 3
Fahrpropverstellung /defekt/Verkabelung 1
Speisepumpe / Speisedruckbegrenzungsventil(e)
2 3
verschmutzt/defekt
Pumpenansteuerung (Servoverstellung) 2 1 2 3
Druckabschneidung/ Hochdruckbegrenzung Fahrpumpe
3 2 3 3
verschmutzt/verstellt/defekt
Fahrhebel 1 2
Nullage Fahrpumpe 3 3
Fahrpumpe(n) defekt 3 3 2
Stellventil Fahrmotoren (elektrisch / mechanisch / hydraulisch) 1 2
Spülventil Fahrmotoren hängt 3
Fahrmotor(en) defekt 3 3
Hydraulikölkühler verschmutzt (intern/extern) 1
Thermostat (Hydraulik) verschmutzt/verklemmt/defekt 2
Kupplung Dieselmotor-Pumpe 2
Dieselmotor 1
Drehzahl-Flanschsensoren im Fahrmotor (Verkabelung) 1 1 2
FEHLERSUCHE
3
4
The vibration system on these single drum rollers works with different frequencies and tow amplitudes.
This enables perfect adaptation of the machine to various types of soil and different applications.
The vibration circuit is also a closed hydraulic circuit, similar to the travel circuit.
vibration pump,
Vibration motor
Vibration pump and travel pump are joined to a tandem unit, which is driven by the flywheel end of the
diesel engine.
By operation of a proportional valve the pilot oil is guided to one of the control piston sides. This actuates
the pump from neutral position to one of the two possible maximum displacement positions.
When changing the swashing angle through the neutral position to the opposite side, the flow direction
of the oil and the sense of rotation of the vibration motors will change.
Since the engine speed is variable in "Position AUTO", the pump displacement must always be
proportionately adapted in order to maintain the vibration frequency at a constant level.
The vibration motor output shaft is joined with the exciter shaft in the drum via a Bowex coupling. The
rotation of the exciter shaft with the bolted on eccentric weights causes the vibration of the elastically
suspended drums.
The eccentric weights on the vibrator shaft are fitted with additional change-over weights.
Depending on the sense of rotation of the vibrator shaft these change-over weights add to or subtract
from the basic weights.
The displacement of the pump may be different to both flow directions. This results in different exciter
shaft speeds for the different senses of rotation of the motor.
The vibration system is designed in such a way, that the high exciter shaft speed (frequency) is coupled
with the low amplitude and the low exciter shaft speed (frequency) with the high amplitude.
Vibration pump
The vibration pump is a swash-plate controlled axial piston pump with variable displacement of type 90
R 075 EP from Sauer-Danfoss. The pump is fitted with all control and safety elements needed for
operation in a closed hydraulic circuit.
5 4
2 6 3
1 2
5 4 3
1 Servo piston
2 Working pistons
3 Charge pump
4 Valve plate
5 Roller bearing
6 Swash plate
1
2
5
4 3
1 Control
2 Servo piston
4 Attachment plate
5 Spool valve
The engine drives the drive shaft with the cylinder block. The cylinder block carries the working pistons.
The slipper pads rest against the sliding surface of the swash plate and are at the same time held on
the sliding surface by a retaining device.
During each rotation the piston pass through their upper and lower dead centre back to their initial
position. Between both dead centres each piston performs a full working stroke. During this stroke
movement oil is drawn in from the low pressure side of the closed circuit and pressed out through the
slots in the valve plate into the high pressure side. The oil quantity depends on the piston area and the
length of the working stroke.
During the suction stroke the oil is drawn into the piston chamber, i.e. the charge pressure forces it into
the piston chamber. On the opposite side the piston presses the oil out into the high pressure side of he
closed circuit.
Control
The electro-hydraulic displacement control converts the electric proportional input signal into a load
controlling output signal.
The vibration pump has an integrated charge pump, an internal gear pump with a displacement of 17
cm³ per revolution
The vibration pump is equipped with an integrated charge pressure relief valve, which is set to a
pressure of 40 bar. This valve only has a safety function in the charge circuit.
As a measure to protect the closed vibration circuit against to high pressures the vibration pump is fitted
with pressure relief valves.
2 Closed circuit
Since the heavy mass of the vibrator shaft must be set into motion during the acceleration of the
vibration, very high pressure peaks will occur in the high pressure side of the closed circuit during this
phase. The high pressure relief valve reduces these pressure peaks to a value of max. 426 bar
(pressure difference between high and low pressure side = 400 bar + charge pressure = 26 bar).
The screw-type cartridges of the high pressure relief valves contain also the boost check valves for the
closed vibration circuit.
The vibration motor is a Bosch-Rexroth axial piston motor of series A2FM 56 with fixed displacement in
bent axle design. Since the motor can be subjected to pressure from both sides, it is most suitable for
the use in closed hydraulic circuits.
A MA
3 1
B MB
1 Vibration motor
2 Flushing valve
The vibration motor is equipped with an integrated flushing valve. This flushing valve is located inside
the bolted on connecting block. When switching the vibration on a pressure difference will appear
between the two sides of the closed circuit. The higher pressure moves the valve spool of the flushing
valve against the neutral setting spring, so that oil can flow out of the low pressure side.
1
A
Flushing valve
1 Flushing spool
The flushing valve is fitted with a downstream 16 bar pressure relief valve. This valve ensures that only
a certain quantity of hydraulic oil is flushed out of the low pressure side.
This oil flows via a thermostat valve back to the hydraulic tank. The flushed out oil is immediately
replaced with fresh and filtered oil through the corresponding boost check valve.
The fixed displacement vibration motor A2FM56 is equipped with a Bosch-Rexroth speed sensor
HDD1L16 or HDD2L16 with an installation depth of 16 mm, which uses the Hall-effect.
4
14
5 9
7 13
6
10
3 8 11
12
Vibration pump
7 8
6 6 72
1
8
6 5
7
5 1
5 4
3 4 1
2
3
4 2 3
Pos. Designation Pos. in wiring diagram Pos. in hydraulic Measuring values
diagram
1 Pressure test port, vibration 11 - B - ME Starting pressure
pressure low amplitude 330 -400 bar
2 Pressure test port, vibration 11 - A - MF Starting pressure
pressure high amplitude 330 -400 bar
3 High pressure port low amplitude 11 - B max. 426 bar
4 High pressure port high amplitude 11 - A max. 426 bar
5 Multi-function valve with high 11 - B
pressure limitation low amplitude
6 Multi-function valve with high 11 - A
pressure limitation high amplitude
7 Solenoid valve, low amplitude Y07 / X 8 11 - B 12V / 0,4 - 1,2A
8 Solenoid valve, high amplitude Y07 / X 7 11 - A 12V / 0,4 - 1,2A
5 3
1
1 2
2
4
3
2 31
For a detailed description of how to read out fault codes and the display
please refer to the page on "Electrics" (Service Training Electrics)
The following trouble shooting chart contains a small selection of possible faults, which may occur
during operation of the machine. The fault list is by no means complete, however, the fault table is based
on the experience of the central service department, i.e. the list covers almost all faults that have
occurred in the past.
The following trouble shooting table contains both electrical as well as mechanical and hydraulic faults.
The number specified in the table indicate the probability of the fault cause and thereby the
recommended trouble shooting sequence, based on our latest field experience.
SYMPTOME
MÖGLICHE URSACHEN
Vibrationschalter (Amplitudenvorwahl) 1 1
Fahrhebel, Taster Vibration (an/aus), Verkabelung 1
Elektrik defekt / Verkabelung 2 2
Pumpenansteuerung (elektrisch / hydraulisch) 1 1
Druckabschneidung/ Hochdruckbegrenzung Vibrationspumpe
2
verschmutzt/verstellt/defekt
Speisepumpe / Speisedruckbegrenzungsventil
2
verschmutzt/defekt
Frequenzeinstellung Vibrationspumpe 2
Vibrationspumpe defekt 2 2
Kupplung zwischen Dieselmotor und Fahrpumpe defekt
Erregerwellenlager defekt 3
Vibrationsmotorkupplung defekt 2
Vibrationsmotor defekt 2 1
Dieselmotor 1 1 1
Drehzahlsensor (Verkabelung) 1 1 1
Spülventil Vibmotor hängt 2
FEHLERSUCHE
The steering system mainly consists of steering pump, steering valve, steering cylinders and pressure
resistant connecting hoses.
to charge
system
1
7
6
5
3
2
4
1 Rating pump
2 Distributor valve
3 Steering pressure relief valve (∆p =175 bar)
4 Check valve (pre-loaded to 0.5 bar)
5 Anti-cavitation valve
6 Shock valves (240 bar)
7 Steering cylinders
The steering pump draws the hydraulic oil out of the hydraulic oil tank and delivers it to the steering valve
and the connected steering unit under the operator's platform of the machine. If the steering is not
operated, the complete oil supply will flow through the fine filter to the charge system for the closed travel
circuits.
When turning the steering wheel the distributor valve guides the oil flow to the piston or piston rod side
of the steering cylinder. A rating pump inside the steering unit measures the exact oil quantity
corresponding with the turning angle of the steering wheel and delivers the oil to the steering cylinders.
The steering cylinders retract or extend and steer the machine.
The steering unit is equipped with a pressure relief valve. This valve limits the steering pressure to 175
bar. The charge pressure must, however, be added to this value, because the oil leaving the steering
system enters the charge circuit. The actual steering pressure is therefore approx. 200 bar.
The charge pump for travel circuit and vibration works also as steering pump The pump is an external
gear pump with fixed displacement.
The oil flow generated by the charge pump is joined together with the return flow from the steering valve
before the hydraulic oil filter and flows through the filter to the charge ports on travel pump and vibration
pump.
The steering pump is a gear pump with fixed displacement. It is driven by the auxiliary drive of the diesel
engine, draws the hydraulic oil out of the hydraulic oil tank and pumps it through the steering valve to
the steering cylinders or to the boost check valves for travel and vibration circuits.
9 9 6 1 7
8
2
4 5
1 Housing
2 Flange
3 Shaft
4 Bearing plate
5 Bearing plate
6 Cover
7 Gear (driving)
8 Gear (driven)
9 Seals
The drive gear of the steering pump is connected with the auxiliary drive of the diesel engine via a
coupling. Drive gear and driven gear are positioned by a bearing plate in such a way, that the teeth of
both gears mesh with minimum clearance when rotating.
The displacement chambers are created between the tooth flanks, the inside wall of the housing and
the faces of the bearing plates.
When the pump is running the chambers transport hydraulic oil from the suction side to the pressure
side. This causes a vacuum in the suction line by which the hydraulic oil is drawn out of the tank. The
tooth chambers transport the fluid to the outlet of the pump from where it is pressed to the consumers.
To ensure a safe function of the pump the tooth chambers must be so tightly sealed that the hydraulic
fluid can be transported from the suction side to the pressure side without any losses.
For this purpose external gear pumps are fitted with gap seals. This causes pressure dependent fluid
losses from the pressure side to the suction side. As a measure to ensure that these losses are reduced
to a minimum, the bearing plate on the cover side is pressed against the faces of the gears by an axial
pressure field.
The steering valve block consists mainly of distributor valve, measuring pump, pressure relief valve and
shock valves.
9 2
5
8
240 bar
∆p = 175 bar
240 bar
0,5 bar
The high pressure relief valve in the steering unit limits the pressure in the steering system to 175 bar.
The charge pressure value must be added to this pressure, because the oil leaving the steering system
is fed into the charge circuit for the closed travel circuits.
The steering unit is fitted with so-called shock valves in each supply line to the steering cylinder. These
valves are adjusted to an opening pressure of 240 bar. The valves compensate extreme pressure peaks
which may occur, e.g. when driving over obstructions, and protect the system against overloads.
Each of these shock valves is fitted with an additional anti-cavitation valve. If the shock valves respond
these anti-cavitation valves protect the system against cavitation damage.
A check valve at the inlet of the steering unit makes sure that no oil will flow back to the pump in case
of pressure peaks caused by sudden steering movements. In such a case the steering cylinders would
act as pumps and press the oil back to the pump.
Front and rear frames of the single drum rollers BW 177 D-4 are connected by an oscillating articulated
joint. This ensures that drum and wheels are at all times in contact with the ground, even when driving
extreme curves.
The front console is fastened with screws to the rear cross-member of the front frame. The use of rocker
bearings between front and rear frame ensures that both frames can oscillate to each other for +/- 12°.
This gives drum and wheels excellent ground contact, even under extremely severe conditions.
The front console is connected with the rear console by two vertical bolts. The vertical bolts are mounted
in friction bearings.
When turning the steering wheel the steering cylinder will extend or retract. The piston rod swivels the
front console around the vertical bolts. This articulates the machine and results in a steering movement.
All bearings on the articulated joint are maintenance free and do not require any lubrication.
Notes on assembly:
When assembling or repairing the articulated joint the correct pretension of the centre pin is of highest
importance.
Please follow the instructions in the repair manual for the articulated joint.
3 4
1
2
2
Steering pump
The damper is located in the steering/charge circuit directly after the steering and charge pump.
It is subjected to hydraulic oil flow and has the function of eliminating any vibrations and noises.
The damper is mounted to the front plate of the rear frame, between both steering cylinders.
For a detailed description of how to read out fault codes and the display
please refer to the page on "Electrics" (Service Training Electrics)
The following trouble shooting chart contains a small selection of possible faults, which may occur
during operation of the machine. The fault list is by no means complete, however, the fault table is based
on the experience of the central service department, i.e. the list covers almost all faults that have
occurred in the past.
The following trouble shooting table contains both electrical as well as mechanical and hydraulic faults.
The number specified in the table indicate the probability of the fault cause and thereby the
recommended trouble shooting sequence, based on our latest field experience.
FEHLERSUCHE LENKUNG
BW 213/214 DH/PDH-4
Endanschläge werden nicht erreicht
Lenkung schwergängig
Keine Lenkfunktion
SYMPTOME
MÖGLICHE URSACHEN
Lenkorbitrol 2 2 1
Lenk- Speisepumpe 1 1 2
Lenkzylinder 3 3 3
Knickgelenk 3 3 2
Version 2.0
Table of contents
1 Confirmation of changes
Preheating of engine
Brake
ASC
Various error causes and reaction times.
See error codes
Hydraulic oil filter
5502 5503
after 5s after 2min.
Water separator in fuel filter
5028 5029
after 5s after 2min.
Ant-theft warning display
(Option)
Seat contact
(Option)
1) 3)
After reaching the warning limit! Shut-down currently deactivated via parameter
2)
After reaching the shut-down limit!
Known faults
Despite the fault monitoring of inputs and outputs on the ESX control, the ESX control is not able to
detect all faults. The following list contains a selection of known fault reactions of the control, which
mostly have a different cause to the one described in this documentation.
Effect: Cause:
Display remains dark, no voltage applied PIN in display plug connector X 28 bent
Error code 5100, 5140 and engine does not Shut down the machine, switch the ignition back
respond to full speed switch or travel lever on and start immediately.
After switching on the display shows "Error Code Code 8224 is no error code, but a software fault of
8224" the display software, which has been rectified from
display firmware version 1.36
Currently available 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 indicated by a "minus sign".
The following text describes the operation of the LC-display via the travel lever buttons.
Change
Wertevalue
ändern Navigieren
(green)
(grün) (blau)
INFO
INFO11Taste
button
(gelb)
(yellow)
INFO 2 Taste
Change
Werte value
ändern
(gelb)
(green)
(grün)
Navigieren
Navigate
(blau)
(blue)
The travel lever must be in locked braking position in order to activate input mode! Input mode
is switched on by simultaneously pressing both INFO – buttons over a period of approx. 3 seconds.
„Input“ - Modus:
Changeover display function
Display setting
Press INFO 1 +
INFO 2 approx. 3s
Plate adjustment deactivated!
Press INFO 1 +
INFO 2 approx. 3s Input
or shift travel Access code
lever out of 9999
brake gate
„Service“- Modus:
CODE – input „0000" or Input diagnostic codes
Ignition off
Calling up / deleting the error log
Change machine type
Plate adjustment deactivated!
For simple checking the currently adjusted machine type is displayed for approx. 3 seconds on the
display module when switching the ignition on. It can also be checked by entering code 0720.
0 1 2 3 4 5 6 7 8 9
72XX
0 Default BW 177 BW 177 BW 179 BW 179 BW 213/ BW 213 BW 213 BW 213 BW 216 DH
DH-4 PDH-4 DH-4 PDH-4 BW 214 BW 214 DH-4 PDH-4 DH-4
(Planier- DH-4 PDH-4 USA USA
schild)
1 BW 216 BW 219 BW 219 BW 226 BW 226 BW 226 BW 226 DH
PDH-4 DH-4 PDH-4 DH-4 PDH-4 DH-4 PDH-4
147kW 147kW 174kW 174kW
2 DH
3 DH
4 DH
7 BVC
8 BVC
9 BVC
Note: Parameter adjustments can only be performed when the engine is not running.
Note: This function can only be activated / deactivated when the travel lever is locked
! Input mode)
in the brake gate. (!
The following procedure must be used for initial start-up of a control:
• After a period of approx. 7 seconds the adjusted machine code, e.g. 7 2 1 2 is displayed for
approx. 3 seconds. The new parameters are loaded according to the machine type setting. Do not
switch the ignition off during this time!
• After this switch the ignition off and on again to accept the configuration.
• After this the normal display will appear again.
The following applies for a correction of the machine type code after it has been set.
• Select the machine code from the table above and confirm it with the Arrow Right key. After
operating the Arrow Right key the control switches automatically off and on again.
• After a period of approx. 7 seconds the adjusted machine code, e.g. 7 2 1 2 is displayed for
approx. 3 seconds. The new parameters are loaded according to the machine type setting. Do not
switch the ignition off during this time!
• After this switch the ignition off and on again to accept the configuration.
• After this the normal display will appear again.
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 enable to drive or steer the machine. It only 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 hydraulic
steering option is selected, the electric steering must be deactivated as follows.
Attention: The steering unit can only be changed when the engine is not running!
For a sensitive and exact function of the travel system the surge currents in the travel system must be
determined for both travel directions. The surge currents are automatically determined after entering a
code number, so that no electric meter is required.
The surge currents must only be determined during initial commissioning in the factory, after a service
during which the control on a steering valve or the complete steering valve has been replaced and after
the replacement of the ESX-control.
The measurement is identical for both travel directions: After entering the respective code number the
current is increased by the control solenoid 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! First set the machine to input mode (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 speed selection switch must be in position ECO.
• If necessary enter code number 9 9 9 9 to access the service mode.
• Then enter 1 0 9 0 . This code number activates the function "Automatic detection of surge currents
in the travel system"; the display now shows the reading 0 0 0 0 with the first digit flashing. This
code number must be entered to be able to perform the following steps. From this point the
machine can no longer be operated with the travel lever! The travel lever will only be in
function again after the teach function has been completed or the machine has been
restarted.
• The measurements (forward/reverse) must be started by entering a code number. The code
number required to teach the travel direction is as follows:
• After the input of the above code number the display shows " F O R E ". Shifting the travel lever
forward starts the first surge current measurement for forward travel.
• During the measurement the actual current is displayed (display value = current in mA).
• Once the surge current measurement is finished the display will show the reading O K for a period
of 5 seconds.
• After this wait time the display reading changes to " B A C K ". Now shift the travel lever backward
to start the surge current measurement in reverse.
• During the measurement the actual current is displayed (display value = current in mA).
• After completion of the measuring process in reverse the display will show O K again.
• The travel lever must now be returned to braking position.
• Once both surge currents have been learned correctly and the travel lever is in "braking position",
the display shows the reading "D O N E", the values are saved and the function is completed. Now
the machine can be operated again with the travel lever. The new surge current values for the travel
system are valid from the next start.
• The teach function can at any time be aborted by operation of the emergency stop or the ignition
switch.
The following procedure applies for software versions 1.07 and 1.08:
The automatic measurement of the travel system surge currents is performed as follows:
• The seat must be adjusted for travel direction forward!
• The speed selection switch must be in position ECO.
• If necessary enter code number 9 9 9 9 to access the service mode.
• Then enter 1 0 9 0 . This code number activates the function "Automatic detection of surge currents
in the travel system"; the display now shows the reading 0 0 0 0 with the first digit flashing. This
code number must be entered to be able to perform the following steps. From this point the
machine can no longer be operated with the travel lever! The travel lever will only be in
function again after the teach function has been completed or the machine has been
restarted.
• Both measurements (forward/reverse) must be started by entering a code number. The code
numbers for both travel directions are:
• After entering one of the above code numbers the measurement will only start after moving the
travel lever to the respective travel direction. ATTENTION: The ASC fault
indicator light will come on during the teach process. In this case this is of no relevance. The
warning will disappear when restarting the machine.
• During the measurement the actual current is displayed (display value = current in mA).
• Teaching is required for both travel directions.
• When returning the travel lever to neutral position after the two measurements, the display will show
O K for 3 seconds and the averaged values will be saved.
• Once both surge currents have been measured the machine can be operated again with the travel
lever. The new surge current values for the travel system are valid from the next start.
• The teach function can at any time be aborted by operation of the emergency stop or the ignition
switch.
3.7 Teaching the electronic end stops of the steering angle sensor (BVC)
Attention: Does not apply for BVC machines with "hydraulic steering" option!
Note: During the measurement the machine should be parked on level ground.
The drum should be standing on old rubber tires or a metal plate.
Specify the engine speed -> travel lever out of braking position = neutral position
(Not while entering a code).
To prevent the steering from moving all the way to the mechanical stops of the steering cylinder it is
necessary to determine a defined safety distance to these end stops.
START
Machine on level
ground
Machine on level
ground
9999 enter
2010 enter
Travel lever in
neutral position
Travel lever in
brake position
Travel lever in
brake position
Switch ignition of
and on again OR 2011 enter
FINISHED
Attention: Does not apply for BVC machines with "hydraulic steering" option!
Note: Execute this function only AFTER "Teaching electronic end stops of angle sensor".
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 measurement is identical for both solenoids:
The automatic measurement of the steering valve surge currents is performed as follows:
• The engine must be operated in ECO-mode!
• Enter code number 9 9 9 9 to access the 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
steering valve surge currents"; the display now shows the reading 0 0 0 0 with the first digit
flashing.
• Now code number 2 0 0 1 must be entered.
• After entering one 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 valve current is displayed (display value in mA).
• Attention! During the measurement the drum cannot be steered ! 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 with the first digit flashing, the next measurement can be started.
• The new surge current values are valid from the next start.
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 code number 0 5 0 1 the function is aborted and OK is displayed
as confirmation for 5 seconds. After this the code needs to be entered again.
Note: This function can only be activated / deactivated when the travel lever is locked
! Input mode)
in the brake gate. (!
The faults stored in the ESX are displayed in flashing mode. If several faults are stored, these are
successively displayed in cycles of 3 second. After the last fault has been displayed, the first fault will
appear again. If no faults are stored in the ESX, the display will show "- - - - - "
Note: Apart from the stored faults the current faults are also displayed.
Note: This function can only be activated / deactivated when the travel lever is locked
in the brake gate. (! Input mode)
Note: The stored faults can only be deleted when the engine is not running.
Note: This function can only be activated / deactivated when the travel lever is locked
! Input mode)
in the brake gate. (!
Attention: Before performing one of the following steps you must first set the corresponding
machine type (see chapt. 3.3)!
When changing the machine type all previously made adjustments will be lost!
• From DH
• Automatic detection of surge currents in the travel system (see chapt. 3.6)
• On BVC
• Automatic detection of steering valve surge currents (see chapt. 3.7)
• Teaching the electronic end stops of the steering angle sensor (see chapt. 3.8)
4.2 Replacement of a travel pump / axle drive motor / drum drive motor
• Automatic detection of travel system surge currents (see chapt. 3.6)
•
9 Description of signals on the DIOS module (only with optional attachment plates)
10.1 Overview
Fault code Fault description
0000 - General faults / warnings / machine tests
0999
1000 - Fault in travel system
1999
2000 - Fault in steering system
2499
2500 - Fault in remote control
2999
3000 - Faults in work functions (vibration, attachment plates, rotor, chip
4499 spreader)
4500 - Fault in measuring systems
4999
5000 - Fault diesel engine
5499
5500 - Fault hydraulic system
5999
6000 - Fault anti-theft warning system, localization system, access
6999 system, time account, etc.
7000 - Input of machine codes
7499
7500 - Input of codes for measuring technology
7899
7900 - Operating hours, load spectrum, etc.
7999
1
8000 - Severe software error
8999
9000 - Errors of external IO-nodes (joystick, data collector, Dios module,
1
9999 LC-display, etc.)
1
These faults are not broken down hereunder!
2 Warning.
Fault code is displayed.
Audible signal
4 Partial function faulty, the partial function cannot be overridden by an emergency function.
The machine is stopped if this fault occurs.
The machine can still be driven to a limited extent, but must be repaired by the service department as soon as possible.
Fault code is displayed.
Audible signal
5 Partial function faulty, the partial function cannot be overridden by an emergency function.
The machine is no longer able to drive, e.g. because parts of the travel system are defective " the diesel engine is shut
down.
Fault code is displayed.
Audible signal
Note: Errors with error reaction 1 and 2 are only warning messages and are NOT stored in the error log.
10.3.1 General
Fault Fault description Possible causes Terminal Assignment Input code Fault
Code DH-4 BVC-4 for reaction
diagnose
500 Driving against brake – warning A corresponding input code has been entered X X
The function "Driving against brake" is activated
502 Simulated engine run - warning A corresponding input code has been entered X X
The function "Simulated engine run" is activated
504 Ant- Slip Control (ASC) deactivated - warning A corresponding input code has been entered X X
The function "Anti Slip Control (ASC)" is deactivated
507 Drum drive deactivated - warning A corresponding input code has been entered X X
Test mode "Drum drive deactivated" was activated.
508 Axle drive deactivated - warning A corresponding input code has been entered X X
Test mode "Axle drive deactivated" was activated.
560 Overvoltage 8,5V Connection of voltage level to operating voltage, another voltage X35:23 X X
The voltage level of the 8,5V range is impermissibly potential or control defective
exceeded
(see signal description)
561 Undervoltage 8,5V Connection of voltage level to ground, another voltage potential X35:23 X X
The voltage level of the 8,5V range is impermissibly fallen or control defective
short of
(see signal description)
562 Error "Voltage Override Relay" X X
The voltage level of the 8,5V range is...
10.3.2 Brake
Fault Fault description Possible causes Terminal Assignment Input code Fault
Code DH-4 BVC-4 for reaction
diagnose
1001 Brake valve line breakage The connecting line between control output and control solenoid X35:61 X X
The required control power cannot be transmitted to the is interrupted, or
control solenoid. The proportional solenoid is defective
1002 Brake valve Cable breakage in ground line, or X35:61 X X
Signal outside the valid range (see signal description) Connecting cable between valve and ground connection has
come loose
1003 Brake valve Cable breakage in connecting line, or X35:61 X X
Signal outside the valid range (see signal description) Connecting cable between valve and supply has come loose
1004 BTS brake / travel lever (BTS=output driver) Hardware defect on travel lever X35:17 X X
Overheating of the BTS has the effect, that the braking
position of the travel lever is not correctly recognized
1005 BTS brake / plausibility (BTS=output driver) Hardware defect on travel lever, input X35:17 has not the same X35:17 X X
Plausibility conflict in evaluation of travel lever X- and y- voltage as the BTS
axes to the brake contact signal
1028 Travel lever direction evaluation X-axis Internal fault in travel lever -> Replace travel lever. X X
The direction of travel lever movement could not be
determined
1029 Travel lever difference error X-axis Internal fault in travel lever -> Replace travel lever. X X
Error in redundant evaluation of travel lever signal
1030 Travel lever software error X-axis Internal fault in travel lever -> Replace travel lever. X X
Software does not work fault free
Fault Fault description Possible causes Terminal Assignment Input code Fault
Code DH-4 BVC-4 for reaction
diagnose
Fault Fault description Possible causes Terminal Assignment Input code Fault
Code DH-4 BVC-4 for reaction
diagnose
1031 Travel lever sum error Y-axis Internal fault in travel lever -> Replace travel lever. X X
Error in redundant evaluation of axis
1032 Travel lever line break Y-axis Cable breakage in travel lever -> Replace travel lever. X X
Signal outside the valid range (see signal description)
1033 Travel lever EEP alarm Y-axis Internal fault in travel lever -> Replace travel lever. X X
1034 Travel lever direction evaluation Y-axis Internal fault in travel lever -> Replace travel lever. X X
The direction of travel lever movement could not be
determined
1035 Travel lever difference error Y-axis Internal fault in travel lever -> Replace travel lever. X X
Error in redundant evaluation of travel lever signal
1036 Travel lever software error Y-axis Internal fault in travel lever -> Replace travel lever. X X
Software does not work fault free
1080 Output travel pumps reverse The connecting line from the output of the control to the X35:64 X X
The required control power cannot be transmitted to the proportional solenoid is interrupted or the proportional solenoid
proportional solenoid. is defective
1081 Fault of current regulator reverse Faults in valve control Check wiring. X X
1082 Fault of current regulator reverse Faults in valve control Check wiring. X X
1083 Output travel pumps reverse Short circuit of connecting line (control to proportional valve) to X35:64 X X
Supply voltage UB applied to the output to the proportional voltage supply
valve.
1084 Error in teaching the surge current reverse Machine mechanically blocked X35:64
Travel system bypass valves out of adjustment
1088 Note! Surge currents for travel pump have NOT been The function "Teaching pump surge currents" for the travel X X Note
learned. See 3.6 pump has not yet been executed.
-> New machine/replacement of control
1100 Output front travel motor The connecting line from the output of the control to the X35:46 X X
The required control power cannot be transmitted to the proportional solenoid is interrupted or the proportional
proportional solenoid. solenoid is defective
1105 Speed sensor pulses front travel motor Check connecting lines and plugs on wheel speed sensor, if X35:34 X X
Incorrect or non-existent signal "Frequency" necessary replace the wheel speed sensor
1106 Direction signal pulses front travel motor Check connecting lines and plugs on wheel speed sensor, if X35:37 X X
Incorrect or non-existent signal "Direction" necessary replace the wheel speed sensor
1107 Output front travel motor Short circuit of connecting line (control to proportional valve) to X35:46 X X
Supply voltage UB applied to the output to the proportional voltage supply
valve.
1110 Output rear travel motor The connecting line from the output of the control to the X35:47 X X
The required control power cannot be transmitted to the proportional solenoid is interrupted or the proportional solenoid
proportional solenoid. is defective
1115 Speed sensor pulses rear travel motor Check connecting lines and plugs on wheel speed sensor, if X35:12 X X
Incorrect or non-existent signal "Frequency" necessary replace the wheel speed sensor
1116 Speed sensor direction signal rear travel motor Check connecting lines and plugs on wheel speed sensor, if X35:38 X X
Incorrect or non-existent signal "Direction" necessary replace the wheel speed sensor
1117 Output rear travel motor Short circuit of connecting line (control to proportional valve) to X35:47 X X
Supply voltage UB applied to the output to the proportional voltage supply
valve.
1140 Travel system pressure sensor "Signal" The connecting line between control output and pressure sensor X35:31 X X
The current signal is not transmitted (see signal is interrupted, or
specification The pressure sensor is defective
1141 Travel system pressure sensor "Signal range" The pressure sensor is defective X35:31 X X
The current signal is outside the valid range (see signal
specification)
1142 Travel system pressure sensor "no pressure" No pressure connection on sensor or supply line clogged, or X35:31 X X
The electric signal indicates that the travel pressure is No travel pressure built up
permanently missing.
1145 Inclination sensor "Supply connection" Cable breakage in connecting line, or X35:?? X X
Signal outside the valid range (see signal description) connecting cable between sensor and power supply has come ..
loose X35:30
1146 Inclination sensor "Ground connection" Cable breakage in ground line, or X35:1 X X
Signal outside the valid range (see signal description) Connecting cable between sensor and ground connection has
come loose
1300 Seat connect not occupied Cable breakage in signal line, or X35:15 X X
driver's seat not occupied (driver not seated!)
1500 Warning "Dangerous condition ASC" Due to counter-rotating drive units the machine was stopped X X
and the brake applied.
After setting the travel lever to brake position the brake can be
released.
10.3.6 Steering
(Only machine with electric steering)
Fault Fault description Possible causes Terminal Assignment Input code Fault
Code DH-4 BVC-4 for reaction
diagnose
2060 Output steering valve right The connecting line between control output and proportional X35:20 X
The required control power cannot be transmitted to the solenoid is interrupted, or
proportional solenoid. The proportional solenoid is defective
2061 Output steering valve left The connecting line between control output and proportional X35:21 X
The required control power cannot be transmitted to the solenoid is interrupted, or
proportional solenoid. The proportional solenoid is defective
2065 Error when teaching the surge current for the right Drum was not moved, maximum current was reached, steering X35:20
hand valve is blocked (e.g. articulation lock applied)
2066 Error when teaching the surge current for the left Drum was not moved, maximum current was reached, steering X35:21
hand valve is blocked (e.g. articulation lock applied)
2068 Note! Surge currents for steering pump have NOT been The function "Teaching pump surge currents" for the steering (X) Note
learned. See 3.7 pump has not yet been executed.
(Only machine with electric steering) -> New machine/replacement of control
2170 Steering valve (arm rest) "direction change" Wiring fault or steering sensor in left hand arm rest defective X35:18 X
X35:19
X35:40
X35:41
2171 Steering valve (arm rest) "Pulse coverage" Steering sensor in left hand arm rest defective. X35:18 X
High difference in measuring values between sensor 1 X35:19
and 2 X35:40
X35:41
2172 Steering wheel (arm rest) "Sensor 1 pulse range" Check connecting line to steering sensor 1 or X35:18 X
The detected steering pulses on steering sensor 1 are replace the steering sensor in the left hand arm rest, if X35:19
outside the valid range necessary
(see signal description)
2173 Steering wheel (arm rest) "Sensor 2 pulse range" Check the connecting lines to steering sensor 2, or replace the X35:40 X
The detected steering pulses on steering sensor 2 are steering sensor in the left hand arm rest, if required. X35:41
outside the valid range
(see signal description)
2174 Steering wheel A45 (arm rest) "Sensor 1" Steering sensor in left hand arm rest defective. X35:18 X
X35:19
2175 Steering wheel A45 (arm rest) "Sensor 2" Steering sensor in left hand arm rest defective. X35:40 X
X35:41
2176 Steering wheel A45 (arm rest) "Sensor 1 cable Check the connecting lines to steering sensor 1, or replace the X35:18 X
breakage" steering sensor in the left hand arm rest, if required. X35:19
2177 Steering wheel A45 (arm rest) "Sensor 2 cable Check the connecting lines to steering sensor 2, or replace the X35:40 X
Fault Fault description Possible causes Terminal Assignment Input code Fault
Code DH-4 BVC-4 for reaction
diagnose
breakage" steering sensor in the left hand arm rest, if required. X35:41
10.3.8 Vibration
Fault Fault description Possible causes Terminal Assignment Input code Fault
Code DH-4 BVC-4 for reaction
diagnose
3000 Vibration sensor "No signal" Check connecting lines and plugs to the vibration sensor, or X35:35 X X
The sensor in the vibration motor does not pick up any replace the sensor in the vibration motor, if necessary.
pulses.
3001 Valve vibration pump (low amplitude on DH) Details in 3004 – 3008 X35:48 X X
General fault.
3002 Valve vibration pump (low amplitude on DH) System fault! Replace the control X35:48 X X
Internal system fault.
3003 Valve vibration pump (low amplitude on DH) Faults in control line, or X35:48 X X
"Current range" Connection to another potential (e.g. operating voltage)
The control current is outside the valid range (see signal
specification)
3004 Valve vibration pump (low amplitude on DH) The connecting line between control output and proportional X35:48 X X
Line interruption solenoid is interrupted, or
The proportional solenoid is defective or the changeover relay /
bridge is missing
3005 Valve vibration pump (low amplitude on DH) System fault! Replace the control X35:48 X X
Internal system fault.
3006 Valve vibration pump (low amplitude on DH) Faults in connecting line, incorrect valve coil, or X35:48 X X
"Control fault regulating up" Connection to another potential (e.g. operating voltage)
The control current is outside the valid range (see signal
specification)
3007 Valve vibration pump (low amplitude on DH) Faults in connecting line, incorrect valve coil, or X35:48 X X
"Control fault regulating down" Connection to another potential (e.g. operating voltage)
The control current is outside the valid range (see signal
specification)
3008 Valve vibration pump (low amplitude on DH) System fault! Replace the control X35:48 X X
Internal system fault.
3009 Vibration adaptation control (low amplitude on DH) Wear or damage in vibration system hydraulic circuit. X35:48 X X
"Frequency adaptation"
Limits of adaptation range exceeded
(see signal specification)
3011 Valve vibration pump (high amplitude on DH) Details in 3014 – 3018 X35:48 X
General fault.
3012 Valve vibration pump (high amplitude on DH) System fault! Replace the control X35:48 X
Internal system fault.
3013 Valve vibration pump (high amplitude on DH) Faults in control line, or X35:48 X
"Current range" Connection to another potential (e.g. operating voltage)
The control current is outside the valid range (see signal
specification)
3014 Valve vibration pump "Cable breakage" The connecting line between control output and proportional X35:48 X
(high amplitude only DH) solenoid is interrupted, or
Line interruption The proportional solenoid is defective
changeover relay / bridge missing
3015 Valve vibration pump (high amplitude on DH) System fault! Replace the control X35:48 X
Internal system fault.
3016 Valve vibration pump (high amplitude on DH) Faults in connecting line, incorrect valve coil, or X35:48 X
"Control fault regulating up" Connection to another potential (e.g. operating voltage)
The control current is outside the valid range (see signal
specification)
3017 Valve vibration pump (high amplitude on DH) Faults in connecting line, incorrect valve coil, or X35:48 X
"Control fault regulating down" Connection to another potential (e.g. operating voltage)
The control current is outside the valid range (see signal
specification)
3018 Valve vibration pump (high amplitude on DH) System fault! Replace the control X35:48 X
Internal system fault.
3019 Vibration adaptation control (high amplitude on DH) Wear or damage in vibration system hydraulic circuit. X35:48 X
"Frequency adaptation"
Limits of adaptation range exceeded
(see signal specification)
3060 Warning ! Attachment plate lowered and backward The attachment plates are lowered and an attempt is made to X
travel drive backwards
5110 Diesel engine EMR "Nominal speed value" " CAN connection between ESX and EMR interrupted X X
" CAN connection has short circuit against ground, against
+12 V or connection between CAN+ and CAN-.
" ESX without voltage supply
" Battery charge level too low
5111 Diesel engine EMR "Engine oil filling level" " Engine oil filling level too low X X
5112 Diesel engine EMR "Oil pressure" " Engine oil pressure too low X31:21 X X
5113 Diesel engine EMR "Charge air pressure" " Charge air pressure too low X31:24 X X
5114 Diesel motor EMR "Temperaturein intake line" " Charge air temperature too high X31:4 X X
5116 Diesel engine EMR "Coolant temperature" " Coolant temperature too high X31:9 X X
5117 Diesel engine EMR "Fuel temperature" " Fuel temperature too high X X
5118 Diesel engine EMR "Engine speed" " Speed sensor 1 or 2 defective X31:13 X X
" Connection between EMR and speed sensor 1 or 2 X31:11
interrupted
5120 Diesel engine EMR "CAN communication" " CAN connection between ESX and EMR interrupted
" CAN connection has short circuit against ground, against
Fault Fault description Possible causes Terminal Assignment Input code Fault
Code DH-4 BVC-4 for reaction
diagnose
+12 V or connection between CAN+ and CAN-.
" ESX without voltage supply
" Battery charge level too low
5121 Diesel engine EMR "CAN communication" " CAN connection between ESX and EMR interrupted
" CAN connection has short circuit against ground, against
+12 V or connection between CAN+ and CAN-.
" ESX without voltage supply
" Battery charge level too low
" Ground to EMR control unit not or incorrectly connected.
5122 Diesel engine EMR "Nominal speed value" " CAN connection between ESX and EMR interrupted
" CAN connection has short circuit against ground, against
+12 V or connection between CAN+ and CAN-.
" ESX without voltage supply
" Battery charge level too low
5123 Diesel engine EMR CAN communication " CAN communication between EMR and ESX X31:12 X X
X31:13
5124 Diesel engine EMR CAN communication " CAN communication between EMR and ESX X31:12 X X
X31:13
5125 Diesel engine EMR CAN communication " CAN communication between EMR and ESX X31:12 X X
X31:13
5126 Diesel engine EMR CAN communication " CAN communication between EMR and ESX X31:12 X X
X31:13
5130 Diesel engine EMR "Oil pressure sensor" " Sensor defective X31:22 X X
" Wire breakage in current path X31:20
" Current path has short circuit to ground
5131 Diesel engine EMR "Charge air pressure sensor" " Sensor defective X31:25 X X
" Wire breakage in current path X31:23
" Current path has short circuit to ground
5132 Diesel engine EMR "Charge air temperature" " Sensor defective X31:25 X X
" Wire breakage in current path X31:23
" Current path has short circuit to ground
5133 Diesel engine EMR "Coolant temperature sensor" " Sensor defective X31:8 X X
" Wire breakage in current path
" Current path has short circuit to ground
5134 Diesel engine EMR "Speed sensor" " Speed sensor 1 or 2 defective X31:10 X X
X31:12
5140 Diesel engine EMR "unknown fault" Fault diagnostics only possible with DEUTZ diagnostics tool X X
(SERDIA)
10.3.12 Miscellaneous
Fault Fault description Possible causes Terminal Assignment Input code Fault
Code DH-4 BVC-4 for reaction
diagnose
5502 "Hydraulic oil filter" warning Hydraulic oil filter soiled or sensor defective X X
5503 "Hydraulic oil filter" fault shut-down Hydraulic oil filter soiled or sensor defective X X
5504 "Oil temperature" warning Hydraulic oil temperature too high or sensor defective X X
5005 "Oil temperature" fault shut-down Hydraulic oil temperature too high or sensor defective X X
11.1.1 General
Input code Description of display function Display values
0555 Display of "machine control software version ( ESX)" e.g.: "1.13" for software version V 1.13
0556 Display of Firmware version "LCD Display" e.g. "1.36" for version 1.36
0557 Display of Firmware version "Data Collector" e.g. "1.11" for version 1.11
0720 Display of "Machine Code" The machine code is displayed (72xx) (see chapt. 3.6)
11.1.2 Brake
Input code Description of display function Display values
1001 Display of voltage at control output "Valve Brake" Display in V (e.g. 12.6 corresponds with 12,6V)
1078 Initial current value (learned surge current) of the valve Display in mA
1079 Maximum current value (derived end current) of the valve Display in mA
1088 Initial current value (learned surge current) of the valve Display in mA
1089 Maximum current value (derived end current) of the valve Display in mA
2130 Steering wheel sensor 1 track 1 absolute pulses Number of total pulses
2131 Steering wheel sensor 1 track 2 absolute pulses Number of total pulses
2132 Steering wheel sensor 1 total pulses of sensor
2133 Steering wheel sensor 1 sense of rotation 1=steering wheel steers to the right (clockwise); 2=steering
wheel steers to the left
2140 Steering wheel sensor 2 track 1 absolute pulses Number of total pulses
2141 Steering wheel sensor 2 track 1 absolute pulses Number of total pulses
2142 Steering wheel sensor 2 total pulses of sensor
2143 Steering wheel sensor 2 sense of rotation 1=steering wheel steers to the right (clockwise); 2=steering
wheel steers to the left
11.1.17 Vibration
Input code Description of display function Display values
3000 Display "Switch for vibration mode" Off = 0
On = 1
3001 Display "Status of vibration relay“ 0 = Relay K43 not switched
1 = Relay K43 switched
3002 Display "Vibration pump valve current" Display value = mA
The display shows the actual pump current.
3003 Display "Vibration pump valve current" (high amplitude on DH) Display value = mA
The display shows the actual pump current.
11.1.19 Engine
Input code Description of display function Display values
5024 Display "Status engine coolant level" 0= Coolant level OK; 1= Coolant level too low
5026 Display "Status engine air filter" 0= Air filter OK; 1= Air filter soiled
5028 Display "Status of water separator" 0= Water separator OK; 1= Water or dirt in fuel filter
11.1.20 Hydraulics
Input code Description of display function Display values
5502 Display "Status hydraulic oil filter" 0= Hydraulic oil filter OK; 1= Hydrauli oil filter soiled
11.3.1 Brake
Input code Description of display function Display values
0500 Activates the function "Driving against the closed brake" 500 and brake control light stays on when shifting the travel
lever out of the brake gate
0501 Deactivates the function "Driving against the closed brake" O K for 3seconds, then 0000
11.4.3 Disable electric supply to wheel and drum drive motors (switch off)
Input code Description of display function Display values
1120 Enable function
1121 Switch off function "Disable electric supply for drum drive motor"
Motor remains in position: max. displacement.
1122 Function "Disable electric supply for drum drive motor"
Motor remains in position: max. displacement.
2060 Activates function „Change steering unit“ see chapter "Change steering unit"
2061 Activates the electric steering unit see chapter 3.6
2062 Activation of hydraulic steering unit see chapter "Change steering unit"
1
Only optional function! The logical sense of rotation is automatically adjusted
Wire breakage
This generally means that a connection is interrupted. Possible reasons may be:
Line:
• torn (not necessarily visible from outside)
• rubbed through
• chafed mostly in connection with a short circuit to ground
Digital
There are only two permissible states, e.g. switched on or off; lamp on / off; current flows /
does not flow; valve open / closed (black-white valve)
Analogue
In contrast to Digital many conditions are permitted within a certain range. For instance room
temperature 0° to 40°; current 4mA to 20mA; voltage 0V to 8,5V; resistance 100 Ω to 300 Ω;
valve 0% to 100% opened (proportional valve)
Control
Controlling describes the process during which an input value influences a distance (the
value to be controlled), following a fixed command. For this purpose all possible interfering
factors (e.g. temperature, humidity ...) must be known.
Ohm’s law:
U =R∗I
U = Voltage
R = Resistance U
I = Current
I=
R
U
R=
I
Plausibility check
The control (ESX) runs a plausibility check on all inputs. This means the control checks
permanently whether certain state combinations are permitted; e.g. travel lever position
forward and reverse will cause an fault message, because this condition is normally not
possible.
GND - AGND
Besides the "normal" battery ground (terminal 31) in the vehicle there is an additional
analogue ground, which is only to be used for sensors. (see description of the signals on the
ESX-control)
28.06.2004
Seis Stromlaufplan 001 001 582 700 95
28.06.2004 circuit diagram
Werner 001
30
K11
2:10
87
K30 11:1
30 4:1 K11:87 5:1
X1:9
X1:10
F13 1 F05 1 F95 1 F23 1 F39 1
30A 15A 15A 15A 15A
2 2 2 2 2
X1:15A X1:16A X1:27A X1:28A
X1:30A
6:17
X36:B
X36:A
4:9
X37:A X1:151
30 21 11 31 41 51 61
Startschalter NOT−Aus
K32:86
starting swwitch 15 54 58 19 17 50a Emerg.−Stop 11:1
X1:152 X1:155
X1:79
Sicherung Heizflansh
S01:22 3:1
X37:B
F05:2
Hauptsicherung
K05 30
X34:P
main fuse
2 1 7:3
125mA
5
87 87a
K14 86 30
K61 K61
13 23
3:19 3 2:6 S03
2 2
F48 F00
125A 125A 85 87 87a X1:7 X1:8 Taster Hupe
push button, horn 14 24
D+ MESX 8:2
Anzugsw.:50A / Haltew.:10A
G01 G03 X38:A X1:97 X1:98
+ +
− −
X1:1 X1:101 X1:102
X1:109
167A
30 50
1 B+ D+ 86 86 B11 B11
1 K09 K11 1 2 2 1
G02 M01 V02 XS +
R19 S30 M
12V
2 2 1 V03 1 2 −
85 85 −
2
31 EMR 3:5 B− W
31 31 3:1
28.06.2004
1 1 582 700 95
Seis Versorgung, Starten, Hupe
28.06.2004
Werner supply, starting unit, signal horn 002
2:17 S01:22 S01:22 6:1
X1:95
1
K14
Relais Heizflansch
relay heating−flange 2
X1:179 X1:96
X1:185
Steckerschnittstelle Deutz
connector interface Deutz
X33:7
X33:2
X33:3
X33:5
X33:6
X33:1
X33:4
X33:8
max 7A
8−polig PNEUTRON
A48
Motorsteuerung EMR2
X30:14
engine−controller EMR2
X31:21
X31:22
X31:13
X31:11
X31:14
X31:15
X31:24
X31:25
X31:4
X31:9
X31:5
X31:6
X31:3
X31:2
X31:7
X30:10
X30:11
X30:12
X30:13
X31:20
X31:12
X31:10
X31:17
X31:18
X31:19
X31:16
X31:23
X30:1
X30:2
X31:8
X31:1
AGND
AGND
AGND
AGND
AGND
STG−
STG+
K
L
+5V
+5V
CAN low
CAN high
Signal
Signal
Signal
Signal
Ubat −
Signal Druck
Signal Temperatur
X1:180
X1:181
X57:20
X57:21
X57:22
X57:12
X57:13
X57:10
X57:11
X57:14
X57:15
X57:17
X57:18
X57:19
X57:16
X57:23
X57:24
X57:25
CAN2− 4:11
X57:4
X57:9
X57:8
X57:1
X57:6
X1:183
X1:184
ESX Fahrst.
CAN2+ 4:11
RF REF
RF MESS
RF−
1 2 3 1 2 1 2 7 2 6 1 1 4 3 2 1 2
EMR Stellglied
EMR commander
X32:G
X32:H
X32:K
X32:B
X32:A
X32:L
X1:182
Diagnosestecker EMR
diagnosis interface EMR
2:4
X1:186
31 EMR
2:20 31 31 4:1
2:2
Motordrehzahlsensor
sender engine rpm 2
28.06.2004
1 1 582 700 95
Seis Motor Deutz EMR II
28.06.2004
Werner engine Deutz EMR II 003
2:14 30 30 5:1
F24:2 5:3 X1:2 3:4 CAN2+ CAN2+ 7:6
EMR Deutz Fahrhebel
3:4 CAN2− CAN2− 7:6
X1:145
X1:42 CAN1+ 5:8
31 CAN1− 5:8 LC−Display, OPUS 21
X1:119 X1:120
S01
2:16
120 OHM 120 OHM
X52:1
X52:2
X1:146 32 1 2 1 2
R22 R20
rt sw X1:17E X1:34E
Diagnosestecker Fahrzeug
F67 1 F84 1 X34:G X34:H X34:C X34:D X34:A X34:B diagnosis interface equipment
B112
15A 10A
2 2
Drucksensor Fahrpumpe X1:17A X1:34A
X1:51
X1:52
X1:53
X1:54
X1:47
X1:48
X1:49
X1:50
pressure sensor drive pump
X1:34A
8:2
120 OHM 120 OHM
1 2 1 2
Drucksensor
Elektronik
Leistung
R23 R21
CAN2+
CAN2−
CAN1+
CAN1−
RxD
TxD
A34
X35:31
X35:56
X35:57
X35:59
X35:60
X35:53
X35:33
X35:5
X35:58
X35:27
X35:26
X35:28
X35:54
X35:4
Fahr−Steuerung
driving controller
X35:38
X35:12
X35:37
X35:34
X35:30
X35:15
X35:24
X35:49
X35:64
X35:46
X35:47
X35:55
X35:65
X35:66
X35:67
X35:68
Gehäuse
housing
Neigung
speed
speed
Richtung
Richtung
Achsmotor
Bandagenmotor
Fahrpumpe vorw.
Fahrpumpe rückw.
Rückfahrwarnsum.
Sitzkontakt
X1:45
X1:44
X1:173
X1:175
X1:177
X1:176
+ −45_G=0,5V
B57 1V
ws
br
bl
speed
+ + 0,46A
dir. dir.
B60 B59 2,5V X14:B X9:1
speed
S06 + + X16:1 1 X15:1 1 1 1
− X1:172 −
8:2
4V H14 Y17 Y16 Y30 Y31
sw
sw
DIR MESX −
− 2 2 2 2
X1:124
X1:142
X1:142
X1:143
X1:143
11:6 − S X1:46 X16:2 X15:2
X1:82
SPEED TAC X14:A X9:2
X1:174 8:2 X1:178 X1:55 6:4 8:2 X1:149 X1:117 X1:123 X1:123 X1:144 X1:144
SPEED MESX
PITCH MESX
3:20 31 31 5:1
Sensor Achse Sensor Bandage Neigungssensor Sitzkontaktschalter Prop.−Pumpe Vorw. Prop.−Ventil Bandagenmotor
sender axle sender drum slope sensor switch, seat contact prop.−pump forwards prop.−Valve drum motor
28.06.2004
1 1 582 700 95
Seis Fahrantrieb, Neigungssensor, Sitzkontakt
28.06.2004
Werner driving system, slope sensor, seat contakt switch 1 004
30 30 8:1
4:20
2:20 K11:87 K11:87 7:14
4:3 F24:2 F24:2 6:15
X1:40
X34:R
not connected
not connected
CAN1 high
CAN1 high
CAN1 low
CAN1 low
Ub "30"
Ub "15"
Ub out
VCC
X27:8
X28:6
X29:8
Steckerfarbe: X26−grau; X27−schwarz
A80 A81
X28:1
X27:6
X27:7
X29:7
X28:3
X28:5
connector−colour: X26−grey; X27−black
X28:4
Datensammler LC−Display
data−collector LC−display
X26:10
X26:11
X27:10
X27:11
X27:12
X26:3
X26:5
X26:8
X27:4
X27:9
X27:2
X26:7
X26:9
X26:1
X26:2
X26:6
X26:4
X27:1
X27:3
X29:2
X29:1
X29:3
X29:4
X29:5
X29:6
X26:12
X27:5
X28:2
DIN11
UIN1
GND
GND
GND
DIN10
DIN1
DIN1
AIN1
UIN3
UIN2
DIN3
DIN5
DIN7
DIN9
DIN6
DIN3
DIN5
DIN6
DIN8
DIN2
DIN2
Sepa1
GND/UIN3
DIN4
DIN4
AIN2
Sepa2
BR 10:17 23 13 23 13
coolant stock level
hydraulic oil filter
water−seperator
Füllstand Diesel
Kühlmittelvorrat
Hydraulikölfilter
BEL S120
10:4
KLIMA
12:6 S139
air cleaner
fuel−level
24 14 24 14
Luftfilter
D+ R03
2:6 P P Q
Schalter Motordrehzahl
2 2 switch engine−rpm mode switch frequency−control
X21:2 X8:2 X10:3 Schalter Frequenzverstellung
28.06.2004
1 1 582 700 95
Seis Datensammler, LC−Display
28.06.2004
Werner data−collector, LC−display 005
3:20 S01:22 S01:22
5:20 F24:2 F24:2
X1:148 Lenkwinkelsensor
X23:1 steering angle sensor
7:1
X1:41
X1:201
X51:1 Lenkeinheit X1:187
B65 + A45 steering unit
Aufnehmer Vibrationsmotor
S X22:1 sensor vibration motor
br +
X1:161 X41:1 X39:1 VCC X39:2
S1 B − X22:2
−
X1:160 X41:3 X40:1 VCC X40:2
X1:203
X1:55 X1:202
bl
B B16
0V S1 A X22:4
Vib.− Richtung
armrest−switch
1 1 1
X41:5
X41:7
X41:8
X41:6
BTS BREMSE 7:2
X34:J
X1:189
X1:188
−
Sig.
AGND
Vib.− Frequenz
BTS Bremse
X1:205
X1:207
X1:206
X1:208
X1:55
X1:42
4:6
nur BVC
only BVC
8,5V
A34
X35:1
X35:19
X35:17
X35:18
X35:41
X35:35
X35:29
X35:23
X35:40
Fahr−Steuerung
driving controller
X43:2 X43:1
X35:21
X35:20
X35:25
X35:16
X35:22
X35:48
X35:61
X35:2
X35:3
Bremse
Warnsummer
Armlehne
Umsch. Amplitude
Prop. out
K57 30 K56 30
Pumpe Vib.−Platten
30
X51:3
X51:2
6:9 6:8 30
K48 7:2
87 87a 87 87a X1:89
K43 6:12 87 87a
X1:154 87 87a X1:147
KA MESX
8:2 11
X35:16 X1:38
X1:199 X1:198 X1:196 X1:195 X35:16 X35:22 GA MESX
6:9 6:2 7:14 8:2 S01
X1:37
400 ... 1.200mA
2:16
X1:116 X1:115 12
150mA
X1:113 8:2
X6:1 X7:1 BRAKE MESX
Y113 1 Y112 1 1 1 K56 86 K57 86 K43 86 Y08 1 Y07 1 H07
+ Y04 1
Y93 Y92
2 2 2 2 85 85 85 2 2 − 2
max.1.8A
X6:2 X7:2
X1:149 X1:200 X1:200 X1:197 X1:197 X1:82 X1:117 X1:190
X1:118
5:20 7:1
31
31 Anbau 177DH: h.r. Anbau 177DH: h.l.
6:4 6:3 6:14 Anbau 213DH: oben Anbau 213DH: unten
28.06.2004
1 1 582 700 95
Seis Lenkung, Vibration
28.06.2004
Werner TS022 steering, vibration 006
6:2 X23:1 4:17 CAN2+ 5:14 CAN1+ CAN1+ 8:16
ESX Fahrst. LC−Display BTM
4:17 CAN2− 5:14 CAN1− CAN1− 8:16
5:20 K11:87 K11:87 8:1
Taster 1 = Platten rechts
push button 1 = plates right X1:31E
Taster 2 = Platten heben
push button 2 = lift plates 1 F145
Taster 3 = Vibration EIN/AUS Näherungssch. Platten oben
push button 3 = vibration ON/OFF 15A
Taster 4 = Platten links
sensor plates up 2
push button 4 = plates left
Taster 5 = platten senken
Näherungssch. Platten Mitte X1:31A
sensor plates centered
X1:213
X1:214
push button 5 = lower plates
X1:156
X1:157
Taster 7 = Infotaste 1
push button 7 = info button 1
X1:209
Taster 8 = Infotaste 2
BTS BREMSE
push button 8 = Info button 2
B135 + B134 +
6:18 − −
3 2
1 7 Fahrstufenschalter S S
4
5 8 speed range selector
S42
X62:12
X62:10
X62:1
X62:3
X62:9
X62:2
X62:4
+ − S A54
Platten Steuerung
plate−controller
X25:4
X25:2
X25:3
Ub in CAN−
Bremse zu = 0V 1 7
Bremse auf = Ub BTS Bremse CAN+
3 S55 6 X35:22
6:11
X62:11
X62:13
X62:14
X62:5
X62:6
X62:7
X62:8
X1:153 BTS zus.
4 Fahrhebel 5 +5V out
travel lever
0V in 0V (Ref PIN5)
2 8
Add1 AK Ext1
9 11
Add2 AK Ext2
10 12
Stecker X23
Stecker X24
1 2 3 4 5 6 7 8
DK Ext1
DK Ext3
DK Ext5
DK Ext6
DK Ext2
OV out
DK Ext4
Ub out
400 .. 1.200 mA
X50:3
X50:2
X50:1
X1:210
S − + Y123 1 Y143 1 Y145 1
nicht bei BVC Nur bei BVC Schalter Schwimmstellung Platten MV Platten heben MV Platten rechts
not at BVC Only at BVC sw. swimming pos. plates plates up plates right
Frequenzverstellung Platten
freq. adjust plates MV Platten senken MV Platten Schwimmst
Schalter Amplitude Schalter Vibration Ein/Aus Schalter Betriebsart Platten Prop−Pumpe Platten plates down plates float−pos.
switch amplitudes switch vibration on/off modesw. plates prop.−valve plates MV Platten links MV Platten Priorität
plates left plates priority
28.06.2004
1 1 582 700 95
Seis Fahrhebel, Vibrationsplatten
28.06.2004
Werner TS022 joystick, vibration−plates 007
Beschleunigungssensoren Beschleunigungssensoren Aufnehmer Verstellmotor Drucker Bedieneinheit BEM Display Messtechnik BOP
acc. sensor front acc. sensor rear sens. adjust. motor printer control−unit BEM display measurem. BOP
X1:34A
4:9 GND
5:20 30 30 10:1
Pot 30
X2:47
Pot 15
31.1
X2:48 X2:49
+ −
X2:66
X2:70
8:19
nur bei BEM
X42:1
only at BEM
X42:5
X42:3
X42:2
X1:32E X1:35E
X2:77 P16 F1 F2
CAN+
CAN−
X1:32A X1:35A X48:2 X48:1 X49:2 X49:1 X2:78 P33
X2:67 X2:68
X4:C
X4:E
X4:D
F148:2 B62 B62
+/sw
+/sw
9:15
−/gg −/gg X47:A X47:B
X42:6
X42:7
X42:8
X42:4
X74:3
X74:5
X74:4
−/sw
20g/br
20g/br
7:20
X2:57 CAN1−
DIOS Platten
B61 P11
+/rt 7:20
X48:3 X48:4 X49:3 X49:4 S/ws
CAN1+
X74:1 X74:2
1 R20 2
X2:54 X2:55 X2:58 X2:59 X47:C
AGND MESX
Aufn. hinten 15g
X2:50 X2:51
Erregerpos.
Pot. 15
R21
8.5V
X2:69 X2:64 X2:65 1 2
RxD TxD CAN1+ 120 OHM CAN1−
X44:27
X44:26
X44:31
X44:1
X44:56
X44:57
X44:59
X44:60
X44:30
X44:7
X44:9
X44:5
X44:58
X44:29
X44:23
X44:28
X44:54
X44:4
A83
X44:15
X44:38
X44:35
X44:14
X44:32
X44:36
X44:37
X44:41
X44:47
X44:46
X44:53
X44:33
X44:55
X44:65
X44:66
X44:67
X44:68
X44:3
Messtechnik−Rechner
measurement calc. unit
CAN3+ CAN3−
KA MESX
EVIB
0..6VDC
6:15
Prop.
Prop.
400 .. 1.200mA
400 .. 1.200mA
GND
6:15 GA MESX
SPEED MESX X1:85 9:15
4:3 CAN3−
DIR MESX X2:75 X2:73 X2:60 +
4:3
P07 E 9:15
8:20
4:8 PITCH MESX Y140 1 Y141 1 VIB CAN3+
BRAKE MESX
v.r.
v.l.
6:17 −
31.1
D+ MESX BEL MESX 2 2
2:6 10:4 X2:76 X2:74 X2:63 X2:66 X1:82
31 31 9:1
7:20
28.06.2004
1 1 582 700 95
Seis Variocontrol, Messtechnik
28.06.2004
Werner TS022 Variocontrol, measurement equipm. 008
F148:2
8:4
CAN3−
8:18
8:18 CAN3+
CAN3+
1 R242 CAN3−
120 OHM
X2:61 X2:62
R25
1 2
120 OHM
X4:N X4:M
X75:7 X75:2
A87
USB−CAN Schnittst.
USB−CAN Interface BCM
X2:70
X76:1 X4:G
P15 X76:2
X4:F
X2:63
BCM 05
BCM 05
nur bei BCM
only at BCM
8:20 31 31 10:1
28.06.2004
1 1 582 700 95
Seis Bomag Compaction Management BCM
28.06.2004
Werner TS022 Bomag Compaction Management BCM 009
8:3 K11:87 K11:87
8:19 30 30
X1:18E X1:26E X1:19E X1:25E
X1:2
F11 F18 F07 F08
15A 10A 15A 15A
30
X1:301
X1:18A K06 X1:19A X1:25A
X1:26A
10:4 X1:305
X1:83
Schalter StvZO 87 87a
switch, StvZO
13 23
012 31 11 23 Anschluß Arbeitsschein− L0R
werfer ohne StvZO L0R Schalter Blinker
S37
connection working head X1:21E X1:22E switch indicator
lights without StvZO 5 4 14 24
S15 F22 F19
32 12 24 15A 15A
Anschluß Arbeitsscheinwerfer
X1:306
X1:307
X1:21A E X1:22A D bei Kabine
Connection head lights
X1:302
X1:304
werfer ohne StvZO
X1:311
X1:310
X1:319
X1:313
X1:312
X1:321
X1:314
X1:309
X1:303
X1:320
X1:322
13 23
01
01
S14
X1:84
X61:1
X61:3
X60:1
X59:5
X60:3
X59:3
X58:5
X58:3
X59:2
X58:2
Warnblinkschalter 14 24
BEL MESX
8:7 switch, hazard light
0,125A
X1:43
E16 1 E17 1 E13 1 E12 1 E14 1 E15 1 E27 1 E28 1 E23 1 E25 1 E08 1 E09 1 E10 1 E11 1
0,125A
2 2 86 2 2 2 2 86 2 2 2 2 + 2 2 2 2
4,6A
4,6A
4,6A
4,6A
K06 K16
X1:324 X61:2
X1:324 X61:4
X1:316 X59:6
X1:316 X59:6
X1:316 X59:6
X1:315 X58:6
X1:315 X58:6
X1:315 X58:6
X1:323 X60:2
X1:323 X60:4
H06
0,42A
0,42A
0,42A
0,42A
1,75A
1,75A
1,75A
1,75A
4,6A
4,6A
85 85 −
X3:1
9:20 11:1
31 10:10 Schlußleuchte links 10:2 Bel. Warnbinkschalter 31
Scheinwerfer links tail light, LH illumination, switch hazard light
head light LH Parkleuchte links Blinkleuchte VL Blinkleuchte HR
Anschluß Arbeitsscheinwerfer
parking light, LH bei ROPS/SD Aufbau indicator front, LH indicator rear, RH
Scheinwerfer rechts
Parkleuchte rechts Blinkleuchte HL
head light RH parking light, RH Connection head lights indicator rear, LH
acc.to ROPS/SD
Schlußleuchte rechts Blinkleuchte VR
tail light, RH indicator front, RH
28.06.2004
1 1 582 700 95
Seis Beleuchtung und StvZO
28.06.2004
Werner illumination and StvZO 010
K30 X3:6
2:14 K32:87 12:2
X3:7
K32 30 STV2
X3:8 10:13
11:1 10:13 STV1
87 87a
G H A B C E F
F143 F42 F43 F44 F130 F41 F144
15A 10A 15A 15A 10A 10A 15A
7 8 1 2 3 6
5
F42 12:8
F130 11:9 F130 F130 12:7
11:14
A12
1,75A
0,83A
15
K141 30 1 B51 + + 30 01W 7 2 01W 7 2
+ + B51 1 S163 5 1 S38 5
01 01 E72
K32:86 11:16 E29 E70
− − − − 1
87 87a 2 2 2 1
2:19 31 S21 5 4 S20 5 4
Radio
night illumination
radio
Nachtleuchte
inside light, cabin
1 Tachographenmodul
Kontrolleuchte
E71 1
Innenleuchte
module, tachograph
indicator
R80 A2+A3
X3:17
X55:1
X56:1
X55:3
X56:3
X55:4
X56:4
4,6A
4,6A
4,6A
4,6A
2 4 6 A1
Steckdose
4:3 P09 +
2 1 E28 1 E23 1 E25 1 XS
socket
SPEED TAC A16 E27
Heizung Heckscheibe
1 B3 12V
−
heating rear screen
max. 13A
+ 7,8,9 2 B4 2 2 2 2
Schalter Innenleuche
3,8A
3,8A
3
5A
86 S86 + + + S158 I 15 +
K32 E32
M05 M M04 M K141
M M
31
− − M07 −
Abfallverzögert
− M06 4
3 min
85 2,9A
4,7A
ZA
X55:2 X56:2 option
12:18
KABINE 31
Relais Kabine Türkontaktschalter Tachograph Schalter Nachtleuchte
relais cabin door switch tachograph switch, night illumination
X3:1
X3:2
Schalterbel.
switch illum.
10:20 31 31 12:1
28.06.2004
1 1 582 700 95
Seis Kabinenausrüstung, Beleuchtung, Radio, Tachograph
28.06.2004
Werner cabin−equipment, headlights, radio, tachograph 011
11:19 K32:87
Potential 15 aus Kabine
11:17 F130
F42 Potential 15 aus Kabine
11:9
F31 D Potential 30 aus Kabine
F40 H F15 A
20A 20A 5A
4 8 1
Bedienteil Kabinenheizung/Klimaanlage
1 2 3 12 11 13 14 16
X53:B X53:C control−unit cab−heater /air conditioning X54:4 X54:3 X54:2
Schalter Kabinenzusatzheizung
0123 4 3 2
S44 A72
X53:H
X53:L
K09 30
X3:14
temperature sensor air conditioning
2:8
87 87a X1:167 10 9 5 6 8 7 4 15
X3:12
X3:9
X1:169 X18:1
Thermofühler Klimaan
X19:1
Thermofühler Heizung
B131
B103 1
X17:1 X1:163
X17:2 X1:165
X17:3 X1:166
1
_t _t
2 2
monitoring coolant pressure
X19:2
X20:1 X18:2
B104 4
Überwachung Kühlmitt
P
LP 3 HP
1A
X20:4
ge rt or ge rt or
X20:3
Y138 1 1
X1:170 11:19
V06 Y14 KABINE 31
M09 M M09 M 5:9
KLIMA 2 2
Stromaufnahme Lüfter / current blower br br
Stufe 1: 3.0A pro Lüfter
X20:2
Stufe 2: 4.5A pro Lüfter
Stufe 3: 11.5A pro Lüfter
Y15 1 2
X17:4 V04 X1:168
3,5A
2 1
X1:164
11:20 31 31
28.06.2004
1 1 582 700 95
Seis Kabinenheizung, Klimaanlage, Zusatzheizung
28.06.2004
Werner cabin−heater, air conditioning, add. heater 012
Name Bl. Pf. Benennung title TYP
A02 010 17 Blinkrelais indicator relay
A12 011 5 Radio Radio
A16 011 6 Elektronik Tachograph Electronic system, tachograph
A34 004 6 Prozessorplatine Prozessing circuit board
A34 006 5 Prozessorplatine Prozessing circuit board
A45 006 9 Lenkrad Steering wheel
A48 003 3 Elektronische Motorsteuerung Electronic engine management
A54 007 17 Modul Pumpenansteuerung Modul pump control
A72 012 11 Steuergeraet Klimaanlage, Heizung Control unit,air conditioning,heating
A80 005 3 Modul Datensammler modul data−collector
A81 005 18 Anzeigeeinheit Display−Unit
A83 008 6 Elektronik Messtechnik electronic measurement−equipment
A87 009 15 USB−CAN Schnittstelle BCM USB−CAN Interface BCM
Werner
28.06.2004
Seis
28.06.2004
E08 010 17 Blinkleuchte vorne links Indicator, front, lh. MAX. 1,75A
Bauteilliste
E09 010 18 Blinkleuchte hinten links Indicator, rear, lh. MAX. 1,75A
E10 010 19 Blinkleuchte vorne rechts Indicator, front, rh. MAX. 1,75A
E11 010 19 Blinkleuchte hinten rechts Indicator, rear, rh. MAX. 1,75A
E12 010 7 Parkleuchte links Parking light, lh. MAX. 0,42A
E13 010 6 Schlussleuchte links Tail light, lh. MAX. 0,42A
E14 010 7 Parkleuchte rechts Parking light, rh. MAX. 0,42A
E15 010 8 Schlussleuchte rechts Tail light, rh. MAX. 0,42A
E16 010 2 Scheinwerfer links Head light, lh. MAX. 4,6A
E17 010 2 Scheinwerfer rechts Head light, rh. MAX. 4,6A
E23 010 11 Arbeitsscheinwerfer vorne links Working head light, front, lh. MAX. 4,6A
E23 011 18 Arbeitsscheinwerfer vorne links Working head light, front, lh. 4,6A
E25 010 12 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. MAX. 4,6A
E25 011 19 Arbeitsscheinwerfer vorne rechts Working head light, front, rh. 4,6A
E27 010 10 Arbeitsscheinwerfer hinten links Working head light, rear, lh. MAX. 4,6A
E27 011 17 Arbeitsscheinwerfer hinten links Working head light, rear, lh. 4,6A
E28 010 11 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. MAX. 4,6A
E28 011 17 Arbeitsscheinwerfer hinten rechts Working head light, rear, rh. 4,6A
E29 011 3 Innenleuchte Kabine Inside light, cabin 1,75A
E30 012 13 Heizgeraet Heating unit
E32 011 19 Kennleuchte Warning light 5A
E70 011 15 Nachtleuchte Night lamp 0,83A
E71 011 3 Kontrolleuchte Schalter Heckscheibenheizung indicator light switch rear screen 1,75A
E72 011 16 Beleuchtung Bedienschalter illum. Switches
F67 004 7 Sicherung Steuerung (Potential 30) Fuse, controller (pot.30) 15A
F84 004 9 Sicherung Steuerung (Klemme 54) Fuse, controller (Pin 54) 10A
F95 002 16 Sicherung Motormanagement intern Fuse, engine controller (internal) 15A
FM1 006 6 Platinensicherung Multifuse MULTIFUSE
FM2 006 5 Platinensicherung Multifuse MULTIFUSE
101
H06 010 15 Meldeleuchte Warnblinker Indicator light, hazard light LED ROT
H07 006 16 Warnsummer Betriebsstoerung Warning buzzer, breakdown 0.15A
H14 004 11 Warnsummer Rueckwaertsfahrt Back−up alarm buzzer MAX O,46A
Werner
28.06.2004
Seis
28.06.2004
A80
X1:1 … X1:61
A02 K05
K16 K06
K11
K09 K43
K48
K61
B57
K57
K56
X32:1-12 X34:1-19
CAN 1
A34
Fahrsteuerung
LCD +
CAN 1 Datensammler
+ OPUS 21
A83
Messtechnik Steuerung
CAN 3 BCM
1 05756417
6 05756537
7 3 x 05756540 "R" + 793-501
10 05756537
11 05756540 "R" + 793-501
13 05756537
14 2 x 05756538 "R" + 793-501
18 05756537
19 4 x 05756540 "R" + 793-501
23 05756537
24 4 x 05756540 "R" + 793-501
30 05756537
31 05756540 "R" + 793-501
33 05756537
34 4 x 05756540 "R" + 793-501
39 05756537
40 4 x 05756540 "R" + 793-501
Optional1 : Zeichnungsnummer :
Projektgruppe : Walzenzüge-4 Klemmenleisten
Artikelnummer :
Optional2 : Projekt : Artikelnummer lang :
Zeichnung : Konstrukteur :
Optional3 : Plan : geprüft :
Ort :
Optional4 :
Betriebsmittel : Kabelbäume DH-4 VErsion Lieferadresse: :
Optional5 : ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick
Optional6 : Artikelnummer : 210-112
Bohrungsabmessungen : 5.20 x 25.00 [mm]
Optional7 :
44 05756537
45 05756540 "R" + 793-501
47 05756537
48 05756540 "R" + 793-501
50 05756537
51 05756538 "R" + 793-501
55 05756537
56 3 x 05756540 "R" + 793-501
60 05756537
61 3 x 05756540 "R" + 793-501
65 05756537
66 2 x 05756540 "R" + 793-501
69 05756537
70 3 x 05756540 "R" + 793-501
74 05756537
75 2 x 05756540 "R" + 793-501
78 05756537
79 05756417
Optional1 : Zeichnungsnummer :
Projektgruppe : Walzenzüge-4 Klemmenleisten
Artikelnummer :
Optional2 : Projekt : Artikelnummer lang :
Zeichnung : Konstrukteur :
Optional3 : Plan : geprüft :
Ort :
Optional4 :
Betriebsmittel : Kabelbäume DH-4 VErsion Lieferadresse: :
Optional5 : ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick
Optional6 : Artikelnummer : 210-112
Bohrungsabmessungen : 5.20 x 25.00 [mm]
Optional7 :
Optional1 : Zeichnungsnummer :
Projektgruppe : Walzenzüge-4 Klemmenleisten
Artikelnummer :
Optional2 : Projekt : Artikelnummer lang :
Zeichnung : Konstrukteur :
Optional3 : Plan : geprüft :
Ort :
Optional4 :
Betriebsmittel : Kabelbäume DH-4 VErsion Lieferadresse: :
Optional5 : ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick
Optional6 : Artikelnummer : 210-112
Bohrungsabmessungen : 5.20 x 25.00 [mm]
Optional7 :
Optional1 : Zeichnungsnummer :
Projektgruppe : Walzenzüge-4 Klemmenleisten
Artikelnummer :
Optional2 : Projekt : Artikelnummer lang :
Zeichnung : Konstrukteur :
Optional3 : Plan : geprüft :
Ort :
Optional4 :
Betriebsmittel : Kabelbäume DH-4 VErsion Lieferadresse: :
Optional5 : ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick
Optional6 : Artikelnummer : 210-112
Bohrungsabmessungen : 5.20 x 25.00 [mm]
Optional7 :
1 05756417
6 05756537
7 2 x 05756540 "R" + 793-501
15 05756537
16 05756417
Optional1 : Zeichnungsnummer :
Projektgruppe : Walzenzüge-4 Klemmenleisten
Artikelnummer :
Optional2 : Projekt : Artikelnummer lang :
Zeichnung : Konstrukteur :
Optional3 : Plan : geprüft :
Ort :
Optional4 :
Betriebsmittel : Optionen Beleuchtung Lieferadresse: :
Optional5 : ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick
Optional6 : Artikelnummer : 210-112
Bohrungsabmessungen : 5.20 x 25.00 [mm]
Optional7 :
Optional1 : Zeichnungsnummer :
Projektgruppe : Walzenzüge-4 Klemmenleisten
Artikelnummer :
Optional2 : Projekt : Artikelnummer lang :
Zeichnung : Konstrukteur :
Optional3 : Plan : geprüft :
Ort :
Optional4 :
Betriebsmittel : Optionen Beleuchtung Lieferadresse: :
Optional5 : ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick
Optional6 : Artikelnummer : 210-112
Bohrungsabmessungen : 5.20 x 25.00 [mm]
Optional7 :
1 05756417
5 05756537
6 05756538 "R" + 793-501
7 2 x 05756540 "R" + 793-501
10 05756537
11 2 x 05756540 "R" + 793-501
14 05756537
15 05756540 "R" + 793-501
16 05756538 "R" + 793-501
18 05756537
19 05756540 "R" + 793-501
20 05756539 "R" + 793-501
21 05756537
22 2 x 05756438 "R" + 793-501
24 05756421
25 05756417
Optional1 : Zeichnungsnummer :
Projektgruppe : Walzenzüge-4 Klemmenleisten
Artikelnummer :
Optional2 : Projekt : Artikelnummer lang :
Zeichnung : Konstrukteur :
Optional3 : Plan : geprüft :
Ort :
Optional4 :
Betriebsmittel : Klemmenleiste X2 / Lieferadresse: :
Optional5 : ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick
Optional6 : Artikelnummer : 210-112
Bohrungsabmessungen : 5.20 x 25.00 [mm]
Optional7 :
Optional1 : Zeichnungsnummer :
Projektgruppe : Walzenzüge-4 Klemmenleisten
Artikelnummer :
Optional2 : Projekt : Artikelnummer lang :
Zeichnung : Konstrukteur :
Optional3 : Plan : geprüft :
Ort :
Optional4 :
Betriebsmittel : Klemmenleiste X2 / Lieferadresse: :
Optional5 : ausgewählte Tragschiene : Stahl-Tragschiene 35x7,5 mm, 1 mm dick
Optional6 : Artikelnummer : 210-112
Bohrungsabmessungen : 5.20 x 25.00 [mm]
Optional7 :
X29
X28 X21
X39 X23 X24 X50
X59 X40 X25 X41
X58 X42 X51 X43 X57
X20
X14
X61
X9
X21
X74 X75 X72
X59 X62
X76
X8
X42 X23 X24 X50 X57
X10
X25 X41 X51
X55
X53
X20
X29 X18
X17 X14
X28 X19 X56 X6 X7
X54 X15 X16
X39
X43
X40
X30
X58 X52 X33
X31 X4 X3
X36 X35 X1 X26
X37 X44 X2 X27
X38 X32 X34 X60
X47
X45
X48 X49
X46 (BVC) (BVC)
X48 X49
X22