Service Training Electric BF800

Service Training Electrics BF800

Version 1.40

1 of 36

Table of contents 1

2

Confirmation of changes__________________________________________4 1.1

Document___________________________ _____________________________ ______________ 4

1.2

Glossary ____________________________ _____________________________ ______________ 4

1.3

Software ________________________________________________ _______________________ 5

The main mai n display ________________________________________________6 2.1

General display functions and operation __________________________ __________________ 6 2.1.1 2.1.2

3

Entering input codes _____________________________________ _________________ 6 Calling up service mode _____________________________ ______________________ 6

Settings________________________________________________________7 3.1

General _____________________________ _____________________________ ______________ 7 3.1.1

3.2

Machine type ____________________________ _________________________________________________________ _____________________________ ___ 7

Tractor control (TCU) __ ______________________________ ____________________________ 8 3.2.1

Propel system ______________________________________________ _____________ 8

3.2.1.1 3.2.1.2 3.2.1.3 3.2.1.4 3.2.1.5 3.2.1.6 3.2.1.7 3.2.1.8

3.2.2

Miscellaneous __________________________________________________________ 13

3.2.2.1 3.2.2.2 3.2.2.3 3.2.2.4 3.2.2.5

3.3

Teach L.C.S. potentiometers max. values _________________________ _____________________________________ ____________ Adjust currents for the tamper pump _____________________________ ____________ Adjust tamper ramps ___________________________ _____________________________________________________ __________________________ Adjust currents for the vibration pump ____________________________ ________________________________________ ____________ Miscellaneous __________________________________________________________

3.3.5.1 3.3.5.2 3.3.5.3

Store settings ________________________________ __________________________________________________ ________________________________19 ______________19 Restore settings _________________________________ ___________________________________________________ _____________________________19 ___________19 Return to the default values _________________________________ __________________________________________________ ____________________19 ___19

Enable/disable hoppers front flap ___________________________________________ _________________ __________________________ Adjust maximum current for augers pumps _____________________________ _______ Adjust augers ramps ___________________________________________________ __ Adjust maximum current for conveyor pumps __________________________________ Enable / disable lifting auger box with screed __________________________________ Miscellaneous __________________________________________________________

3.4.6.1 3.4.6.2 3.4.6.3

4

15 16 16 18 19

Material flow control (MCU) ___________________________ ___________________________ 20 3.4.1 3.4.2 3.4.3 3.4.4 3.4.5 3.4.6

3.5

Enable / disable force heating in LOW idle ____________________________ __________________________________________13 ______________13 Enable / disable cleaning function___________________________________ _________________________________________________13 ______________13 Store settings ________________________________ __________________________________________________ ________________________________13 ______________13 Restore settings _________________________________ ___________________________________________________ _____________________________13 ___________13 Return to the default values _________________________________ __________________________________________________ ____________________14 ___14

Screed control (SCU) ___________________________ _____________________________ ___ 15 3.3.1 3.3.2 3.3.3 3.3.4 3.3.5

3.4

Learn function for the start currents of the propel pumps (BF800 C only) ___________________8 Teach the forward and backward start currents of the propel pumps (BF800 C only) __________9 Learn function for the start currents of the front wheel drive proportioning valves valves (BF800 P) ___10 Speed command by Boost button in case of a broken speed potentiometer ________________11 ________________11 Steer with spin switch in case of a broken steering wheel transducer (BF800 C only) ________11 Change speed potentiometer type __________________________________ ________________________________________________12 ______________12 Drive against closed brake __________________________________ ___________________________________________________ ____________________12 ___12 Block screed extensions during transport (BF800P with road homologation only) ____________12

20 20 21 22 23 23

Store settings ________________________________ __________________________________________________ ________________________________23 ______________23 Restore settings _________________________________ ___________________________________________________ _____________________________23 ___________23 Return to the default values _________________________________ __________________________________________________ ____________________23 ___23

Store / Restore settings ______________________________ ___________________________ 24

Fault log – display and delete _____________________________________25 4.1

Showing stored faults___________________________ _____________________________ ___ 25

4.2

Showing saved faults with operating hours ____________________________ _____________ 25

4.3

Delete all stored faults __________________________ _____________________________ ___ 25

5

How to proceed when updating controller software __________________27

6

How to proceed when replacing r eplacing components _______________________28 2 of 36

7

6.1

Replacement of an electronic control unit _____________________________ _____________ 28

6.2

Replacement of a propel pump _____________________________ ______________________ 28

6.3

Replacement of front wheel drive proportioning valve block ___________________________ 28

6.4

Replacement of an auger or conveyor pump ___________________________ _____________ 28

6.5

Replacement of a tamper or vibration pump ___________________________ _____________ 28

6.6

Which components can be replaced without an adjustment procedure? _________________ 29

Fault codes ____________________________________________________ ____________________________________________________30 7.1

Overview ___________________________ _____________________________ _____________ 30

7.2

Description of fault reactions______ ______________________________ _________________ 31

7.3

Detailed description of fault codes and their possible causes __________________________ 32 7.3.1 7.3.2 7.3.3

8

General _______________________________________________________________ 32 Relay engine shutdown ______________________________ ___________________________________________________ _____________________ 32 Brake valve ________________________________________________ ____________ 32

Input codes____________________________________________________34 8.1

Command codes __________________________ _____________________________ ________ 34 8.1.1 8.1.2

8.2

Fault log___________________________ ________________________________________________________ _____________________________ _______ 34 Changing the machine code _______________________________________________ 34

Display codes ____________________________ _____________________________ ________ 35 8.2.1 8.2.2 8.2.3

General _______________________________________________________________ 35 Brake _____________________________ _____________________________ _______ 35 35 Hydraulics _____________________________________________________________ 35

3 of 36

1

Confirmation of changes

1.1 Document Version 1.00 1.10 1.20 1.30

1.40

Date Description of changes 15.05.2011 Initial version. 11.10.2011 3.2.4 Teach L.C.S. potentiometers max. values, display codes updated. 23.03.2012 3.2.3.2 Adjust tamper ramps. 02.10.2012 Chapter “Enable/disable hoppers front flap” added. Chapter “Block screed extensions during transport (BF800P with road homologation only) added. Chapter “Adjustments” added. 05.12.2012 Chapters added: “Steer with spin switch”, “Change speed potentiometer type”, “Enable / disable force heating in LOW idle”, “Enable / disable lifting auger box with screed”, “Enable / disable cleaning function” (SCU and MCU), “Return to the default values” (SCU and MCU), “Store / Restore settings”, “How to proceed when updating controller software”, s oftware”, “Replacement of a auger or conveyor pump”, “Replacement of a tamper or vibration pump”, “Command Codes”, “Display Codes”

Resp. M. Nick M. Nick M. Nick M. Peri

M. Peri / M. Nick

1.2 Glossary

MCU SCU TCU

Description Material flow control unit Screed control unit Tractor control unit

4 of 36

1.3

Software

Control Unit

Version Start

Version End

Software Part Number Comment

TCU, A34

0.19 (Setup_19_17)

05767318

SCU, A121 MCU, A121

0.17 (Setup_19_17)

05767319

Support BF800 P and BF800 P with stage IIIA and stage IIIB engines

The TCU and its dedicated software basically supports the propel systems of crawler and wheel machines. The MCU and SCU are using the same software, in doing so the MCU controls the material flow functions and the SCU the screed functions. The software for a BF800 machine always consists of compatible setup, named Setup_xx_xx , containing a TCU software and common software for SCU and MCU.

5 of 36

2

The main display

Button 1

14

Button 2

2.1 General display functions and operation Apart from its normal display function the LC display is also able to show error codes. Currently existing faults and warnings are displayed by flashing. If several faults are detected, the displayed fault codes will change in a 3 second cycle. Display values are permanently displayed, whereby values values from 0000...9999 are possible. Negative values are identified by a "minus sign". The following chapter describes the operation of the LC display with the dedicated buttons.

2.1.1

Entering input codes

Note:

The brake has to be engaged (indicated by LED 14) to get in input mode.

For this purpose the display must be switched in the input mode. This is accomplished by pressing Button 1 and 1 and Button Button 2 simultaneously 2 simultaneously for at least 2 sec. When the input mode is active 0000 is 0000 is shown in the display and the most left digit is blinking.

2.1.2

Calling up service mode

In order to call the service mode the input mode has to be reached before. Here service code 0001 provides the possibility to change to the service mode. The Button 1 can 1 can be used to increase the value of the corresponding digit. By operating Button 2 the 2 the next right will start to flash. If the most right digit is reached and Button 2 is 2 is pressed again the selected code is entered. The service mode is indicated by a wrench symbol.

6 of 36

3 Settings 3.1 3.1.1

General Machine type

Since the same control can be used for different pavers (option) with different traction systems, it is necessary to adjust the machine type after installing a new control. This is necessary during first time commissioning as well as in case of a spare parts installation. This type adjustment is necessary, because the machines may e.g. be equipped with different valves, propel pumps, etc. 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. 0720. The following machine types can be adjusted: Machine type Default BF 800 P TCU BF 800 C TCU

First serial number

Last serial number

Code

-

-

7870

Available from version 0.01

XXX XXXX XXXXX XXX XXXX XXXXX

XXX XXXX XXXXX XXX XXXX XXXXX

7873 7878

0.22 0.10

7 of 36

3.2 Tractor control (TCU) 3.2.1

Propel system

3.2.1.1 Learn function for the start currents of the propel pumps (BF800 C only) only) For a sensitive and exact function of the propel system the start currents of the propel pumps must be determined for both propel directions and for both tracks. The start currents are determined after entering a code number, so that no electric meter is required. The start currents must only be determined during initial commissioning in the factory, after the control on a propel pump or the complete propel pump has been replaced during service or after the replacement of the TCU. The learn process is identical for both tracks: After entering the respective code number the current for a control solenoid of the propel pump is increased in steps of 5mA, starting from the default value for the minimum current (e.g. 185mA). After each current increase the system waits for 3 seconds. If a considerable movement of a track is performed the related current value is memorised. In order to enhance the result this measurement is performed five times. The final start current is the mean value of these measurements. This start 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 teaching process. Attention! During learning the machine will move when the start current is reached! Do not leave the machine while the teach function is progressing! During learning keep an eye on your environment! To stop the machine reset the travel lever to neutral position or press the park-brake-button! How to perform the learning of the start currents of the propel pumps? Note:

• • • • • •

•

•

• •

• •

At first the machine has to be moved with min. half speed and high gear (rabbit) in order to ensure that the speed signals are validated!

Start the engine The engine speed selection switch must be in ECO position. The gear selection switch must be in Low (turtle) position. If necessary enter code number 0001 to 0001 to access the service mode. The travel lever has to be in neutral position. 1090. This code number activates the function "Learn start currents of the propel Then enter 1090. 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 learn function has been completed or the machine has been restarted. The learning (forward/backward) must be started by entering a code number. The code number number required to learn the left side start currents is as follows: Determination of control start currents left 1091 After the input of the above code number the display shows "F O R E". Shifting Shifting the travel lever lever to the forward position starts the first start current learning for the forward travel of the left track. During the learning process the actual current is displayed (display value = current in mA). As soon as the machine starts moving, a current value is memorised. Once the start current learning is finished the display display will show the “O K”. After a wait time time the display display changes to "B A C K". Now shift the travel lever to the backward position to start the start current learning for the backward travel of the left track. During the measurement the actual current is displayed (display value = current in mA). As soon as the machine starts moving, a current value is memorised. After completion completion of the backward learning learning process the display will show “O K”. The travel lever must now be returned to neutral position.

8 of 36

•

•

• •

• • •

• •

Now the display will show “0 0 0 0”. In order to continue with with learn procedure of the right-side the following code number is required: Determination of control start currents right 1092 After the input of the above code number the display shows "F O R E". Shifting Shifting the travel lever lever to the forward position starts the first start current learning for forward travel of the right track. During the learning process the actual current is displayed (display value = current in mA). As soon as the machine starts moving, a current value is memorised. Once the start current learning is finished the display display will show the “O K”. After a wait wait time the display reading changes to to "B A C K ". ". Now shift the travel lever to the backward position to start the start current learning in backward. During the learning the actual current is displayed (display value = current in mA). As soon as the machine starts moving, a current value is memorised. After completion completion of the backward learning learning process the display will show “O K”. The travel lever must now be returned to neutral position. Once all start currents have have been learned correctly and the travel lever lever is in "neutral position", the display shows "D O N E" then “E X I T”, the values are saved and the function is completed. Now the machine can be operated again with the travel lever. The new start current values for the propel system are are valid valid from the next start. The learn function can at any time be aborted by operation of the emergency stop or the ignition switch.

3.2.1.2 Teach the forward and backward start currents of the propel pumps (BF800 C only) • • • •

•

Start the engine If necessary enter code number 0001 to 0001 to access the service mode. The travel lever has to be in neutral position. Then enter 1095. 1095. This code number activates the function "Teach start currents of the propel system "; the display now shows the reading “0 0 0 0” with the first digit flashing. In this condition also the steer direction LEDs are flashing. From this point the machine can no longer be operated with the steering wheel! The teaching must be started by entering a code number. The code number required to teach the forward start currents is as follows: 1096

Attention! During teaching the machine will move in straight line direction! Do not leave the machine while the teach function is progressing! During teaching keep an eye on your environment! •

After the input of the above code number the display shows "F O R E". Shifting Shifting the travel lever lever to the forward position and applying a speed command with the speed potentiometer starts the start current teaching for the forward travel of both crawlers. During the teaching process the actual current offset is displayed (display value = current offset in mA). Depending on the steering wheel position the displayed offset value is added to base value on the one side and subtracted from the base value on the other side.

Note:

•

• • • • •

To stop the machine reset the travel lever to neutral position or press the park-brakebutton!

Once the desired desired offset value value is adjusted the travel lever lever must be returned to the neutral position position and speed potentiometer has to be returned to the zero position. Keep the position of the steering wheel! The display display will show “O K” and the adjusted value value is memorised. Then the display now shows the the reading “0 0 0 0” with the first digit flashing. Now the steering wheel should be returned to the neutral position. Enter the code number 1097 to teach the backward start currents is as follows: After the input of the above code number the display shows "B A C K". Shifting Shifting the travel lever lever to the backward position and applying a speed command with the speed potentiometer starts the start current teaching for the backward travel of both crawlers. During the teaching process the actual current offset is displayed (display value = current offset in mA). Depending on the steering wheel position the displayed offset value is added to base value on the one side and subtracted from the base value on the other side.

9 of 36

•

• • • •

Once the desired desired offset value value is adjusted the travel lever lever must be returned to the neutral position position and speed potentiometer has to be returned to the zero position. The display display will show “O K and the adjusted value is memorised. The display will show “D O N E”. The steering wheel must now be returned to the neutral position. Then “E X I T” will be shown in the display, the offset value value will will be saved and the function is completed. The steer direction LEDs stop flashing. Now the machine can be operated again with the steering wheel.

3.2.1.3 Learn function for the start currents of the front wheel drive proportioning valves valves (BF800 P only) This learning function determines the start currents for the four front wheel drive proportioning valves. A suitable start current is detected and stored as soon as a good pressure level at proportional valve output is present. The learning procedure works with following order: 1. front left, 2. front right, 3. mid left, 4. mid right. • • • • • • • • • •

•

Start the engine The engine speed selection switch must be in ECO position. The hydraulic gear selection switch must be in Low (turtle) position. position. The mechanical gear selection switch must be in Low (L) position. position. The speed potentiometer must be set to position “0.5”. The wheel torque front traction potentiometer must be set to position “50”. Then front wheel drive must be switch on. Enter code number 0001 to 0001 to access the service mode. The travel lever has to be in neutral position. Then enter 1095. 1095. This code number activates the learn function. The display now shows the reading “0 0 0 0” with the first digit flashing. Enter code 1096 to start the learning function.

Attention! During learning procedure machine will move! Do not leave the machine while the learning function is progressing! During learning keep an eye on your environment! • • • •

After the input of the above code number the display display shows "F O R E". E". Shift the travel lever to the forward position. The display shows "R U N". The actual front left current is displayed (display value = current in mA).

Note:

• • • • • • • • • •


Once the start current for the front left proportioning valve is is learned the display will show “O K”. The actual front right current is is displayed displayed (display value = current in mA). Once the start current for the front right proportioning valve is learned the display will show “O K”. The actual mid left current is displayed (display value = current in mA). Once the start current for the mid left proportioning valve is is learned the display will show “O K”. The actual mid right current is displayed (display value = current in mA). Once the start current for the mid right proportioning valve is learned the display will show “O K”. The display will show “D O N E”. Return the travel lever to the neutral position. Then “E X I T” will will be shown in the display, display, the learned start current values will be saved and the function is completed

10 of 36

3.2.1.4 Speed command by Boost Boost button in case of of a broken speed potentiometer This override mode for speed the potentiometer is only available if an error related to speed potentiometer is present (fault codes: 1020, 1021, 1022, 1025,1026). With a P-machine the work mode has to be selected additionally. As long as the speed command by Boost button mode is active the Boost function of the L.C.S. is not available. Proceed the following steps to enable the speed command by Boost button mode: Switch ignition on. Don’t start the engine! Enter code 0001 with 0001 with the display buttons in order to get in the service mode (wrench symbol). Enter code 1100 with 1100 with the display buttons in order to allow changes of parameters related to the propel system. Enter code 1121 with 1121 with the display buttons in order to enable the speed command by Boost button mode. Enter the code 0000 in 0000 in order to leave the service mode. • • •

•

•

From now on a speed command can be applied if the operator brings the travel lever to the forward or backward position and keeps the Boost button pressed. The machine will accelerated in the requested direction as long as the operator keeps the Boost button pressed until the maximum speed is reached. As soon as the operated brings the travel lever back to neutral position the machine stops. Note:


In order start again the operator has to bring the travel lever out of the neutral position and keep the boost button pressed until the desired speed is reached. Once the potentiometer fault is not present anymore, e.g. after a repair, the speed command by Boost button mode is disabled automatically in next ignition cycle. If the speed command by Boost button mode has to be disabled manually the following steps have to be executed: Switch ignition on. Don’t start the engine! Enter code 0001 with 0001 with the display buttons in order to get in the service mode (wrench symbol). Enter code 1100 with 1100 with the display buttons in order to allow changes of parameters related to the propel system. Enter code 1122 with 1122 with the display buttons in order to disable the speed command by Boost button 0000 in order to leave the service mode. mode. Enter the code 0000 in

• • •

•

3.2.1.5 Steer with spin switch switch in case of a broken steering wheel transducer (BF800 C only) only) This override mode for the steering wheel transducer is only available if at least one error related to steering wheel transducer is present (fault codes: 2010 to 2017). As long as the steer with spin switch mode is active the Boost function of the L.C.S. is not available. • • •

•

Switch ignition on. Don’t start the engine! Enter code 0001 with 0001 with the display buttons in order to get in the service mode (wrench symbol). Enter code 1100 with 1100 with the display buttons in order to allow changes of parameters related to the propel system. Enter code 2021 with 2021 with the display buttons in order to enable the steer with spin switch m ode. Enter the code 0000 in 0000 in order to leave the service mode.

From now on a fixed steer command can be applied by using the spin switch for steering to the left or by using the spin switch + Boost button for steering to the right. The steering emergency mode works only if the travel lever is in neutral position. Once the steering wheel transducer fault is not present anymore, e.g. after a repair, the steer with spin switch mode is disabled automatically in next ignition cycle. If the steer with spin switch mode has to be disabled manually the following steps have to be executed: Switch ignition on. Don’t start the engine! Enter code 0001 with 0001 with the display buttons in order to get in the service mode (wrench symbol). Enter code 1100 with 1100 with the display buttons in order to allow changes of parameters related to the propel system. Enter code 2022 with 2022 with the display buttons in order to disable the steer with spin switch m ode. Enter the code 0000 in 0000 in order to leave the service mode.

• • •

• •

11 of 36

3.2.1.6 Change speed potentiometer type type BF800 machines were equipped with speed potentiometers with parallel output signals as well as with speed potentiometers with cross output signals. The TCU software supports both types of potentiometers. Follow the procedures below to do the correct setting: Speed potentiometer with parallel output signals: Switch ignition on. Don’t start the engine! Enter code 0001 with 0001 with the display buttons in order to get in the service mode (wrench symbol). Enter code 1100 with 1100 with the display buttons in order to allow changes of parameters related to the propel system. Enter code 1131 to enable the monitoring of a potentiometer with parallel output signals (older machines). Switch ignition off/on.

• • •

•

•

Speed potentiometer with cross output signals: Switch ignition on. Don’t start the engine! Enter code 0001 with 0001 with the display buttons in order to get in the service mode (wrench symbol). Enter code 1100 with 1100 with the display buttons in order to allow changes of parameters related to the propel system. Enter code 1130 to enable the monitoring of a potentiometer with cross output signals. Switch ignition off/on.

• • •

• •

3.2.1.7 Drive against closed brake • • • •

•

• •

• •

Start the engine. The travel lever has to be in neutral position. Enter the code 0001 with 0001 with display buttons in order to get in the service mode (wrench symbol). Enter the code 0500 in 0500 in order to start the mode drive against closed brake. From now on the brake LED 11 is blinking. Shift the travel lever to the forward or backward position position and apply a speed command with the speed potentiometer in order to control the propel pump. Then the display now shows the the reading “0 0 0 0” with the first digit flashing. Bring the travel lever back to neutral and enter the code 0501 in 0501 in order to quit the mode drive against closed brake. The brake LED 11 stops blinking and will be lightened permanently. The display will show the reading “0 0 0 0” with the first digit flashing. Enter the code 0000 in 0000 in order to leave the service mode.

3.2.1.8 Block screed extensions during transport (BF800P with road homologation homologation only) If the BF800P is equipped with road homologation kit, it is necessary, for safety reasons, to inhibit the movement of the screed extension when in transport mode. Switch ignition. Don’t start the engine. First get into the to service mode (code 0001). 0001). Enter 3175 to 3175 to enable road homologation. Enter 3176 to 3176 to disable road homologation. Switch ignition off /on

• • • • •

12 of 36

3.2.2 Miscellaneous 3.2.2.1 Enable / disable disable force heating in LOW idle Starting from software version 0.24 / 0.21, any screed heating request - when no further power request is present - will accelerate engine up to 1300rpm, independently from the position of the engine speed switch. Attention! In case of screed width greater than 8m, it necessary to disable the “heating in LOW idle” function! To disable heating in LOW idle: Switch ignition. Don’t start the engine. 0001). First get into the to service mode (code 0001). Enter 5041. 5041. Enter the code 0000 in 0000 in order to leave the service mode

• • • •

To enable back heating in LOW idle: Switch ignition. Don’t start the engine. First get into the to service mode (code 0001). 0001). Enter 5040. 5040. Enter the code 0000 in 0000 in order to leave the service mode.

• • • •

3.2.2.2 Enable / disable cleaning cleaning function Starting from software version 0.24 / 0.21, it has been introduced the possibility to activate the cleaning function on BF800 by “triple-click” from the load switch. Note:

The function is enabled by default!

To disable the cleaning function: Switch ignition. Don’t start the engine. 0001). First get into the to service mode (code 0001). Enter 5614. 5614. Enter the code 0000 in 0000 in order to leave the service mode

• • • •

To enable the cleaning function: Switch ignition. Don’t start the engine. First get into the to service mode (code 0001). 0001). Enter 5613. 5613. Enter the code 0000 in 0000 in order to leave the service mode.

• • • •

3.2.2.3 Store settings • •

• • • • •

Switch ignition on. Don’t start the engine. First get into the to service mode (code 0001). 0001). Enter 8887 to 8887 to enable storing. Enter 8889 Enter 8889 for for storing the settings. Wait! The store process can take time up to 10 seconds. “O K” is shown shown in the display display to confirm that the settings were were successfully stored. Enter the code 0000 in 0000 in order to leave the service mode.

3.2.2.4 Restore settings • •

•

Switch ignition on. Don’t start the engine. First get into the to service mode (code 0001). 0001). Enter 8887 to 8887 to enable storing.

13 of 36

• • • • •

Enter 8888 Enter 8888 for for storing the settings. Wait! The restore process can take time up to 10 seconds. “O K” is shown shown in the display display to confirm that the settings were were successfully stored. Enter the code 0000 in 0000 in order to leave the service mode. Switch ignition off/on

3.2.2.5 Return to the default values • •

• • • • •

• •

• •

Switch ignition. Don’t start the engine. First get into the to service mode (code 0001). 0001). Enter 7010. 2. Wait for the reset the TCU will perform. Confirm the machine type “7 8 7 0” with the Button 2. Switch ignition off/on. Check that the machine type code “7 8 7 0” is shown at the start-up. Get into the to service mode (code 0001). 0001). Enter 7010. 7010. Select the machine type type “7 8 7 3” or “7 8 7 8” 8” with the Button 1 and 1 and confirm this code with the Button 2. 2. Wait for the reset the TCU will perform. Switch ignition off/on. Check that the selected selected machine type code is is shown shown at the next start-up.

Attention! It is not possible to move the machine as long as the machine type code 7870 is present.

14 of 36

3.3 Screed control (SCU) 3.3.1

Teach L.C.S. potentiometers max. values

Note:

During teaching procedure the travel lever has to stay in neutral position!

• • • • • • • •

•

• • • • •

• • •

•

• • • • •

Start the engine. Turn all potentiometers to the min. position. Enter the code 0001 with 0001 with display buttons in order to get in the service mode (wrench symbol). Enter the code 3018 in 3018 in order to start the teaching procedure. Then the display now shows the the reading “0 0 0 0” with the first digit flashing. Enter the code 3019 in 3019 in order to teach the WORK max. pressure. After the input of the above code number the display display shows "F O R E". E". Now use the WORK potentiometer to set the the requested max. pressure. At the same time the potentiometer position (range: 0 -1000) shown in the display. Turn the TIMELOCK potentiometer potentiometer from the min. position to the max. position and back to the min. position in order to confirm the pressure setting. The display will show “O K” K” then “D O N E”. Turn the WORK potentiometer to the min. position. Wait until the display shows “E X I T”. After a while the display shows the reading “0 0 0 0” with the first digit flashing. flashing. 0000 in order to leave the service If you don’t want to teach the stop pressure, enter the code 0000 in mode. Otherwise proceed as follows in order to teach the stop pressure. Enter the code 3018 again 3018 again in order to start the teaching procedure. 3020 in order to teach the STOP max. pressure. Enter the code 3020 in Use the STOP potentiometer to set requested requested max. pressure. At At the same time the potentiometer potentiometer position (range: 0 -1000) shown in the display. Turn the TIMELOCK potentiometer potentiometer from the min. position to the max. position and back to the min. position in order to confirm the pressure setting. The display display will show “O K” K” then “D O N E”. Turn the STOP potentiometer to min. position. Wait until until the display shows “E X I T”. After a while the display shows the reading “0 0 0 0” with the first digit flashing. flashing. Enter the code 0000 in 0000 in order to leave the service mode.

15 of 36

3.3.2

Adjust currents for the tamper pump

Adjusting the currents for the tamper pump it is necessary to have an accurate correlation between the set frequency on the display and the actual frequency of the tamper. To achieve this result it is necessary to manually measure the rotation frequency of the shaft of the tamper with an RPM-meter. Note:

Enter command 5611 in advance in order to increase the engine rpm (HIGH idle) with the travel lever while park brake button is pressed!

The start current for current for the tamper pump has to be set in order to have 60 rpm on rpm on the shaft when 1 Hz is set and the engine is in HIGH idle. To adjust the start current of the tamper pump: Start the engine First get into the to service mode (code 0001). 0001). Enter 3120. 3120. The display now shows shows the value in mA of the start current for the pump. By pressing Button 1 it is possible to increase this value. By pressing Button 2 it is possible to decrease this value. When the desired desired current has been set, press both Button Button 1 and Button Button 2 simultaneously. Then the display now shows the the reading “0 0 0 0” with the first digit flashing. Enter 3121 to 3121 to memorize the new value. The display will show the new memorized value and then “D O N E”. E”. After a while the display shows the reading “0 0 0 0” with the first digit flashing. flashing. • • • • • • • • • • •

The maximum current for current for the tamper pump has to be set in order to have 1800 rpm on rpm on the shaft when 30 Hz is set and the engine is in HIGH idle. To adjust the start current of the tamper pump: Start the engine First get into the to service mode (code 0001). 0001). Enter 3122. 3122. The display display now shows the value value in mA of the maximum current for the pump. pump. By pressing Button 1 it is possible to increase this value. By pressing Button 2 it is possible to decrease this value. When the desired desired current has been set, press both Button Button 1 and Button Button 2 simultaneously. Then the display now shows the the reading “0 0 0 0” with the first digit flashing. Enter 3123 to 3123 to memorize the new value. The display will show the new memorized value and then “D O N E”. E”. After a while the display shows the reading “0 0 0 0” with the first digit flashing. flashing. • • • • • • • • • • •

Note:

Enter command 5612 to ensure ensure normal working mode operation!

3.3.3

Adjust tamper ramps

There are two possible settings for the control: 1. Automatic variable ramps: the starting ramp is fixed, the stopping ramp depends on the decelerating ramp of the machine 2. Adjustable manual ramps By default automatic variable ramps are enabled. They can be disabled/ enabled through input codes: Start the engine Enter the code 0001 with 0001 with display buttons in order to get in the service mode (wrench symbol) 3102 to 3102 to enable 3103 to 3103 to disable Enter the code 0000 in 0000 in order to leave the service mode

• • • • •

To manually adjust starting and stopping ramps (faster or slower) a procedure has been introduced:

16 of 36

Note:

The bigger is the value, the faster is the ramp. The smaller is the value, the slower is the ramp.

To adjust the starting ramp for ramp for the tamper: Start the engine. Enter the code 0001 with 0001 with display buttons in order to get in the service mode (wrench symbol) Enter 3104 to 3104 to start modifying the start ramp The display will show the actual value of the ramp The value of the ramp can be modified from 10 to 2000 with a step of 10 Button 1 increases 1 increases the value, Button 2 decreases 2 decreases it When the right value has been found, by pressing for few moments Button 1 and 1 and Button 2 simultaneously, the display will show 0000 with the first figure blinking Enter 3105 to 3105 to finish modifying the start ramp The display will show the new memorized value and then “D O N E”. E”. Enter the code 0000 in 0000 in order to leave the service mode • • • • • • •

• • •

To adjust the stopping ramp for ramp for the tamper: Start the engine. Enter the code 0001 with 0001 with display buttons in order to get in the service mode (wrench symbol) Enter 3106 to 3106 to start modifying the stop ramp The display will show the actual value of the ramp The value of the ramp can be modified from 10 to 2000 with a step of 10 Button 1 increases 1 increases the value, Button 2 decreases 2 decreases it When the right value has been found, by pressing for few moments Button 1 and 1 and Button 2 simultaneously, the display will show 0000 with the first figure blinking Enter 3107 to 3107 to finish modifying the stop ramp The display will show the new memorized value and then “D O N E”. E”. Enter the code 0000 in 0000 in order to leave the service mode • • • • • • •

• • •

So if the operator is not satisfied by the ramps of the tamper, the variable ramps should be disabled first, then manually adjust them. It is also possible to use a manually adjusted starting ramp and leave the stopping ramp automatic.

17 of 36

3.3.4

Adjust currents for the vibration pump

Adjusting the currents for the vibration pump it is necessary to have an accurate correlation between the set frequency on the display and the actual frequency of the vibration. To achieve this result it is necessary to manually measure the rotation frequency of the shaft of the vibration with an RPM-meter. Note:


The start current for current for the vibration pump has to be set in order to have 60 rpm on rpm on the shaft when 1 Hz is set and the engine is in HIGH idle. To adjust the start current of the vibration pump: Start the engine. First get into the to service mode (code 0001). 0001). Enter 3164. 3164. The display now shows shows the value in mA of the start current for the pump. By pressing Button 1 it is possible to increase this value. By pressing Button 2 it is possible to decrease this value. When the desired desired current has been set, press both Button Button 1 and Button Button 2 simultaneously. Then the display now shows the the reading “0 0 0 0” with the first digit flashing. Enter 3165 to 3165 to memorize the new value. The display will show the new memorized value and then “D O N E”. E”. After a while the display shows the reading “0 0 0 0” with the first digit flashing. flashing. • • • • • • • • • • •

The maximum current for current for the vibration pump has to be set in order to have 3600 rpm on rpm on the shaft when 60 Hz is set and the engine is in HIGH idle. To adjust the maximum current of the tamper pump: Start the engine. First get into the to service mode (code 0001). 0001). Enter 3166. 3166. The display display now shows the value value in mA of the maximum current for the pump. pump. By pressing Button 1 it is possible to increase this value. By pressing Button 2 it is possible to decrease this value. When the desired desired current has been set, press both Button Button 1 and Button Button 2 simultaneously. Then the display now shows the the reading “0 0 0 0” with the first digit flashing. Enter 3167 to 3167 to memorize the new value. The display will show the new memorized value and then “D O N E”. E”. After a while the display shows the reading “0 0 0 0” with the first digit flashing. • • • • • • • • • •

Note:


18 of 36

3.3.5 Miscellaneous 3.3.5.1 Store settings • •

• • • • •



• • • • • •

Switch ignition on. Don’t start the engine. First get into the to service mode (code 0001). 0001). 3210 to enable storing. Enter 3210 to Enter 3211 Enter 3211 for for storing the settings. Wait! The restore process can take time up to 10 seconds. “O K” is shown shown in the display display to confirm that the settings were were successfully stored. Enter the code 0000 in 0000 in order to leave the service mode. Switch ignition off/on


• • •

Switch ignition on. Don’t start the engine. First get into the to service mode (code 0001). 0001). Enter 3003. 3003. Enter the code 0000 in 0000 in order to leave the service mode. Switch ignition off/on.

19 of 36

3.4 Material flow control (MCU) 3.4.1 Enable/disable hoppers front flap • •

• •

Switch ignition on. Don’t start the engine. First get into the to service mode (code 0001). 0001). Enter 4160 to enable hoppers front flap (if available as option on the machine). Enter 4161 to 4161 to disable hoppers front flap (if not available on the machine).

3.4.2

Adjust maximum current for augers pumps

By adjusting the maximum current to the pumps it is possible to adjust the maximum speed of the augers. The maximum current has to be set in order to have 104 rpm (+/-4 rpm (+/-4 rpm) on the augers shaft. Note:


To adjust the maximum current of current of the left auger left auger pump: Start the engine. First get into the to service mode (code 0001). 0001). Enter 4060. 4060. The display now shows the value value in mA of the maximum current for the pump. pump. By pressing Button 1 it is possible to increase this value. By pressing Button 2 it is possible to decrease this value. When the desired desired current has been set, press both Button Button 1 and Button Button 2 simultaneously. Then the display now shows the the reading “0 0 0 0” with the first digit flashing. Enter 4061 to 4061 to memorize the new value. The display will show the new memorized value and then “D O N E”. E”. After a while the display shows the reading “0 0 0 0” with the first digit flashing. flashing. • • • • • • • • • • •

To adjust the maximum current of current of the right auger right auger pump: Start the engine. First get into the to service mode (code 0001). 0001). Enter 4062. 4062. The display now shows the value value in mA of the maximum current for the pump. pump. By pressing Button 1 it is possible to increase this value. By pressing Button 2 it is possible to decrease this value. When the desired desired current has been set, press both Button Button 1 and Button Button 2 simultaneously. Then the display now shows the the reading “0 0 0 0” with the first digit flashing. Enter 4063 to 4063 to memorize the new value. The display will show the new memorized value and then “D O N E”. E”. After a while the display shows the reading “0 0 0 0” with the first digit flashing. flashing. • • • • • • • • • • •

Note:


20 of 36

3.4.3

Adjust augers ramps

Note:

The bigger is the value, the faster is the ramp. The smaller is the value, the slower is the ramp.

To adjust the starting ramp for ramp for the augers when manually operated: operated: Start the engine. First get into the to service mode (code 0001). 0001). Enter 4070. 4070. The display now shows the value of the ramp. By pressing Button 1 it is possible to increase this value. By pressing Button 2 it is possible to decrease this value. When the desired desired value has been set, press both Button Button 1 and Button Button 2 simultaneously. Then the display now shows the the reading “0 0 0 0” with the first digit flashing. Enter 4071 to 4071 to memorize the new value. The display will show the new memorized value and then “D O N E”. E”. After a while the display shows the reading “0 0 0 0” with the first digit flashing. flashing. • • • • • • • • • • •

To adjust the stopping ramp for ramp for the augers when manually operated: operated: Start the engine. First get into the to service mode (code 0001). 0001). Enter 4072. 4072. The display now shows the value of the ramp. By pressing Button 1 it is possible to increase this value. By pressing Button 2 it is possible to decrease this value. When the desired value value has been set, press both Button 1 and Button 2 simultaneously. simultaneously. Then the display now shows the the reading “0 0 0 0” with the first digit flashing. Enter 4073 to 4073 to memorize the new value. The display will show the new memorized value and then “D O N E”. E”. After a while the display shows the reading “0 0 0 0” with the first digit flashing. flashing. • • • • • • • • • • •

To adjust the starting ramp for ramp for the augers when automatically operated: operated: Start the engine. First get into the to service mode (code 0001). 0001). Enter 4074. 4074. The display now shows the value of the ramp. By pressing Button 1 it is possible to increase this value. By pressing Button 2 it is possible to decrease this value. When the desired value value has been set, press both Button 1 and Button 2 simultaneously. simultaneously. Then the display now shows the the reading “0 0 0 0” with the first digit flashing. Enter 4075 to 4075 to memorize the new value. The display will show the new memorized value and then “D O N E”. E”. After a while the display shows the reading “0 0 0 0” with the first digit flashing. flashing. • • • • • • • • • • •

To adjust the stopping ramp for ramp for the augers when automatically operated: operated: Start the engine. First get into the to service mode (code 0001). 0001). Enter 4076. 4076. The display now shows the value of the ramp. By pressing Button 1 it is possible to increase this value. By pressing Button 2 it is possible to decrease this value. When the desired value value has been set, press both Button 1 and Button 2 simultaneously. simultaneously. Then the display now shows the the reading “0 0 0 0” with the first digit flashing. Enter 4077 to 4077 to memorize the new value. The display will show the new memorized value and then “D O N E”. E”. After a while the display shows the reading “0 0 0 0” with the first digit flashing. flashing. • • • • • • • • • • •

21 of 36

3.4.4

Adjust maximum current for conveyor conveyor pumps

By adjusting the maximum current to the pumps it is possible to adjust the maximum speed of the conveyors. The maximum current has to be set in order to have 62 rpm (+2 rpm (+2 / -1 rpm) on the shaft of the conveyor motor. Note:


To adjust the maximum current of current of the left conveyor left conveyor pump: Start the engine. First get into the to service mode (code 0001). 0001). Enter 4140. 4140. The display now shows the value value in mA of the maximum current for the pump. pump. By pressing Button 1 it is possible to increase this value. By pressing Button 2 it is possible to decrease this value. When the desired desired current has been set, press both Button Button 1 and Button Button 2 simultaneously. Then the display now shows the the reading “0 0 0 0” with the first digit flashing. Enter 4141 to 4141 to memorize the new value. The display will show the new memorized value and then “D O N E”. E”. After a while the display shows the reading “0 0 0 0” with the first digit flashing. flashing. • • • • • • • • • • •

To adjust the maximum current of current of the right conveyor right conveyor pump: Start the engine. First get into the to service mode (code 0001). 0001). Enter 4142. 4142. The display now shows the value value in mA of the maximum current for the pump. pump. By pressing Button 1 it is possible to increase this value. By pressing Button 2 it is possible to decrease this value. When the desired desired current has been set, press both Button Button 1 and Button Button 2 simultaneously. Then the display now shows the the reading “0 0 0 0” with the first digit flashing. 4143 to memorize the new value. Enter 4143 to The display will show the new memorized value and then “D O N E”. E”. After a while the display shows the reading “0 0 0 0” with the first digit flashing. flashing. • • • • • • • • • • •

Note:


22 of 36

3.4.5

Enable / disable lifting auger box with screed screed

To enable the possibility of lifting the auger box when the screed is lifted: Switch ignition on. Don’t start the engine. First get into the to service mode (code 0001). 0001). Enter 4056 Enter the code 0000 in 0000 in order to leave the service mode.

• • • •

To disable the possibility of lifting the auger box when the screed is lifted: Switch ignition on. Don’t start the engine. 0001) First get into the to service mode (code 0001) Enter 4057 Enter the code 0000 in 0000 in order to leave the service mode.

• • • •

3.4.6 Miscellaneous 3.4.6.1 Store settings • •

• • • • •



• • • • • •

Switch ignition on. Don’t start the engine. First get into the to service mode (code 0001). 0001). Enter 4210 to 4210 to enable storing. Enter 4211 Enter 4211 for for storing the settings. Wait! The restore process can take time up to 10 seconds. “O K” is shown shown in the display display to confirm that the settings were were successfully stored. Enter the code 0000 in 0000 in order to leave the service mode. Switch ignition off/on


• • •

Switch ignition on. Don’t start the engine. First get into the to service mode (code 0001). 0001). Enter 4003 Enter the code 0000 in 0000 in order to leave the service mode. Switch ignition off/on

23 of 36

3.5 Store / Restore settings In order to store individual settings of a machine it is possible to store these settings. It is recommended to store the settings especially if adjustment procedures for ramps or start / maximum current values have been executed. See: 3.2.2.3, 3.2.2.4, 3.3.5.1, 3.3.5.2, 3.4.6.1, 3.4.6.2.

24 of 36

4

Fault log – display and delete

4.1 Showing stored faults Switch on function “Show stored faults”: Switch ignition on. Don’t start the engine 0700 (!! WITHOUT service WITHOUT service code 0001). 0001). This code number enables the function Enter code number 0700 ( “Show stored faults”

• •

The faults stored in the controllers (TCU, MCU, SCU) 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 controllers, the display will show "- - - - - ". In this case the function “Show stored faults” will terminate automatically after 4 seconds. Switch off function “Show stored faults”: Switch ignition on. Don’t start the engine. Enter code number 0701 ( 0701 (!! WITHOUT service WITHOUT service code 0001). 0001). This code number disables the function “Show stored faults”.

• •

Note:

Apart from the stored faults the current faults are also displayed. displayed.

Note:

This function can only be activated / deactivated when the brake is engaged (see chapter 3.1.1).

4.2 Showing saved faults with operating hours Switch on function "Show stored faults with operating hours": Switch ignition on. Don’t start the engine Enter code number 0705 ( 0705 (!! WITHOUT service WITHOUT service code 0001). 0001). This code number enables the function “Show stored faults with operating hours”

• •

The faults stored in the controllers (TCU, MCU, SCU) are displayed in a flashing mode. If several faults are saved, you can select these one after the other with the Button 1. 1. Pressing the Button 2 displays 2 displays the operating hour at which the fault code occurred last. By pressing the Button 2 again 2 again the number of occurrences of the fault since the last reset of the fault memory can be displayed. After the last fault has been displayed, the first fault will appear again. If no faults are stored in the controllers, the display will show " - - - - - ". In this case the function “Show stored faults” will terminate automatically after 4 seconds. Switch off function "Show stored faults f aults with operating hours": Switch ignition on. Don’t start the engine Enter code number 0706 ( 0706 (!! WITHOUT service WITHOUT service code 0001). 0001). This code number disables the function “Show stored faults”.

• •

Note:

Apart from the stored faults the current faults are also displayed. displayed.

Note:


4.3 Delete all stored faults Execute the function “Delete all stored faults”: Switch ignition on. Don’t start the engine Enter code number 0710 ( 0710 (!! WITHOUT service WITHOUT service code 0001) 0001) Switch the ignition off and on again

• • •

25 of 36

All stored faults are now deleted. Note:


26 of 36

5

How to proceed when updating controller software

Actually it is possible to update the software of the TCU, MCU and SCU. In case of a software update it has to be taken into consideration that all controllers have to be updated with compatible software version. Therefore software setups are available.

Before a software update is update is executed it is recommended to store the settings of TCU, MCU and SCU. See: 3.2.2.3, 3.3.5.1, 3.4.6.1. After a software update (new update (new version) default parameters are selected. Individual are not available anymore. In order to restore individual setting use the procedures described in 3.2.2.4, 3.3.5.2, 3.4.6.2.

Note: If the fault code 5100 occurs after a TCU software update switch ignition off and wait for 20 seconds. This time is needed by electronic engine control to perform a shutdown. Note: If the fault code 1022 1022 occurs after a TCU software update use the procedure described in 3.2.1.6 to enable the correct setting Note: If the indication of voltage or frequency does not work as expected after a TCU software update use Button 2 to correct the display setting.

27 of 36

6

How to proceed when replacing components

Each machine is adjusted individually during initial commissioning. This adjustment or teaching process is necessary to make sure that the travel and steering functions are almost identical on all machines. Background of these adjustment procedures are the tolerances of the components used, e.g. hydraulic pump for travel system and The TCU. These tolerances apply for both mechanical as well as electrical functions and are unavoidable for manufacturing reasons. To enable simple and quick adjustment procedures we have decided to do without expensive tools. All that is needed is this manual and a bit of time. By following the described procedure it is possible to take a machine back into operation after the replacement of one of the components specified above and to re-establish the usual functional quality, with almost any previous knowledge. Even an incorrectly or incompletely conducted teaching procedure can be repeated without problems as often as necessary. At the first glance it seems to be at bit awkward to perform this adjustment work on every machine, but this procedure enables the operation of all machines with the same operating software. At the end of the day this considerably increases the spare parts availability. availability.

6.1 Replacement of an electronic control unit Since the control stores all teach values of the machine, each learning / teaching procedure must be performed with the new control after a replacement. Attention! Before performing one of the following steps, the machine type must first be set (see 3.1.1)! When changing the machine type all previously made adjustments will be lost! Now the teach functions must be executed. • •

Learn function for the start currents of the propel system (see 3.2.1.1) If necessary teach function function for the start currents of the propel system (see 3.2.1.2)

6.2 Replacement of a propel pump Now the following functions must be executed. Learn function for the start currents of the propel pumps (see 3.2.1.1) If necessary teach function function for the start currents of the propel pump (see 3.2.1.2)

• •

6.3 Replacement of front wheel drive drive proportioning valve block Now the following functions must be executed. Learn function for the start currents of the front wheel wheel drive proportional valves (see 3.2.1.3) 3.2.1.3)

•

6.4 Replacement of an auger or conveyor conveyor pump Now set the proper maximum current, depending on which pump has been replaced. In case of auger pump (see 3.4.2). In case of conveyor pump (see 3.4.4).

• •

6.5 Replacement of a tamper or vibration pump Now set start and maximum currents for the new pump. In case of tamper pump (see 3.3.2) In case of vibration pump (see 3.3.4)

• •

28 of 36

6.6

• • • • • • • • •

Which components can be replaced without an adjustment procedure? Display Diesel engine Engine controller All switches in the dashboard and side panels. Steering transducer (A45) Speed potentiometer (R07) Hydraulic on/off valves L.C.S. hydraulic block All hydraulic pumps beside propel pumps, pumps, auger pump, conveyor conveyor pump, tamper and vibration pump (see 6.2 to 6.5)

Note:

A final function test of the complete machine is highly recommended. recommended.

29 of 36

7

Fault codes

7.1 Overview Fault code 0000

-

0999

1000

-

1999

2000

-

2499

2500

-

2999

3000

-

4499

4500

-

4999

5000

-

5499

5500

-

5999

6000

-

6999

7000

-

7499

7500

-

7899

7900

-

7999

8000

-

8999

9000

-

9999

Fault description General faults / warnings / machine tests Fault in propel system Fault in steering system Reserved Fault in work functions (screed control, material flow control) Reserved Fault related to the diesel engine Fault related to the hydraulic system Reserved Input of machine codes Reserved Operating hours, load spectrum, etc. Severe software error 1 Errors of external IO-nodes (data collector, module, LC-display, etc.)

1

Not all of these fault codes are decrypted here; please ask the after sales service for assistance!

30 of 36

7.2

Description of fault reactions

Fault reaction Description of fault reaction 1 Warning Fault code is displayed. No audible No audible signal! 2

Warning Horn Fault code is displayed. Audible signal!

3

Function Interference The faulty function is replaced by an emergency function. Fault code is displayed. Audible signal!

4

Partial Error 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

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

6

Fatal Error The function of the control can no longer be guaranteed. Control is switched off. off. The diesel engine is shut down, if possible. possible. The fault code is displayed; the signal light in the monitoring board is permanently on. No audible No audible signal!  

Note:

Errors with error reaction 1 and 2 are only warning messages and are NOT stored in the error log!

31 of 36

7.3

Detailed description of fault codes and their possible possible causes

All fault codes are shown in the documents: _error_list_BF800C_20xx_xx_xx.pdf, _error_list_BF800C_20xx_xx_xx.pdf

7.3.1 General Fault Code

7.3.2

Fault description

Possible causes

Terminal

Input code for diagnosis

Fault reaction

Possible causes

Terminal


Fault reaction

Relay engine shutdown

Fault Code

Fault description

510

Relay engine shutdown short circuit Ub Signal outside the valid range (see signal description)



The connecting cable has short circuit to battery voltage.

3

511

Relay engine shutdown short circuit to ground Signal outside the valid range (see signal description)



The connecting cable has short circuit to ground. Coil defective.

3

Relay engine shutdown line break The required control power cannot be transmitted to the control solenoid.



512

7.3.3 Fault Code 1001

1002 1003





The connecting line between output of control and control solenoid is interrupted. The solenoid is defective.

3

Brake valve Fault description

Brake valve line break The required control power cannot be transmitted to the control solenoid. Brake valve short circuit to ground Signal outside the valid range (see signal description). Brake valve short circuit Ub

Possible causes



   

The connecting line between output of control and control solenoid is interrupted. The solenoid is defective. The connecting cable has short circuit to ground. Coil defective. The connecting cable has short circuit to battery voltage.

Terminal


Fault reaction 5

5 5

32 of 36

7.3

Detailed description of fault codes and their possible possible causes

All fault codes are shown in the documents: _error_list_BF800C_20xx_xx_xx.pdf, _error_list_BF800C_20xx_xx_xx.pdf

7.3.1 General Fault Code

7.3.2

Fault description

Possible causes

Terminal


Fault reaction

Possible causes

Terminal


Fault reaction

Relay engine shutdown

Fault Code

Fault description

510

Relay engine shutdown short circuit Ub Signal outside the valid range (see signal description)



The connecting cable has short circuit to battery voltage.

3

511

Relay engine shutdown short circuit to ground Signal outside the valid range (see signal description)




3

Relay engine shutdown line break The required control power cannot be transmitted to the control solenoid.



512

7.3.3 Fault Code 1001

1002 1003





The connecting line between output of control and control solenoid is interrupted. The solenoid is defective.

3

Brake valve Fault description

Brake valve line break The required control power cannot be transmitted to the control solenoid. Brake valve short circuit to ground Signal outside the valid range (see signal description). Brake valve short circuit Ub

Possible causes



   

Terminal


The connecting line between output of control and control solenoid is interrupted. The solenoid is defective. The connecting cable has short circuit to ground. Coil defective. The connecting cable has short circuit to battery voltage.

Fault reaction 5

5 5

32 of 36

Fault Code

1004

Fault description

Signal outside the valid range (see signal description). Brake valve BTS over temperature Overheating of output driver in the controller.

Possible causes

 


Terminal


Fault reaction

5

33 of 36

Fault Code

1004

Fault description

Signal outside the valid range (see signal description). Brake valve BTS over temperature Overheating of output driver in the controller.

Possible causes

 

Terminal



Fault reaction

5

33 of 36

8

Input codes

Display and adjustment functions can generally only be accessed by entering "service code" 0001 beforehand!

8.1

Command codes

All command codes are shown in the documents: _disp_comm_list_BF800C_20xx_xx_xx.pdf, disp_comm_list_BF800P_20xx_xx_xx.pdf

8.1.1

Fault log

Without service code! Input code 0700 0701 0705

0706 0710

8.1.2

Description of display function Function "Show "Show stored faults” faults” activated Function "Show "Show stored faults” faults” deactivated Activate function "Stored "Stored faults with data” data”

Deactivate function "Stored "Stored faults with data” data” Activate function “Delete “Delete stored faults” faults”

Display values Fault codes are displayed one after the other 0000

Fault codes are displayed, jump to the next fault with the up or down key, press key left to view the number of occurrences, press key right to view the time of the last occurrence. Once the fault log is deleted it is returned to 0000

Changing the machine code

Input code 7010

Description of display function Change machine type code

Display values see chapter "Change machine code"

34 of 36

8

Input codes

Display and adjustment functions can generally only be accessed by entering "service code" 0001 beforehand!

8.1

Command codes

All command codes are shown in the documents: _disp_comm_list_BF800C_20xx_xx_xx.pdf, disp_comm_list_BF800P_20xx_xx_xx.pdf

8.1.1

Fault log

Without service code! Input code 0700 0701 0705

0706 0710

8.1.2

Description of display function Function "Show "Show stored faults” faults” activated Function "Show "Show stored faults” faults” deactivated Activate function "Stored "Stored faults with data” data”

Deactivate function "Stored "Stored faults with data” data” Activate function “Delete “Delete stored faults” faults”

Display values Fault codes are displayed one after the other 0000

Fault codes are displayed, jump to the next fault with the up or down key, press key left to view the number of occurrences, press key right to view the time of the last occurrence. Once the fault log is deleted it is returned to 0000

Changing the machine code

Input code 7010

Description of display function Change machine type code

Display values see chapter "Change machine code"

34 of 36

8.2

Display codes

All display codes are shown in the documents: _disp_comm_list_BF800C_20xx_xx_xx.pdf, disp_comm_list_BF800P_20xx_xx_xx.pdf

8.2.1 General Input code 0555 3200 4200 0720

Description of display function Display of TCU software version Display of SCU software version Display of MCU software version Display of machine type code

Display values E.g. 1.13 for software version V 0.21

Description of display function Display of voltage at control output valve brake

Display values V (e.g. 12.6 corresponds with 12,6V)

The machine type code is displayed 78xx (see chapter 3.6)

8.2.2 Brake Input code 1001

8.2.3 Hydraulics Input code 5500

Description of display function Display state hydraulic oil main circuit filter

Display values 0 = Hydraulic oil filter OK 1 = Hydraulic oil filter contaminated

35 of 36

8.2

Display codes

All display codes are shown in the documents: _disp_comm_list_BF800C_20xx_xx_xx.pdf, disp_comm_list_BF800P_20xx_xx_xx.pdf

8.2.1 General Input code 0555 3200 4200 0720

Description of display function Display of TCU software version Display of SCU software version Display of MCU software version Display of machine type code

Display values E.g. 1.13 for software version V 0.21

Description of display function Display of voltage at control output valve brake

Display values V (e.g. 12.6 corresponds with 12,6V)

The machine type code is displayed 78xx (see chapter 3.6)

8.2.2 Brake Input code 1001

8.2.3 Hydraulics Input code 5500

Description of display function Display state hydraulic oil main circuit filter

Display values 0 = Hydraulic oil filter OK 1 = Hydraulic oil filter contaminated

35 of 36

36 of 36

Service Training Electric BF800

Recommend Documents