BW177-213-226 Series 4 Service Training

Service Training
Variocontrol
Single drum roller - 4
BW 177 / 213 / 226 BVC
Teile-Nr. 008 099 94 12/2004

Service Training
Table of contents
Foreword A1
Documentation A2
General B1
Peculiarities B3
Electric steering C1
Steering circuit C2
Steering pump C4
Steering wheel C5
Steering valve C6
Steering angle sensor C12
Trouble shooting C15
Compaction measuring system D1

BEM D1
BTM plus D2
BTM prof. D3
BVC D4
BVC - System E1
Exciter system E4
Gear pump E5
Valve block E7
Swashing motor E9
Acceleration transducer E 10
MESX-control E 11
BOP E 12
Working principle of the system F1
Variocontrol Single Drum Rollers Series 4

Service Training
Repair and adjustments G1
Replacement of swashing motor G2
Replacement of potentiometer G3
Potentiometer adjustment G4
Trouble shooting H1
Electrics I1
Service Training
MESX - Service Training
Wiring diagram
Hydraulic diagrams
Variocontrol Single Drum Rollers Series 4

Service Training
Foreword
Reliable construction equipment is of greatest advantage for all parties involved:
• for the customer/user it is a basis for an exact calculation of utilization periods and the completion of
projects as scheduled.
• in the rental business it means that the equipment can be reliably used and planned without having
to stock a large number of stand-by machines.
• for the manufacturer it means that customers are satisfied, provides him with a good image and gives
him a feeling of confidence.
It is BOMAG’s philosophy to design and produce the machines with highest possible reliability. This
aspect of simple and easy maintenance was one of the key issues when developing and designing the
machine:
• the location of components in the machine eases maintenance work,
• the high quality standard of BOMAG is the basis for the considerable extension of the service and
maintenance intervals.
• the After Sales Service of BOMAG, including excellent operating and maintenance instruction
manuals, high quality training courses and on-site machine demonstrations helps the customer to
maintain their machines in good condition over a long period of time.
Permanent training of BOMAG’s own service personnel as well as the service personnel of BOMAG
Profit Centres and dealers is therefore a general prerequisite for BOMAG’s excellent world-wide service.
This program of permanent training is only possible with appropriate and up-to-date training material for
trainers as well as persons attending the training courses.
This training manual has not only been written as a support for the professional work of the trainer, but
also for the trainees attending these training courses.
The different levels of product training demand, that the training performed by BOMAG, its Profit Centres
or its dealers reflects the high quality of the training conducted at the Training Centre at BOMAG in
Boppard. For this reason we invested a lot of time in the preparation of these materials .
The structure of this training manual enables us to change or up-date individual chapters in case of
alterations to the machine.
Variocontrol Single Drum Rollers Series 4 -A1-

Service Training
Documentation
These Variocontrol training documents are valid for the following single drum rollers of series 4:
BW 177 DH-4 BVC
BW 213 DH-4 BVC
BW 213 DH-4 BVC + vibratory plates
BW 226 DH-4 BVC
For the BOMAG machines described in this training manual the following documentation is additionally
available:
Attention!
The currently valid part numbers for the documents can be taken from the Doclist or the
Customer Service page in the BOMAG (BOMAG Secured Area) in accordance with the serial
number of the machine.
1. Operating and maintenance instructions

2. Spare parts catalogue
3. Wiring diagram *
4. Hydraulic diagram *
5. Repair instructions
6. Service Information
* The document versions valid at the date of printing are part of this training manual.
Variocontrol Single Drum Rollers Series 4 -A2-

Service Training
General
BOMAG VARIOCONTROL (BVC)
The increased demands concerning quantity and quality in the application and compaction of soils and
rolled asphalt inevitably requires a permanent further development of vibratory rollers.
From the contractor's point of view a vibratory roller must fulfil three major requirements:
1. efficient operation
2. fulfilment of a task according to specification
3.flexible in use
Due to the inflexible parameterization, standard compaction systems are not able to adapt to the
permanently changing construction conditions in an optimal way.
However, this problem can be solved by the introduction of intelligent compaction systems. The control
values required for an automatic optimization of the compaction parameters are directly gained from the
interaction between drum and material to be compacted.
BOMAG VARIOCONTROL is a compaction system, which improves the quality and reproducibility of
compaction and enhances the efficiency of the roller, independently from the roller operator.
BOMAG VARIOCONTROL offers the user the following advantages:
1.Automatic adaptation of the emitted compaction energy to the actual compaction status
2. Better, reproducible results on all materials
3.No jump operation and therefore no particle destruction or loosening of material
4. The resulting direction of force is automatically adapted to the travel direction. This improves the
surface quality of the material and the gradability of the roller.
5.Low vibration loads for driver and environment
The further development of the VARIOCONTROL system for earthwork was founded on experiences
gained with the VARIOMATIC system used for asphalt compaction . The basic difference between
VARIOCONTROL and VARIOMATIC is the new exciter system.
It meets the demands of many users for an "intelligent" roller with automatic adaptation
of compaction.
Variocontrol Single Drum Rollers Series 4 -B1-

Service Training
Part of this new further development is the new display and control element BOP (Bomag
Operation Panel) in connection with the MESX.
Besides the display of the entire operation of the measuring technology the BOP also enables a simple
self diagnose of the overall system.
The operation of the BOP is described in detail in the operating and maintenance instructions.
Error and input codes can be found on the electrics page (MESX Service Training).
BOP ----- Bomag Operation Panel

Service Training
Specialities
All BVC single drum rollers of series 4 are equipped with an electric steering
system as standard.
The hydraulic steering is also available as an option.

Service Training
Electric steering
The electric steering consists of an electronically controlled closed control loop and a hydraulic steering
circuit.
The electronically controlled circuit consists of a small electric steering wheel (in the left hand seat
armrest), the ESX-control (located in the electric junction box), which converts the signal from the
steering wheel into electric signals for the proportional solenoids of the steering valve and the
steering angle sensor (located on the articulated joint), which feeds the steering angle back to the
control.
The hydraulic steering circuit consists of steering pump, high pressure filter, steering valve and
steering cylinders.
Variocontrol Single Drum Rollers Series 4 -C1-

Service Training

Service Training
Hydraulic steering circuit
06
to charging
to emergency steering
and Vario control valve
MG
from
hydr.
tank

Service Training
Pos. Designation Pos. in wiring diagram Pos. in hydraulic Measuring values

diagram
05 one steering cylinder on BW 177 05
05 two steering cylinders 05
on BW 213 and 226
06 Steering valve with 2 proportional Y92 / Y93 06
solenoids and an integrated Page 006
accumulator
07 High pressure filter 12µm 07
09 Steering pump and charge pump 09 / MB 200 +/-10 bar
17 additional gear pump 5.5 cm³ on 17 / MG 80 bar
BW 177 BVC
17 additional gear pump 8 cm³ on BW 17 / MG 120 bar
213 and 226 BVC
20 High pressure line filter for 20
Variocontrol 100 µm
21 Optional emergency steering valve Y112 / Y113 21
with 2 B/W solenoids Page 006
Emergency steering:
The emergency steering valve is only an option and can only be operated via a special
input code. The valve is supplied by the additional Variocontrol gear pump.

Service Training
Steering pump with filter
Steering pump
Pressure test port

Steering pressure
Filter outlet
High pressure filter

Steering circuit
12 µm with
Pressure differential switc
3,5 bar
Filter inlet

Service Training
Steering wheel
The small steering wheel is located in the left hand armrest of the driver's seat
VCC 8,5 V

diagram
Electric steering wheel A 45
Page 006

Service Training
Steering valve, electrically proportional
The steering valve, together with the optional emergency steering valve, is located
behind a protection box on the right hand side of the frame under the operator's stand
or the cabin.
to the
Steerin
cylinder
from the
pump
to the charge
system

Service Training
Steering valve
5
7 8
6 1 4 2

diagram
1 Steering valve port P 06
2 Steering valve port T 06
3 Steering valve ports A and B 06
4 Steering valve, pressure relief valve 06 175 + 25 bar
5 Steering valve, shock valves 06 230 bar
6 Steering valve, accumulator 06 Accumulator
pressure 50bar
7 Steering valve, prop. solenoid Y 93 Page 006 0,4 - 1,2 A
8 Steering valve, prop. solenoid Y 92 Page 006 0,4 - 1,2 A
9 Emergency steering valve B/W Y 113 Page 006 0/12 V
solenoid
10 Emergency steering valve B/W Y 112 Page 006 0/12 V
solenoid

Service Training
Emergency steering valve (option, can only be operated via input code) !!!
9
10

Service Training
BW 177 BVC
3 2

diagram
1 Steering valve Y92 / Y93 06
3 High pressure line filter 100µm in 20
Vario-circuit
Variocontrol Single Drum Rollers Series 4 - C 10 -

Service Training
Piping BW 177

Service Training
BW 213 and 226 BVC
5 3

diagram
1 Steering valve Y92 / Y93 06
3 Pressure retaining valve, 22 110 / 99 bar
Variocontrol circuit
4 Accumulator for Variocontrol circuit 23 Accumulator
pressure 85bar
5 High pressure line filter 100µm in 20
Vario-circuit

Service Training
Piping BW 213 and 226

Service Training
Steering angle sensor
The steering angle potentiometer is located on the articulated joint BW 177 and BW 213
The steering angle potentiometer is located inside the articulated joint BW 226

Service Training
BW 177 and 213 BVC

Service Training
BW 226 BVC

Service Training
Trouble shooting
The display shows error codes
A detailed description of how to read out the error codes and on the display
can be found in chapter "Electrics" (Service Training "Electrics")
All electric faults are primarily displayed in the display.
The following trouble shooting chart contains a small selection of possible faults, which may occur
during operation of the machine. The fault list is by no means complete, however, the fault table is based
on the experience of the central service department, i.e. the list covers almost all faults that have
occurred in the past.

Service Training
Procedure:
The following trouble shooting chart mainly lists mechanical and hydraulic faults.
The number specified in the table indicate the probability of the fault cause and thereby the
recommended trouble shooting sequence, based on our latest field experience.
FEHLERSUCHE elektr.LENKUNG
BVC-4 Maschinen
Endanschläge werden nicht erreicht
Lenkung schwergängig
Keine Lenkfunktion
SYMPTOME
MÖGLICHE URSACHEN
Lenkventil 2 2 1
Lenk- Speisepumpe 1 1 2
Lenkzylinder 3 3 3
Knickgelenk 3 3 2
FEHLERSUCHE
Service Training
Compaction measuring system for single drum rollers:
BEM
(Bomag E-vib Meter) for circular exciters
CAN Bus I
BMFSA
E vib
150
50 200
!
0 E VIB 250
MN/mm²
Signale
Beschleunigung
VV / VL 15g
MESX Befehle
Neutral
Pos.
D+ Signal
Bedienfunktionen
Beschleunigung
VH / VL 15g
Vibrationspumpe
Stromsignal
Variocontrol Single Drum Rollers Series 4 -D1-

Service Training
BTM prof
(Bomag Terrameter) for circular exciters
CAN Bus I
Drucker
RS 232
BOP
!
Signale
Beschleunigung
VV / VL 15g
Drehzahlsensor
hinten
MESX
Neutral
Pos.
D+ Signal
Bedienfunktionen
Beschleunigung
VH / VL 15g
Vibrationspumpe
Stromsignal

Service Training
BTM plus
(Bomag Terrameter) for circular exciters
CAN Bus I
BOP
!
Signale
Beschleunigung
VV / VL 15g
Drehzahlsensor
hinten
MESX
Neutral
Pos.
D+ Signal
Bedienfunktionen
Beschleunigung
VH / VL 15g
Vibrationspumpe
Stromsignal

Service Training
BVC
(Bomag Variocontrol) for Vario exciters
CAN Bus I
Drucker
RS 232
BOP
!
Signale
Beschleunigung
VV / VL 15g
Drehzahlsensor MESX Befehle

hinten
Lageregelung Lageregelung
Ventil 2 vorn Ventil 1 vorn
Neutral
Pos.
D+ Signal
Bedienfunktionen
Beschleunigung
VH / VL 15g
Vibrationspumpe
Stromsignal
Erreger
Position vorn

Service Training
BVC - System
BOMAG VARIOCONTROL is able to control the compaction power, independently from the driver. For
this purpose the size and direction of the effective amplitude is automatically adjusted in dependence
on compaction status and travel direction of the roller. This optimal adaptation of compaction ensures
that the roller emits the max. compaction power to the soil at any time. Apart from this, jumping of the
drum with the related over-compaction of the material is automatically prevented.
The VARIOCONTROL system consists of the following primary

components:
1. Exciter unit
2. Additional gear pump with line filter
3. Valve block with pressure relief valve and shock valves and (accumulator on
BW 213 and BW 226)
4. Variable displacement motor with integrated potentiometer based distance
measuring system
5. 2 acceleration transducers
6. Programmable logic control = MESX
7. Display and control unit = BOP
8. ) Optional printer
Variocontrol Single Drum Rollers Series 4 -E1-

Service Training
BVC Circuit diagram for BW 177 DH-4
Legend from the hydraulic
diagram:
17) External gear pump

front rear
5.5 cm³
18) Valve block with 80

bar pressure relief valve
19) Swivel drive, variable

displacement motor
20) High pressure line

filter
Y141 Y140
to the
20 tank
from
tank
to filter
to steering system

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

front rear
18) Valve block with pressure relief valve (120 bar)
19) Swivel drive, variable displacement motor
20) High pressure line filter
22) Pressure override valve (99-110 bar)
23) Accumulator (1.4l, 85bar)
Y141 Y140
to
Emergency
steering
to the
tank
from
tank
to filter
Steering valve

Service Training
Exciter unit
BVC uses a new type of exciter system with two counter-rotating, concentrically arranged
shafts, generating directed vibrations (see Fig. below).
One common shaft carries three eccentrics, the two smaller weights near the ends and the
larger eccentric weight in the middle of the exciter shaft. The middle eccentric weight rotates in
opposite direction to the outer weights. The resulting centrifugal forces add up to a directed
vibration. The effective direction of this directed vibration can be adjusted by turning the
complete vibrator unit. Any desired angle position between horizontal and vertical oscillating
direction is possible.
The adjustment of the exciter unit is accommodated by a hydraulic swashing motor with
integrated displacement measuring system (potentiometer). The vibrator system is driven by a
hydraulic motor, the eccentrics are synchronized by gears.
General design of the VARIOCONTROL - exciter unit

Service Training
Gear pump with high pressure filter
additional
gear pump
for Variocontrol system
Test port input

Variocontrol system
BW 177 BVC
Filter
Input
High pressure
Line filter
Filter
Output

Service Training
BW 213 and 226 BVC
The pressure retaining valve with accumulator is located between Vario pump and valve block.
It helps to keep any losses through the pressure relief valve as low as possible.
7 1
2
8
3
9 4

diagram
1 P3 Input 22
2 P5 to valve block 22
3 T 22
4 T 22
5 Pressure retaining valve, opens and 22 110 bar / 99 bar
closes
6 P6 to accumulator 23 Preload pressure
85bar
7 High pressure line filter 22
8 T1 22
9 P4 22

Service Training
Valve block
The valve block has the function of triggering the adjusting motor. It consists of an electrical proportional
valve.
On BW 213 and BW 226 the valve is equipped with an upstream pressure retaining valve.
Assignment of valves to adjusting motor with exciter:
Y140 ---- valve outlet B ----- control Direction vertical forward
Y141 ---- valve outlet A ----- control Direction vertical backward
8 1
9 2
3
4
10 5
6
8
7
11
diagram
1 Test port BW 177 18 80 bar
1 Test port BW 213 and 226 18 120 bar
2 P2 18
3 A 18
4 T1 18
5 P1 18
6 B 18
7 T2 18
8 Shock valves 18 120 bar
9 Prop. solenoid Y 141 Page 008 18 0,4 - 1,2 A
10 Prop. solenoid Y 140 Page 008 18 0,4 - 1,2 A
11 Pressure relief valve BW 177 18 80 bar

Service Training
diagram
11 Pressure relief valve BW 213 and 18 120 bar
226
Valve block installation front left and protection housing for electric connections
Pressure relief valve
Potentiometer

Service Training
Under the protection

housing there are the
cable connections for
X 22 - speed sensor
X 47 - potentiometer for swa
X 48 - Acceleration
tranducer front
X 49 - Acceleration
transducer rear

Service Training
Swashing motor
with integrated potentiometer based distance measuring
system
As with the VARIOMATIC system, the resulting force may occur at any angle position
between horizontal and vertical direction of vibration. The adjusting motor is equipped
with an integrated displacement measuring system. This displacement measuring
system is based on a potentiometer mounted on the motor output shaft. Each position
of the motor has a resistance or voltage value assigned.
Potentiometer voltage:
Vertical forward approx. 2 V, Horizontal approx. 4,25 V, Vertical backward

approx. 6,5 V
Swashing motor, principle – cross-sectional view (Pleiger)
Variocontrol Single Drum Rollers Series 4 - E 10 -

Service Training

Service Training
Acceleration transducer
The Variocontrol system is equipped with two acceleration transducers arranged one after the other on
the gearbox on the left hand side of the drum. These are mounted under an angle of 45° on either side
of the vertical. These transducer permanently deliver acceleration signals, which form the basis for the
entire control system.
There are two connection assignments

the signal outputs of the transducers:
BW 177 BVC signal brown 20g
BW 213 and 226 BVC signal blue 15g
see wiring diagram, page 008, path 8 and10, B62
Acceleration transducer

Service Training
MESX-control
The MESX-control is located inside the electric junction box, below the ESX-travel control inside the
door of the electrics terminal box. The MESX takes over the function to control the Variocontrol system.
The sticker on the MESX control informs about the installed software version.
A detailed description can be found in the chapter "Electrics", Service

Training MESX.
MESX

Service Training
BOP
Bomag Operation Panel
The operation of the BOP is described in detail in the operating and maintenance instructions!
1 EVIB display 11) Rotary switch for mode selection (Automatic/Manual)

2 not used 12) Push button F12 automatic operation
3 Push button F5 START 13) Push button F11 manual operation
4 Push button F6 STOP 14) Rotary switch, manual setting of amplitude direction
5 Push button F7 PRINT 15) Push button F10 vertical effective direction
6 Push button F8 DELETE 16) Push button F9 horizontal effective direction
7 Display of vibration frequency 17) Travel speed display
8 Rotary switch for setpoint adjustment (automatic operation) 18) Amplitude display
9 Push button F14 setpoint increase 19) Optional measuring value printer
10 Push button F13 Setpoint reduction

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

2. und zerstörende Bewegungen der Bandage verhindern.
Variocontrol Single Drum Rollers Series 4 -F1-

Service Training
Vibration parameters
Für den Verdichtungserfolg ist schon die erste dynamische Überfahrt von entscheidender
Bedeutung.
Die VARIOCONTROL Walzenzüge sind daher auf besonders hohe Zentrifugalkräfte bzw.
Amplituden ausgelegt. Hierdurch wird eine sehr hohe Verdichtung und eine gute
Tiefenwirkung erzeugt.
Durch die große Amplitude würde die VARIOCONTROL Walzenzüge früher springen als
Standardwalzenzüge gleichen Betriebsgewicht. Durch die Automatik wird aber der
Vertikalanteil der Amplitude dann automatisch zurückgenommen und so ein Springen der
Walze verhindert.
Dichte
Hochleistungswalze
große Amplitude
Standardwalze
0 1 2 3 4 5 6 7 Übergänge
BW 177 BW 213 BW 219 BW 225
BVC Standard BVC Standard Standard BVC Standard
Schwingende Masse kg 2440 1970 4800 4250 5500 6630 6300
Zentrifugalkraft kN 189 126/100 365 275/198 326/250 402 330/182
Amplitude mm 2,5 1,8 / 1,0 2,4 1,8 / 0,9 2,1 / 1,2 2,3 2,0 / 1,1
Frequenz Hz 28 30 / 36 28 30 / 36 26 / 30 26 26 / 26
Variocontrol Single Drum Rollers Series 4 -F2-

Service Training
Repair and adjustments
Replacement of swashing motor and potentiometer
Swashing motor
Potentiometer
Fastening
screws
Potentiometer
Variocontrol Single Drum Rollers Series 4 -G1-

Service Training
Locking screw
vertical reverse
Locking screw
horizontal

Service Training
Replaceing the swashing motor
1. If necessary remove the vibration motor
2. Unscrew the bottom plug (Pos.26, P/N 076 320 16) from the gearbox
3. Disconnect the hydraulic hoses and the electric connections from the potentiometer on the swashing
motor
4. Connect the hand pump to the front port (in travel direction) of the swashing motor (Pos.5) and pump
to the right, until the locking recess in the gear is in line with the bore in the gearbox.
5. Turn the locking screw (P/N 955 822 11) into the gearbox, the exciter is thus blocked in position
vertical reverse.
6. Remove the manual pump
7. Remove the swashing motor
8. Connect the manual pump again zo the front port of the new swashing motor and pump to the right
to the same position as with the removed swashing motor (position vertical forward)
9. Install the swashing motor, grease the splined shaft (with Optimol White P/N 009 960 01) and connect
hydraulically and electrically.
10. Remove the bottom locking screw (P/N 955 822 11) again and turn in the plug (Pos.26, P/N
076 320 16) with seal ring.
11. Tighten all fastening screws with the specified torque.

Service Training

Service Training
Adjusting the potentiometer
1. Unscrew the top plug (Pos.16, P/N 076 320 16) from the gearbox
2. Connect the hand pump to the rear port (in travel direction) of the swashing motor (Pos.4) and pump
to the left (middle position of swashing motor), until the locking recess in the upper gear is in line with
the bore in the gearbox.
3. Turn the locking screw (P/N 955 821 69) into the upper bore in the gearbox, the exciter is thus blocked
in position horizontal.
4. Loosen the fastening screws for the potentiometer so that it can be adjusted in the slots.

Service Training
5. Switch on the ignition and measure the supply voltage between X2:67 and X2:68 (e.g. U=8,42V).
6. Measure the signal voltage between X2:69 (white cable) and X2:68 (AGND).
The terminal bar X2 for the volatge measurement is located inside the electrics junction box.
7. Nominal value = 1/2 supply voltage (e.g. 8,42/2 = 4,21V) in case of deviations turn the potentiometer,
until the nominal value is reached.
Wiring diagram Bl 008, Pf 11, B61
8. Fasten the potentiometer.
9. Remove the blocking screw and insert the plug with a new seal ring.
10. Check the swashing motor by pumping it to both end positions with the hand pump and measure the
voltage values. Nominal values: left hand stop vertical forward approx. 2V and right hand stop vertical
reverse approx. 6,5V
This process 1 - 10 must also be performed when changing a potentiometer.

Service Training
Exciter lock in vertical reverse
Exciter lock in horizontal

Service Training
Trouble shooting
In case of a fault in the Vario system the red triangular lamp lights up.
Show the fault code by pressing button „?“ followed by button „F5“
Red fault light
Button „F5“
Button „?“
For detail info on reading out fault codes please refer to the chapter "Electrics, Training MESX".
Variocontrol Single Drum Rollers Series 4 -H1-

Service Training
Electrics
MESX
Version 3.00
Status: 06.12.2004 Page 1 of 48

Author: T.Löw / TE
Dateiname: p:\schulung\wz-4\elektrik\englisch\06_12_04\mesx_schulung_v3.00_berndnick_gb.doc
Service Training MESX
Table cof contents

1 Document updating record ................................................................................................................3
2 Software updating record ..................................................................................................................4
3 Known faults ......................................................................................................................................5
4 How to proceed when replacing components? .................................................................................6
4.1 How to proceed when replacing an ESX control? .......................................................................6
4.2 How to proceed when replacing a rear axle sensor? ..................................................................6
4.3 Which components can be replaced without a subsequent adjustment procedure? ..................6
4.4 List of machine types ...................................................................................................................7
5 Adjustment possibilities on machines without BOP...........................................................................8
5.1 Description of the display module................................................................................................8
5.2 Input of code numbers.................................................................................................................8
5.3 Changing the machine type (only via display module).................................................................9
5.4 Inverting the direction signal (only via display module)..............................................................10
5.5 Changing the bit rate (only with display module) .......................................................................11
6 Adjustment/display possibilities on machines with BOP .................................................................12
6.1 Setting the machine type (BOP) ................................................................................................12
6.2 Inverting the direction signal via the BOP control terminal ........................................................14
6.3 Calling up the diagnostics menu................................................................................................16
6.3.1 Extended diagnose for machines with circular exciter (BTMplus, BTMprof) ................... 18
6.3.2 Extended diagnostics for BVC machines ................................................................................ 19
6.4 Changing the printer language ..................................................................................................20
6.5 Setting the machine serial number ............................................................................................22
6.6 Teaching distance impulses ......................................................................................................24
7 Block diagram BEM.........................................................................................................................27
8 Block diagram BTMplus / VARIOCONTROL ..................................................................................28
9 Description of the signals on the ESX-control .................................................................................29
10 Error codes of the ESX control ..................................................................................................34
10.1 Overview ...............................................................................................................................34
10.2 Description of error reactions ................................................................................................35
10.3 Detailed description of fault codes and their possible causes..............................................36
11 Input codes for ESX control (only via BEM display module)......................................................40
11.1 Travel system ........................................................................................................................40
11.2 Vibration ................................................................................................................................41
11.3 Light.......................................................................................................................................41
11.4 Acceleration transducer.........................................................................................................42
11.5 Diesel engine.........................................................................................................................42
11.6 Setting the machine type.......................................................................................................43
11.7 Parameter change.................................................................................................................44
12 Terminology in connection with ESX .........................................................................................45
Status:06.12.2004 Page 2 of 48
Author: T.Löw / TE
1 Document updating record
Version Date Description of changes resp.

0.00 27.04.2004 Creation of first version Löw
1.00 05.05.2004 ! Block diagrams included Löw
! Description of display module extended
! "Software updating record" included
1.01 23.07.2004 ! Description of BOP display pages added. Löw
2.00 31.08.04 ! Input code 4602 replaced by code 4606 Löw
! Machine type BW219D added
3.00 15.10.2004 ! Subject "How to proceed when replacing components?" Löw
added
! Description for ESX Pin 0:35 added
! Description of error code 4601 and 4606 corrected
! Description of software version 3.00 added
Author: T.Löw / TE
2 Software updating record
Version Date Description of changes resp.

1.00 25.03.2004 Creation of version 1.00 Löw
1.01 05.04.2004 ! Printout modified Löw
! Amplitude limitation Automatic limited to 0,3 mm
! Default settings in Automatic changed to "MAX"
1.02 13.04.2004 ! BW213 BVC implemented Löw
! Printer control modified (Xon, Xoff protocol)
! Software version and revision documented on printout
! Finished criterion extended (2 m of weak spots are
checked)
! Bmfsa code input for DH machines modified
1.03 05.05.2004 ! Teach mode for travel distance modified (value range Löw
check)
! Finished criterion for polygonal drum deactivated
! 2-stage jump information included
! Self-latching of control at shut down implemented
! Storage of the current adjustment values at shut-down
implemented
! Bmfsa code input for DH machines modified
! BW211 D, BW213 D and BW213 DH implemented
! Interrogation of BOP software version implemented
1.04 16.04.2004 ! BW226 BVC Polygon implemented Löw
! Max. swashing angle limited to 80°
! Max valve current for BW177 limited to 1000mA
1.05 26.07.2004 ! BW219DH and BW213 BVC Polygon implemented Löw
! Cancellation criterion for while loops added in Evib
calculations
2.00 31.08.2004 ! Number of machine variants extended to 25 (BW219D) Löw
! Problem with sporadic software crashes eliminated
3.00 15.10.2004 ! Distance impulse changed to 10m for BW226 Löw
! Amplitude limitation in automatic mode realized
! Simulation mode realized
! Change-over metric/imperial realized
! minimum required OPUS version changed to 3.00 (always
the same version as MESX)
Author: T.Löw / TE
3 Known faults
Despite the fault monitoring of inputs and outputs on the ESX control, the ESX control is not able to
detect all faults. The following list contains a selection of known fault reactions of the control, which
mostly have a different cause to the one described in this documentation.
Behaviour of machine Possible cause
During initial start-up the display shows "ct0" Bit rate on bmfsa not set to 125 kBit
=> see "Change bit rate"
Author: T.Löw / TE
4 How to proceed when replacing components?

Each machine is individually adjusted during initial start-up. This is mainly accomplished by setting the
correct machine type (see "4.4 List of machine types", or "6.1 Setting the machine type (BOP)").
The following describes the generally required adjustment measures on the control, if individual
components of the measuring system have to be changed.
4.1 How to proceed when replacing an ESX control?
Attention: A machine must not be operated with a wrong type adjustment,

because in such a case the correct function of the control cannot
be assured!
You should therefore set the machine type as the first step! see
"4.4 List of machine types", or. "6.1 Setting the machine type (BOP)")
Check the following points after setting the machine type:
• Check the direction signal and invert it if necessary, see 5.4, or 6.2.
• Set the machine serial number (only machines with BOP) see: 6.5
• Set the printer language (only machines with printer), see: 6.4
4.2 How to proceed when replacing a rear axle sensor?
Check the direction signal and invert it if necessary, see 5.4, or 5.4.
4.3 Which components can be replaced without a subsequent

adjustment procedure?
• BOP
• Acceleration transducer
• Exciter adjustment valve block
• Printer
• Bmfsa display module
• All switches in the dashboard
Note: A final function test of the complete machine is highly recommended.
Author: T.Löw / TE
4.4 List of machine types

Since the same control is used for all single drum rollers with the new measuring technology, it is
necessary to adjust the machine type after installing a new control.
This work must be carried out during first time commissioning as well as in case of a spare parts
installation. This setting of the machine type is necessary, because the machines e.g. have different
axle loads or different drum widths and the computation of measuring values needs to be adapted for
this reason. A description of the setting procedure can be found under the items "5.3 Changing the
machine type (only via display module)" or "6.1 Setting the machine type (BOP)".
The following machine types can be set:
Code Machine type Available from version

7500 177 D 1.00
7501 177 DH 1.00
7502 177 PDH not available at present
7503 177 BVC 1.00
7511 179 DH not available at present

7520 211 D 1.03
7530 213 D 1.03

7531 213 DH 1.03
7533 213 BVC 1.02
7534 213 BVC Plates not available at present
7535 213 BVC Polygon 1.05

7550 216 D not available at present

7560 219 D 2.00

7561 219 DH 1.05

7573 226 BVC not available at present
7575 226 BVC Polygon 1.04
Author: T.Löw / TE
5 Adjustment possibilities on machines without BOP
5.1 Description of the display module
Note: The display module described next is only used in machines without the Bomag
Operation Panel (BOP). On machines with BOP all settings are made via the BOP!
(see item 6 "Adjustment/display possibilities on machines with BOP")
The display module consists of a 4-digit display and two keys, F1 and F2.
It is used for the output of fault codes and display values as well as for the input of code numbers.
Faults and warnings are displayed by flashing. If several faults are detected, the displayed fault codes
will change in a 3 second cycle.
Display values are permanently displayed, whereby values from 0 0 0 0 ...9 9 9 9 are possible. Higher
values lead to the display „- - - - “, negative values are indicated by the „prefix“ lighting up (see
illustration).
Vorzeichen
057 667 72
15/54
The following description describes the input of code numbers.
5.2 Input of code numbers

For the diagnostics of control inputs and outputs various code numbers can be entered via the display
module of the control. The input of a code number is performed as follows:
1. Press both keys (F1 and F2) on the instrument cluster for 2 seconds.
" The value 0 0 0 0 is displayed with the 1st digit flashing.
2. The value of the flashing digit can be increased by pressing the left hand key (F1). When the figure
9 is displayed and the left hand key (F1) is pressed again, the display will return to the value 0 .
3. When pressing the right hand key (F2) the flashing digit will move one digit to the right. When the
4th digit is flashing, the right hand key (F2) is pressed once again to confirm the input. The desired
function is then executed or the desired value is displayed respectively.
In order to terminate a display function you must either enter code number 0 0 0 0 or switch the
ignition off.
Status: 06.12.2004 Functions of the ESX control Page 8 of 48

Author: T.Löw / TE
5.3 Changing the machine type (only via display module)

For simple checking the currently adjusted machine type is displayed for approx. 3 seconds on the
display module of the central electrics when switching the ignition on. It can also be checked at any
time by entering code 7000.
The machine type is set in the following sequence:
Note: Parameter adjustments can only be performed when the engine is not running.
• Enter code number 7 0 1 0 . This code number activates the function "Adjusting machine type“.
The display module now permanently shows the code 7 0 1 0 .
• select and enter the machine from the table above.
The display module now permanently shows the entered code. (e.g. 7 5 3 3 )
• Enter code number 7 0 1 1 . This code number confirms the entered machine type.
After confirming the machine type the control is restarted, the display module shows the new machine
type for approx. 3 seconds.
• Switch the ignition off and on again.
After this the newly adjusted machine type will be displayed for approx. 3 seconds.
Attention: A machine must not be operated with a wrong type adjustment, because in such
a case the correct function of the control cannot be assured!
New controls are delivered with a default machine type setting 7 5 0 0 .

Author: T.Löw / TE
5.4 Inverting the direction signal (only via display module)

In dependence on the mounting position the axle sensor used delivers a 12 V output signal during
forward or reverse travel.
In order to make sure that exciter position (only BVC machines) and printout correspond with the actual
travel direction, it may be necessary to invert the direction signal.
• Enter code number 7 6 0 0 . This code number activates the function "Invert direction signal“.
• Enter code number 7 6 0 1 . This code number is used to invert the direction signal.
The display module now permanently shows the code 0 0 0 1 (signal inverted), or the code 0 0 0 0
(signal not inverted).
After this the code number 1 0 0 1 can be used to check whether the direction signal is correctly
interpreted (see item 11 "Input codes for ESX control").

Author: T.Löw / TE
5.5 Changing the bit rate (only with display module)

The multi-function display can be operated with different CAN-transmission speeds. Operation in our
machines requires the bit rate 125 kBit/s. The bit rate is changed as follows:
• Hold both keys (F1 and F2) of the multi-function display depressed and switch on the ignition.
" The currently set bit rate is displayed, e.g. 0 1 0 0 .
• By pressing the right hand key (F2) the bit rate can be changed in fixed steps. Keep pressing the
key, until the display shows 0 1 2 5 .
• Press the left hand key (F1) to accept the bit rate and the display will change to the normal display
mode.

Author: T.Löw / TE
6 Adjustment/display possibilities on machines with BOP
6.1 Setting the machine type (BOP)

The machine type is set in the following sequence:
• Press key "?" to call up the screen page "MENU". The following screen appears:
• Press key "F2" to call up the screen page "Set machine type". The following screen appears:

Author: T.Löw / TE
• The required machine type can be selected by pressing keys "F11" and "F12". (see list of machine
types under item 4.4 "List of machine types").
• After selecting the required machine type keep pressing key "F14", until the symbol (F14) lights
green for confirmation (approx. 4s).
When releasing the key the screen will automatically change to the start screen and the control will
reboot.
BOP and MESX are now set to the new machine type.

Author: T.Löw / TE
6.2 Inverting the direction signal via the BOP control terminal
In dependence on the mounting position the axle sensor used delivers a 12 V output signal during
forward or reverse travel.
In order to make sure that exciter position (only BVC machines) and printout correspond with the actual
travel direction, it may be necessary to invert the direction signal.
• Press key "F1" to call up the screen page "Invert direction signal". The following screen appears:

Author: T.Löw / TE
• The direction signal can now be inverted or not inverted by pressing key "F5" ("Invert = 1" or "Invert
= 0").
• After this change press key "F14" to save the setting. The symbol lights green for a moment as
confirmation.
• Press "ESC" to leave the page.
After this check on the printout or in the diagnostics menu whether the travel direction is now correctly
recognized.

Author: T.Löw / TE
6.3 Calling up the diagnostics menu

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

Author: T.Löw / TE
In case of a actually existing code the corresponding error code is displayed in the field "Actual Errors".
• Pressing key "A" brings you to a machine related, extended diagnostics menu (see below).

Author: T.Löw / TE
6.3.1 Extended diagnose for machines with circular exciter

(BTMplus, BTMprof)
4,23 V Ubv: actual voltage of front acceleration transducer
4,24 V Ubh: actual voltage of rear acceleration transducer
98% Small Ampl: Control of solenoid valve for low amplitude in percent
0% Big Ampl: Control of solenoid valve for high amplitude in percent
Direction: Status MESX input travel direction (LED on = 12V)
Ligths: Status MESX input light detection (LED on = 12V)
MD+ Status MESX input MD+ (sensing of engine operation) (LED on = 12V)
Vibration: Status of vibration detection in the MESX (LED on = Vibration ON)
+01234 Distance pulses (10 cm steps) detected by MESX. The actually detected travel
direction can be seen by the roller symbol above.

Author: T.Löw / TE
6.3.2 Extended diagnostics for BVC machines
4,25 V Uexciter: actual voltage exciter position potentiometer
4,23 V Ubv: actual voltage of front acceleration transducer
4,24 V Ubh: actual voltage of rear acceleration transducer
98% Ampl: Control of solenoid valve for vibration pump in percent
Direction: Status MESX input travel direction (LED on = 12V)
Ligths: Status MESX input light detection (LED on = 12V)
MD+ Status MESX input MD+ (sensing of engine operation) (LED on = 12V)
Vibration: Status of vibration detection in the MESX (LED on = Vibration ON)
+01234 Distance pulses (10 cm steps) detected by MESX. The actually detected travel
direction can be seen by the roller symbol above.

Author: T.Löw / TE
6.4 Changing the printer language

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

Author: T.Löw / TE
• The required printer language can be selected by pressing keys "F11" and "F12".
• After selecting the required language press key "F14" to save the setting. The symbol (F14) lights
green for a moment as confirmation.

Author: T.Löw / TE
6.5 Setting the machine serial number

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

Author: T.Löw / TE
• The required serial number can be set by pressing keys "F11" and "F12".
• After completing the setting press key "F14" to save the setting. The symbol (F14) lights green for
a moment as confirmation.

Author: T.Löw / TE
6.6 Teaching distance impulses

The distance impulses for the different machine types have already been set by the setting of the
correct machine type. However, due to slippage of the rear wheels the detected distance measurement
may differ from the actual distance travelled. In this case the distances impulses can be adapted
accordingly.
Note: The distance impulses can only be adapted within the range of +/- 10% of the
previously adjusted value.
• Press key "F8" to call up the screen page "Distance impulses". The following screen appears:

Author: T.Löw / TE
• Press key "F5" to start the Teach-mode. The following symbol is displayed:
• Travel a distance of 10 m forward and press key "F6" at the end. The following symbol is
displayed:
• After completing the measuring pass press key "F14" to save the setting. The following symbol is
displayed:
Note: If the following symbol is displayed after completing the measuring pass, the
measured distance pulses are outside the range of +/- 10% of the preset value. The
setting cannot be saved! The measurement must be repeated!

Author: T.Löw / TE
Service Training MESX Block diagram
7 Block diagram BEM
Status: 06.12.2004 Block diagram Page 27 of 48

Author: T. Löw / TE
Service Training MESX Block diagram
8 Block diagram BTMplus / VARIOCONTROL
Status: 06.12.2004 Block diagram Page 28 of 48

Service Training MESX Description of signals
9 Description of the signals on the ESX-control

Notes:
1. Wherever the value of 12 V is mentioned in the following text it refers to the current battery
voltage under due consideration of voltage drops in the lines.
ESX terminal Signal description Nominal values (voltage / current)

X0:1 AGND = Analogue ground: Ground potential for sensors (steering approx. 0 V measured against ground (terminal 31)
joystick, speed range switch etc.)
X0:2
X0:3 Output Evib display PWM signal (100Hz): " approx. 0..6 V
PWM (max. 2.5 A)
X0:4 Interface RS 232 RxD, is used for printer control. Measurement not possible!
X0:5 Interface RS 232 TxD, is used for printer control. Measurement not possible!
X0:6
X0:7 Input acceleration transducer VH20g/HR15g Acceleration signal (measured against AGND)
Open-circuit voltage (vibration off): " 4,2..4,3 V

Analogue input / voltage input 0..8.5 V
X0:8
X0:9 Input exciter position front Position exciter front (measured against AGND)
Analogue input / voltage input 0..8.5 V Bottom stop " approx. 2,2 V
Neutral position " approx. 4,25 V
Top stop " approx. 6,6 V
Status: 06.12.2004 Description of signals Page 29 of 48


X0:10
X0:11
X0:12
X0:13
X0:14
X0:15 Input vibration 1 On Vibration on " >6V

Digital input active high Vibration off: "approx.0 V
X0:16 Input "START" button (option) Push button pressed " 12 V
Digital input active high Push button not pressed " 2V
X0:17 Input "STOP" button (option) Push button pressed " 12 V
X0:18 Input "PRINT" button (option) Push button pressed " 12 V
X0:19 Input "CLEAR" button (option) Push button pressed " 12 V
X0:20
X0:21
X0:22
X0:23 Output voltage supply for sensors Nominal voltage = 8,5 V

This output supplies steering joystick, travel speed range switch, etc. Permissible range: approx. 7,65..9,35 V
Without this voltage the control cannot work correctly and will switch to This voltage must be measured against AGND.
override condition (emergency operation).
X0:24


X0:25
X0:26 Interface CAN-Bus1 Wire -, is used to communicate with the BOP- Measurement not possible!
operating panel.
X0:27 Interface CAN-Bus1 Wire +, is used to communicate with the BOP- Measurement not possible!
operating panel.
X0:28 Input potential terminal 15 Control switched on " 12 V

Digital input active high Control switched off "approx.2 V
This signal must be present, so that the control can work.
X0:29 Input acceleration transducer VV/VL15g Acceleration signal (measured against AGND)

X0:30 Input acceleration transducer VH/VR15g Acceleration signal (measured against AGND)

X0:31 Input acceleration transducer VV20g/HR15g Acceleration signal (measured against AGND)

X0:32
X0:33 Interface CAN-Bus2 Wire -, is used to communicate with the BCM05. Measurement not possible!
X0:34
X0:35 Input distance transducer Transducer delivers square-wave pulses. Frequency machine type
dependent.
Digital input active high


X0:36
X0:37 Input D+ generator Engine running / engine is started " 12 V

Digital input active high Engine not running " 0V
X0:38 Input vibration 2 On Vibration on " >6V
Digital input active high Vibration off: "approx.0 V
X0:39
X0:40
X0:41
X0:42
X0:43
X0:44
X0:45
X0:46 Output valve 1 front permissible current range: approx. 0..1,5 A

PWM digital output (max. 4 A)
X0:47 Output valve 2 front permissible current range: approx. 0..1,5 A
PWM digital output (max. 4 A)
X0:48
X0:49
X0:50
X0:51
X0:52


X0:53 Interface CAN-Bus2 Wire +, is used to communicate with the BCM05. Measurement not possible!
X0:54 Voltage supply for electronics Emergency stop not actuated " 12 V
Emergency stop actuated " 0V
X0:55 Ground connection electronics 0 V measured against ground
X0:56 Voltage supply for outputs approx. 12 V measured against ground
X0:61
X0:62
X0:63
X0:64
X0:65 Mouse port Baby Boards approx. 0 V

Service Training Error codes of the ESX control
10 Error codes of the ESX control
10.1 Overview
Error code Description of error

4501 - Position controller (exciter potentiometer, valves)
4540
4601 - Acceleration transducer
4620
8000 - Internal software error
8250
Status: 06.12.2004 Error codes of the ESX control Page 34 of 48

Author: T.Löw / TE
Service Training MESX Description of error codes on the ESX control
10.2 Description of error reactions
Error reaction Description of error reaction

1 Warning.
Error code is displayed.
Signal light in BOP (option) lights in 5 second intervals.
2 Function affected, the emergency function overrides the faulty function.
3 Partial function faulty, overriding of the partial function by the emergency function is not possible .
After the occurrence of the fault the machine is stopped, after returning the travel lever to neutral the machine can move
again.
The machine can still be driven to a limited extent, but must be repaired by the service department as soon as possible.
4 Partial function faulty, overriding of the partial function by the emergency function is not possible .
The machine is no longer able to drive, e.g. because parts of the travel system are defective
" the diesel engine is shut down.
5 Fatal fault. The function of the control can no longer be guaranteed.
Control is switched off.
Signal light in BOP (option) lights permanently.
Note: Faults with fault reaction 1 are only warnings and are NOT stored in the error log!
Status: 06.12.2004 Description of error codes on the ESX control Page 35 of 48

10.3 Detailed description of fault codes and their possible causes
Error Description of error Possible cause Terminal Input Error

code on ESX code for reaction
diagnose
450 Input exciter potentiometer front " Wire breakage in current path X0:09 5
1 The voltage applied to the input is below the " Current path has short circuit to ground
specified range (see signal description). " No voltage supply to potentiometer
" Fuse FM ? has tripped or wire breakage in voltage supply
current path
" Potentiometer defective
450 Input exciter potentiometer front " Current path connected to +12 V / +8,5 V X0:09 5
2 The voltage applied to the input is above the " Potentiometer not connected to ground
specified range (see signal description). " Potentiometer defective


diagnose
452 Output proportional solenoid front " Current path has short circuit to voltage supply X0:46 2
1 Valve exciter up " Current path has non-permitted connection to another current
Output current too low. path
" Current path is interrupted
452 Output proportional solenoid front " Current path has short circuit to ground X0:46 2
2 Valve exciter up " Current path has non-permitted connection to another current
Output current too high. path
452 Output proportional solenoid front " Current path is interrupted X0:46 2
3 Valve exciter up " Current path has unpermitted connection to another current
Fault when calibrating the valve path / ground
452 Output proportional solenoid front " Current path has short circuit to voltage supply X0:47 2
6 Valve exciter down " Current path has non-permitted connection to another current
Output current too low. path
" Current path is interrupted
452 Output proportional solenoid front " Current path has short circuit to ground X0:47 2
7 Valve exciter down " Current path has non-permitted connection to another current
Output current too high. path
452 Output proportional solenoid front " Current path is interrupted X0:47 2
8 Valve exciter down " Current path has impermissible connection to another current
Fault when calibrating the valve path / ground


diagnose
453 Position controller has reached positive limit " Supply and ground terminals on exciter potentiometer mixed X0:09 5000 2
1 The exciter does not move to the desired up+ X0:37
direction or does not move at all. " Valves "exciter up" and "exciter down" mixed up
" MD+ input has 12 V potential, even though the engine is not
running
453 Position controller has reached negative limit " Supply and ground terminals on exciter potentiometer mixed X0:09 5000 2
2 The exciter does not move to the desired up+ X0:37
direction or does not move at all. " Valves "exciter up" and "exciter down" mixed up
" MD+ input has 12 V potential, even though the engine is not
running
460 Input acceleration transducer 1 " Current path has no connection to +12 V / +8,5 V X0:29, 4601 2
1 The voltage applied to the input is below the " Current path connected to ground or
specified range (see signal description). " Transducer defective X0:31
460 Input acceleration transducer 1 " Current path connected to +12 V / +8,5 V X0:29, 4601 2
2 The voltage applied to the input is above the " Current path not connected to ground or
460 Input acceleration transducer 2 " Current path has no connection to +12 V / +8,5 V X0:30, 4606 2
6 The voltage applied to the input is below the " Current path connected to ground or
460 Input acceleration transducer 2 " Current path connected to +12 V / +8,5 V X0:30, 4606 2
7 The voltage applied to the input is above the " Current path not connected to ground or


diagnose
800 Error message "BOP Software version incorrect" - - 2
0 The BOP software version is too old, i.e. various
functions cannot be displayed.
This fault cannot be rectified on the machine. The
BOP needs to be replaced.
800 Error message „severe software fault in control“ - - - 5
1 - This fault cannot be rectified on the machine. The
899 control must be immediately replaced.
9
900 Error message "Communication via CAN Bus " Wire breakage in CAN Bus lines X0:26 - 2
0 - disturbed" " Short circuit between CAN Bus lines X0:27-
999 The modules controlled via the CAN Bus cannot " One or both CAN Bus line(s) has (have) connection to +12V or
8 be addressed by the main control (ESX). The ground
related machine functions are not available
Ct0 Display module has no connection to ESX- " Wire breakage in CAN Bus lines X0:26 - -
control. " Short circuit between CAN Bus lines X0:27
" One or both CAN Bus line(s) has (have) connection to +12V or
ground
" Bit rate in display module not correct (nominal value: 125 kBit)

Service Training MESX Description of input codes for the control
11 Input codes for ESX control (only via BEM display module)
11.1 Travel system
Input code Description of display function Display values

1000 Travel direction sensor 0000 " 0V
Displays the status of sensor. 0001 " 12 V
1001 Travel direction 1000 " Forward travel detected

Displays the travel direction derived from the "Travel direction sensor" 0000 " Neutral position
by the control. 000I " Reverse travel detected
1002 Distance impulse sensor Display value = travel distance in 10 cm

The accumulated distance impulses since starting the machine are
displayed. If the machine has travelled a greater distance in reverse
than in forward, the displayed value will be negative.
1003 Travel speed Display value = speed in km/h
Displays the actual speed.
1010 Parameter "Display distance impulses per 10m" Depending on selected machine type, e.g. 5896 at BW177 BVC
Eeprom parameter is displayed
1011 Parameter "Invert travel direction" 0000 " Direction signal is not inverted
Eeprom parameter is displayed 000I " Direction signal is inverted
Status: 06.12.2004 Description of input codes for the control Page 40 of 48

11.2 Vibration

3000 Vibration status general 0000 " Vibration OFF
The status of vibration is displayed. 0001 " Vibration ON
3001 Vibration status low amplitude 0000 " Vibration OFF
The status of vibration with low amplitude is displayed. 0001 " Vibration ON
3002 Vibration status high amplitude 0000 " Vibration OFF
The status of vibration with high amplitude is displayed. 0001 " Vibration ON
11.3 Light

3010 Input light switch 0000 " Light OFF
The status of the lighting system is displayed. 0001 " Light ON

11.4 Acceleration transducer

4601 Acceleration transducer 1 Display value = voltage in V
Displays voltage for transducer 1.
4606 Acceleration transducer 2 Display value = voltage in V
Displays voltage for transducer 2.
11.5 Diesel engine

5000 Input MD+ 0000 " Engine OFF
Displays the status of the diesel engine. 0001 " Engine ON

11.6 Setting the machine type

7000 Displays the set machine type see adjustment instructions (page Fehler! Textmarke nicht
definiert.)!
7010 Switches on function „Set machine type“ see adjustment instructions (page Fehler! Textmarke nicht
definiert.)!
7011 Confirms entered machine type see adjustment instructions (page Fehler! Textmarke nicht
definiert.)!
7500..75 Preselection of machine type see adjustment instructions (page Fehler! Textmarke nicht
99 definiert.)!

11.7 Parameter change

7600 Switches on function "Invert travel direction" Display value 7 6 0 0
7601 Inverts the actually set travel direction see adjustment instructions (page Fehler! Textmarke nicht
definiert.)!

12 Terminology in connection with ESX

Short circuit
A direct, unwanted connection between two different cables or between machine and cables.
Examples:
Two lines rub against each other until the insulation has worn off.
A conductive line rubs off the insulation at the vehicle ground.
Wire breakage
This generally means that a connection is interrupted. Possible reasons may be:
Line:
• torn (not necessarily visible from outside)
• chafed
• chafed mostly in connection with a short circuit to ground
Terminal, cable lug

• loosened, slipped off
• broken off,
• corroded,
• socket / plug faulty
Status: 06.12.2004 General terminology Page 45 of 48

Author: T.Löw / TE
Short circuit to ground

Line, terminal has direct connection to vehicle ground, often in connection with wire breakage
Digital
There are only two permissible states, e.g. switched on or off; lamp on / off; current flows /
does not flow; valve open / closed (black-white valve)
Analogue
In contrast to Digital many conditions are permitted within a certain range. For instance room
temperature 0° to 40°; current 4mA to 20mA; voltage 0V to 8,5V; resistance 100 Ω to 300 Ω;
valve 0% to 100% opened (proportional valve)

Author: T.Löw / TE
Control
Controlling describes the process during which an input value influences a distance (the
value to be controlled), following a fixed command. For this purpose all possible interfering
factors (e.g. temperature, humidity ...) must be known.
Closed loop control

Closed loop control is a process during which a value, the closed loop control value (e.g.
pressure), is continually measured and compared with a nominal value (guide value). The
result of this comparison will affect the closed loop control value, thereby adapting the closed
loop control value to the guide value.
This sequence occurs in a closed circuit, the co-called closed loop control circuit.
Marking Closed loop control Control

Operating path: closed open
(closed loop control circuit) (control chain)
Measurement and Value to be adjusted is Values to be controlled
comparison of value to measured and compared. are not measured and
be adjusted: compared.
Reaction to faults Counteracts to all faults Does not respond to
(generally): targeting the system to be unknown faults
controlled.
Technical expense: Low expense: High expense if many
Measurement of the value to faults have to be
be controlled, comparison of considered, low expense
nominal and actual value, if not faults occur.
power amplification
Performance in For unstable systems closed In unstable systems
unstable systems loop controls must be used. controls cannot be used.

Author: T.Löw / TE
Current and voltage measurement
Ohm’s law:
U = Voltage
R = Resistance
I = Current
Plausibility check
The control (ESX) runs a plausibility check on all inputs. This means the control checks
permanently whether certain state combinations are permitted; e.g. travel lever position
forward and reverse will cause an fault message, because this condition is normally not
possible.
Override / emergency operation

In the event of a major fault the control will switch off and the override function will take over.
This has the effect that the machine can still be moved and steered with reduced speed.
Steering and dozer blade movements are only possible with a constant speed.
(see also: page 28, "")
GND - AGND
Besides the "normal" battery ground (terminal 31) in the vehicle there is an additional
analogue ground, which is only to be used for sensors. (see description of the signals on the
ESX-control)
PWM – digital output

Certain outputs on the ESX are designed as so-called PWM – digital outputs. This means
that these outputs are special current outputs. Here it is possible to measure a current, but
no voltage. These outputs are used to trigger proportional valves.

Author: T.Löw / TE
Service Training
Electrics
Single Drum Rollers – 4
From -DH Version 1.10
Version 1.03
Status: 06.12.04 Page 1 of 46

Author: Seis / TE
Dateiname: p:\schulung\wz-4\elektrik\englisch\dez04\esx_schulung_wz4 v1.03_gb.doc
Service Training WZ-4 from version DH
Table of contents
1 LIST OF CHANGES ............................................................................................. 4
2 SELECTED FAULT REACTIONS OF THE ESX CONTROL ............................... 5
3 DESCRIPTION OF FAULT DISPLAY IN THE LC DISPLAY ............................... 7
3.1 Calling up service mode ............................................................................................................................ 7
3.2 Entering input codes ................................................................................................................................. 7
3.3 Adjusting the machine type ...................................................................................................................... 9
3.4 Changing the steering unit on BVC-4 machines (from version 1.09).................................................. 10
3.5 Teaching the travel direction sensor...................................................................................................... 11
3.6 Automatic detection of surge currents in the travel system................................................................. 11
3.7 Automatic detection of surge currents on steering valves (BVC) ....................................................... 13
3.8 Teaching the electronic end stops of the steering angle sensor (BVC) ............................................... 14
3.9 Driving against the closed brake............................................................................................................ 15
3.10 Showing stored faults.............................................................................................................................. 15
3.11 Deleting all stored faults ......................................................................................................................... 15
4 HOW TO PROCEED WHEN REPLACING COMPONENTS? ........................... 16
4.1 How to proceed when replacing an ESX control?................................................................................ 16
4.2 How to proceed when replacing a travel pump / axle drive motor / drum drive motor?.................. 16
4.3 How to proceed when replacing a steering valve (BVC)? ................................................................... 16
4.4 How to proceed when replacing a steering angle transducer?............................................................ 16
4.5 How to proceed when replacing an front / rear axle sensor? .............................................................. 16
4.6 Which components can be replaced without a subsequent adjustment procedure? ......................... 17
5 DESCRIPTION OF THE SIGNALS ON THE ESX-CONTROL........................... 18
6 DESCRIPTION OF SIGNALS ON THE DATA COLLECTOR............................ 23
7 DESCRIPTION OF SIGNALS ON THE TRAVEL LEVER................................. 25
8 DESCRIPTION OF SIGNALS ON THE LC - DISPLAY ..................................... 27

Author: Seis / TE
9 DESCRIPTION OF SIGNALS ON THE DIOS MODULE (ONLY WITH

OPTIONAL EXTENSION PLATES) ......................................................................... 28
10 FAULT CODES OF THE ESX CONTROL ...................................................... 29
10.1 Overview .................................................................................................................................................. 29
10.2 Description of fault reactions ................................................................................................................. 30
10.3 Detailed description of fault codes and their possible causes ............................................................. 31
11 INPUT CODES FOR ESX CONTROL............................................................. 38
11.1 General..................................................................................................................................................... 38
11.2 Brake ........................................................................................................................................................ 38
11.3 Travel lever / driving ............................................................................................................................. 39
11.4 Steering .................................................................................................................................................... 41
11.5 Vibration .................................................................................................................................................. 42
11.6 Engine....................................................................................................................................................... 42
11.7 Hydraulics................................................................................................................................................ 42
11.8 Changing the machine code.................................................................................................................... 42
12 TERMINOLOGY IN CONNECTION WITH ESX .............................................. 43

Author: Seis / TE
1 List of changes
No. Date Description of changes resp.

1 23.04.2004 Creation of version 1.00 Werner
2 06.05.2004 Revision, teach functions Fondel
3 11.05.2004 Revision, supplements to version 1.01 Seis
4 24.06.2004 Revision, supplement to version 1.02 Seis
Ver. Date Description of changes resp.

1.03 02.09.2004 ⇒ Jump currents travel drive teach function changed Schroeder,
⇒ Known faults Fondel
⇒ Fault - codes revised
⇒ Deactivation of electric steering on BVC machines
⇒ How to proceed when replacing components?

Author: Seis / TE
2 Selected fault reactions of the ESX control

Reaktion Symbol in fault Warning Warning Engine stop
message display
Signal Code output Code output Code output
without buzzer with buzzer with buzzer
Engine oil pressure

(from EMR) 5100 5101
5112 5112
1) 2)
after 10s
Coolant temperature
(from EMR)
5100 5101
5116 5116
1) 2)
after 15s
Coolant level
5024 5025
after 5s after 10s
Engine air filter
5026 5027
after 5s after 2min 3)
Charge control light
Pre-heating of engine
Brake
ASC
Different fault causes and reaction times.
See fault codes
Hydraulic oil filter
5502 5503
after 5s after 2min
Water separator on fuel
filter 5028 5029
after 5s after 2min
Theft warning system
(Option)
Seat contact
(Option)
Fault in air conditioning

(Option)
1) 3)
After reaching the warning limit! Shut-down currently deactivated by parameter
2)
After reaching the shut-down limit!

Author: Seis / TE
Known faults
Despite the fault monitoring of inputs and outputs on the ESX control, the ESX control is not able to
detect all faults. The following list contains a selection of known fault reactions of the control, which
mostly have a different cause to the one described in this documentation.
Effect: Cause:
Display stay dark, no voltage PIN in display plug X 28 bent

Author: Seis / TE
3 Description of fault display in the LC Display

Apart from its normal display function the LC Display is also able to show fault codes, which were
previously visualized by means of a 3-digit fault code display.
Existing faults and warnings are displayed by flashing. If several faults are detected, the displayed fault
codes will change in a 3 second cycle.
Display values are permanently displayed, whereby values from 0 0 0 0 ...9 9 9 9 are possible.
Negative values are marked with a "minus sign".
The following description deals with the operation of the LC-Display via the travel lever buttons.
3.1 Calling up service mode

For this purpose the display must be switched to service mode via input mode. This is accomplished by
the two yellow information buttons "INFO 1" and "INFO 2" on the back of the travel lever. The green
and blue buttons on the front of the travel lever are used to navigate through the input and service
mode.
Werte ändern Navigieren

INFO 1 Taste (grün) (blau)
(gelb)
INFO 2 Taste
(gelb) Werte ändern
(grün)
Navigieren
(blau)
To activate the input mode the travel lever must be engaged in the brake lock! Input mode is
activated by simultaneous pressing of both INFO – buttons over a period of approx. 3 seconds.
3.2 Entering input codes
The input mode starts with flashing of the left hand digit. At this point you have the possibility to change
into service mode by entering 9 9 9 9 . The green buttons are used to increase or reduce the values of
the individual digits. Pressing one of the blue buttons brings you to the next digit (left or right). When
pressing the right hand blue navigation key again after entering the last digit, the code will be
transferred to the control.
If the access code has been entered correctly, the "Spanner" symbol will be displayed and the first
input digit flashes again. By transferring input codes to the control (as described above) individual
operating states of the machine can be interrogated.
When pressing bothINFO buttons over a period of approx. 3 seconds a new input code can be
entered. The service mode can be terminated by entering the code "0 0 0 0 ", or by switching off the
ignition.
If the travel lever is shifted out of brake lock position in service mode, all machine function will become
active again, except the reading in the LC.Display, which remains in service mode and shows the
previously requested operation values.
Status: 06.12.04 Functions of ESX control Page 7 of 46

Author: Seis/ TE
Normalmodus (Fahrhebel in Bremsraste!)

Aufruf optionaler Anzeigen über INFO - Taste 1
und INFO - Taste 2
„Eingabe“ - Modus:
Umschaltung Displayfunktion
Einstellungen Display
Betätigen INFO 1
+ INFO 2 ca. 3s
Plattenverstellung inaktiv!
Bet. INFO 1 +
Eingabe
INFO 2 ca. 3s
Zugangangscode
oder Fahrhebel
9999
aus Bremsr.
„Service“- Modus:
CODE - Eingabe „0000" oder Eingabe Diagnosecodes
Zündung aus
Fehlerspeicher abrufen / löschen
Maschinentypen umstellen
Plattenverstellung inaktiv!
Fahrhebel aus Bremsraste:

Diagnosemodus im Vordergrund aktiv!

Author: Seis/ TE
3.3 Adjusting the machine type

Since the same control is used for all single drum rollers of series DH-4 with electronically controlled
engines (EPA II), it is necessary to adjust the machine type after installing a new control.
This work must be carried out during first time commissioning as well as in case of a spare parts
installation. This type adjustment is absolutely necessary, because the machines have e.g. wheel and
axle drive motors or different tire sizes and therefore different rolling speeds or are equipped with
extension plates or other attachments.
For simple checking the currently set machine type is displayed for approx. 3 seconds on the display
module of the central electrics when switching the ignition on. The machine type can also be checked
by entering code 0720 .
The following machine types can be set:
0 1 2 3 4 5 6 7 8 9
72XX
0 Default BW 177 BW 177 BW 179 BW 179 BW 213 BW 213 BW 213 BW 213 BW 216 DH
DH-4 PDH-4 DH-4 PDH-4 DH-4 PDH-4 DH-4 PDH-4 DH-4
(Dozer USA USA
blade)
1 BW 216 BW 219 BW 219 BW 226 BW 226 BW 226 BW 226 DH
PDH-4 DH-4 PDH-4 DH-4 PDH-4 DH-4 PDH-4
147kW 147kW 174kW 174kW
2 DH
3 DH
4 DH
5 BW 177 BW 213 BW 213 BW 226 BW 226 BVC

DH-4 DH-4 DH-4 DH-4 DH-4
BVC BVC BVC w. BVC BVC
plates 147 kW 174 kW
6 BVC
7 BVC
8 BVC
9 BVC
EXAMPLE: Machine code for BW 219 PDH-4: 7212
Note: This function can only be activated / deactivated when the travel lever is in brake lock
! Input mode)
position. (!
The following method must be used for initial start-up of a control:

Author: Seis/ TE
• Control was installed in the machine.

• Switch on the machine. After switching on the inscription C O D E is automatically displayed for
approx. 3 seconds. After this the code 7200 appears in the display.
• Use the arrow up or down keys to select the correct machine code from the listed codes.
• Confirm the selection by pressing the arrow right key.
• After approx. 7 seconds the set machine type code, e.g. 7 2 1 2 is displayed for approx. 3
seconds. The new parameters are loaded according to the newly set machine type. Do not switch
the ignition off during this time!
• Then switch the ignition off and on again to accept the configuration.
• This is followed by the normal display reading.
The following applies for correcting the machine type code is a code is already set.
• Enter code number 9 9 9 9 (activation of service mode).

• Enter code number 7 0 1 0 . This code number activates the function "Adjusting machine type“.
• Select the machine code from the table above and confirm with the arrow to right key. Pressing the
arrow to right key automatically switches the control off and on again.
• After approx. 7 seconds the set machine type code, e.g. 7 2 1 2 is displayed for approx. 3
seconds. The new parameters are loaded according to the newly set machine type. Do not switch
the ignition off during this time!
• Then switch the ignition off and on again to accept the configuration.
• This is followed by the normal display reading.
Attention: A machine must not be operated with a wrong type adjustment, because in such
a case the correct function of the control cannot be assured!
New controls are delivered with a default machine type setting 7 2 0 0 . This does
not allow driving or steering the machine. It solely serves the purpose of
commissioning.
3.4 Changing the steering unit on BVC-4 machines (from version

1.09)
By standard all BVC-4 machines (code 72xx) are equipped with electric steering. If the option
"hydraulic steering" is selected, the electric steering must be deactivated as follows.
• Enter code number 9999 (activation of service mode).

• Enter code number 2 0 6 0 . This code number activates the function "Adjusting steering unit“.
• The following code numbers are available to activate the installed steering unit.
Hydraulic steering 2062
Electric steering 2061
• The display shows O K
Attention: The steering unit can only be changed when the engine is not running!

Author: Seis/ TE
3.5 Teaching the travel direction sensor

Teaching of the travel direction sensor is required for first commissioning or after replacing a travel
motor. Use the following procedure.
• Turn the travel stage switch to "MAX"
• Slowly displace the travel lever, until the speedometer shows a reading of approx. 1 km/h.
• If one of the two travel direction sensors detects an opposed direction after the machine has
travelled approx. one machine length, fault code 1106 or/and 1116 is displayed. Otherwise no
fault code is displayed. The travel direction detection has now been automatically set.
However, should one of these error messages still be displayed after this measure, there must be
a sensor fault present.
3.6 Automatic detection of surge currents in the travel system

This function sequence is only valid from software version 1.09!
For a sensitive and exact travel function the surge currents in the travel system must be determined for
both travel directions. The surge currents are automatically determined after entering a code number,
so that no electric meter is required.
The surge currents must only be determined during initial commissioning in the factory, after a service
during which the control on a steering valve or the complete steering valve has been replaced and after
the replacement of the ESX-control.
The measurement is identical for both travel directions: After entering the respective code number the
current is increased by the control solenoid on the travel pump in steps of 5 mA, starting from 250 mA..
After each current increase the system waits for 3 seconds. If a considerable drum movement is
measured during the waiting time, the surge current is reached. In order to enhance the measuring
result this measurement is performed three times. The final surge current is the mean value of these
three measurements. This surge current is automatically stored and is valid from the next start of the
machine.
Before the measurement you should strictly make sure that the machine is parked on level ground and
has a sufficient distance for movement to front and back, because the machine will move to the
respective direction when performing the measurement.
Attention! Set the machine to input mode first (code 9 9 9 9 ). It must be strictly assured that the speed
sensor (in front right hand hydraulic motor) is working correctly. For a function test enter code number
1 1 0 6 at the display module. This code can be used to display the number path pulses from the speed
sensor. The displayed value must change when the machine is driven.
If this value does not change even though the machine is moving, the measurement must not
be performed!
The state of the speed sensor must first be corrected, as otherwise the movement of the drum will not
be detected. (See also: „Resetting the surge currents in the travel system”)
Attention!
During the measurement the machine will move when the surge current is reached!
Do not leave the machine while the measurement is progressing!
During the measurement keep an eye on your environment!
To stop the machine reset the travel lever to neutral position!
The automatic measurement of the travel system surge currents is performed as follows:
• The switch for rotary speed preselection must be set to ECO
• If necessary enter code number 9 9 9 9 to enter into service mode.
• Then enter 1 0 9 0 . This code number activates the function "Automatic detection of surge
currents"; the display now shows the value 0 0 0 0 with the first zero flashing. This code number
must be entered before the following steps can be performed. From this point the machine can

Author: Seis/ TE
no longer be operated with the travel lever! The travel lever will only be in function again
after the steering function has been ended or the engine has been restarted.
• The measurement (forward/reverse) must be started by entering a code number. The code number
for teaching the travel direction is as follows:
Determination of surge currents 1 0 9 1
• After entering the above code number the display will show " F O R E". The travel lever must now
be actuated forward, this will also start the measurement for the surge current in forward.
• During the measurement the actual current is displayed (display value = current in mA).
• Once the measurement of the surge current in forward is finished, the display will show O K for 5
seconds.
• After this wait time the display will show the reading "B A C K". The travel lever is now moved
backward, this will start the surge current measurement in reverse.
• Once this measurement is finished the display will show O K again.
• The travel lever must now be returned to brake position.
• Once both jump currents have been learned correctly and the travel lever is back in "brake
position", the display will show the message "D O N E", the values are saved and the function is
finished. Now the machine can be operated again by the travel lever. The new surge current values
for the travel system are valid from the next start.
• The teach function can at any point be aborted by simply pressing the emergency stop button or via
the ignition switch.
With software versions 1.07 and 1.08 use the following procedure:
The automatic measurement of the travel system surge currents is performed as follows:
• The seat must be adjusted for travel direction forward!
• The switch for rotary speed preselection must be set to ECO
• If necessary enter code number 9 9 9 9 to enter into service mode.
• Then enter 1 0 9 0 . This code number activates the function "Automatic detection of surge
currents"; the display now shows the value 0 0 0 0 with the first zero flashing. This code number
must be entered before the next steps are possible. From this point the machine can no longer
be operated with the travel lever! The travel lever will only be in function again after the
steering function has been ended or the engine has been restarted.
• Both measurements (forward/reverse) must be started by entering a code number. The code
numbers for both travel directions are:
Determine surge current for control forward 1 0 9 1
Determine surge current for control reverse 1 0 9 2
• After entering one of the above code numbers the measurement of the surge current will only start
after moving the travel lever to the respective travel direction.
ATTENTION: During the teach process the ASC-lamp will come on. In this case this is without
any meaning. Restarting the machine eliminates the warning.
• Teaching must be performed for both travel directions.
• When returning the travel lever to neutral after the two measurements, O K is displayed for 3
seconds and the determined values will be memorized.
• After both surge currents have been measured the machine can again be driven with the travel
lever. The new surge current values for the travel system are valid from the next start.
• The teach function can at any point be aborted by simply pressing the emergency stop button or via
the ignition switch.

Author: Seis/ TE
3.7 Automatic detection of surge currents on steering valves (BVC)
Attention: Does not apply for BVC machines with the optional hydraulic steering
To enable a sensitive and exact function of the steering the surge currents of the two control solenoids
and both steering valves must be measured. The surge currents are automatically adjusted after
entering a code number, so that no electric meter is required.
The surge currents must only be adjusted during initial commissioning in the factory, after a service
during which the control on a steering valve or the complete steering valve has been replaced and after
the replacement of the ESX-control.
The measuring procedure is identical for both solenoids:
Example BW 177 BVC:

After entering the respective code numbers the current is increased by the control solenoid in steps of
5 mA, starting from 650 mA.. After each increasing step the system waits for 2 seconds. If a change in
drum angle is measured after the waiting time, the surge current is reached. In order to enhance the
measuring result this measurement is performed three times. The final surge current is the mean value
of these three measurements. This surge current is automatically stored and is valid from the next start
of the machine.
For all other machine types the same procedure is used, however, currents and times will vary.
Before the measurement you must strictly make sure that the steering system is „bled“, because an air
cushion in the steering cylinders would have a negative effect on the measurement and therefore on
the steering performance of the machine. Sufficient bleeding is achieved by performing a few quick
steering movements at full engine speed.
The automatic measurement of the steering valve surge currents is performed as follows:
• The engine must be operated in ECO mode!
• Enter code number 9 9 9 9 to enter into service mode.
• Travel lever in neutral position (brake must be relieved!)
• Enter code number 2 0 0 0 . This code number activates the function "Automatic detection of surge
currents on steering valves"; the display now shows the value 0 0 0 0 with the first zero flashing.
• Now you must enter code number 2 0 0 1 .
• After entering o0ne of the above mentioned code numbers the measurement of the surge current
will start immediately.
• The drum is thereby first steered to the right and then to the left.
• During the measurement the actual current is displayed (display value in mA).
• Attention! During the measurement the drum cannot be used for steering ! The steering
wheel has no effect.
• During the measurement the machine should not be driven !
• Once the measurement is completed the display value OK will appear for 3 seconds, after this the
code number 0000 is displayed again with the first digit flashing and the next measurement can be
started.
• The new surge current values are valid from the next start.
Note: During the measurement the machine should be parked on level ground.
Before the measurement both drums should be steered to straight ahead position.

Author: Seis/ TE
3.8 Teaching the electronic end stops of the steering angle sensor (BVC)
Attention: Does not apply for BVC machines with the optional hydraulic steering!
Do prevent the steering from running against the mechanical end stops of the steering cylinder, a
clearly defined safety distance to the end stops must be determined.
• Enter code number 9 9 9 9 to enter into service mode.
• Enter code number 2 0 1 0 to activate the mode for "teaching the steering stops".
• Shift the travel lever to neutral position (no brake function, to relieve the machine). The display now
shows the standardized steering position (0..1000 → right ... left).
• Now turn the electronic steering wheel clockwise, until the mechanical end stop is reached. The
displayed value should be in the range of 100..300. Then shift the travel lever to brake position
and enter code number 2 0 1 2 . Upon acceptance the value 2 2 2 2 is displayed for a moment. In
case of a fault the reading is 9 9 9 9 (see below).
• Shift the travel lever to neutral position (no brake function, to relieve the machine). The display now
shows the standardized steering position (0..1000 → right ... left).
• Now turn the electronic steering wheel anti-clockwise, until the mechanical end stop is reached.
The displayed value should be in the range of 700..900. Then shift the travel lever to brake
position and enter code number 2 0 1 3 . Upon acceptance the value 3 3 3 3 is displayed for a
moment. In case of a fault the reading is 9 9 9 9 (see below).
• To exit this mode shut down the machine or enter code 2 0 1 1 .
Causes for faults (code 9 9 9 9 ) :

If the standardized values are not within the specified ranges, the steering angle sensor on the
articulated joint needs to be adjusted.

Author: Seis/ TE
3.9 Driving against the closed brake

After entering code number 0 5 0 0 the brake is no longer released. When disengaging the travel
lever out of brake lock position and shifting it to one of the travel directions, the travel pumps will be
actuated in accordance with the selected travel direction. At the same time a warning (fault code
0 5 0 0 ) appears on the display and the warning buzzer is triggered, in order to keep the operator
informed about the condition. The brake control light in the LC-Display remains active.
In order to terminate this function and release the brake you must either enter code number 0 5 0 1 or
switch the ignition off. After entering the code number 0 5 0 1 the function is terminated and the
confirmation OK appears for 5 seconds. After this a new code number can be entered.
! Input mode)
position. (!
3.10 Showing stored faults

Switch on function „Show stored faults“:

• Enter code number 0 7 0 0 . This code number enables the function „Show stored faults“.
The faults stored in the ESX are displayed in flashing mode. If several faults are stored, these are
successively displayed in cycles of 3 second. After the last fault has been displayed, the first fault will
appear again. If no faults are stored in the ESX the display will show "- - - - - "
Switch off function „Show stored faults“:

• Enter code number 0 7 0 1 . This code number disables the function „Show stored faults“.
Note: Apart from the stored faults the current faults are also displayed.
position. (! Input mode)
3.11 Deleting all stored faults

Execute the function „Delete all stored faults“:

• The engine must not be running!
• Enter code number 0 7 1 0 .
All stored function are now deleted.
Note: The stored faults can only be deleted when the engine is not running.
! Input mode)
position. (!

Author: Seis/ TE
4 How to proceed when replacing components?

Each machine is individually adjusted during initial start-up. This adjustment or teaching process is
necessary to make sure that the travel and steering functions are almost identical on all machines.
Background of these adjustment procedures are the tolerances of the components used, e.g. hydraulic
pump for travel system, proportional valves for steering, steering angle sensors and ESX control.
These tolerances apply for both mechanical as well as electrical functions and are unavoidable for
manufacturing reasons.
To enable simple and quick adjustment procedures we have decided to do without expensive tools. All
that is needed is this manual and a bit of time. By following the described procedure it is possible to
take a machine back into operation after the replacement of one of the components specified above
and to re-establish the usual functional quality, with almost any previous knowledge. Even an
incorrectly or incompletely conducted teaching procedure can be repeated without problems as often
as necessary. At the first glance it seems to be at bit awkward to perform this adjustment on every
machine, but this procedure enables the operation of all machines with the same operating software.
At the end of the day this considerably increases the spare parts availability.
4.1 How to proceed when replacing an ESX control?
Since the control stores all teach values of the machine, each teaching procedure must be performed
with the new control after a replacement.
Attention: Before performing one of the following steps you must first adjust the respective
machine type (see chapt 3.6 Fehler! Es wurde kein Textmarkenname vergeben.)!
When changing the machine type all previously made adjustments will be lost!
Now you must follow the commissioning instructions.
• Electric pre-adjustment (see commissioning instructions chapter 3)

• Engine start, heating flange inspection, teaching of travel drive and steering (see commissioning
instructions chapter 4)
• Inspection of display and shut-down functions (see commissioning instructions chapter 5)
• Inspection of seat contact circuitry (see commissioning instructions chapter 6)
• Inspection of travel ranges and vibration (see commissioning instructions chapter 7)
• Inspection of ASC function DH-single drum rollers (see commissioning instructions chapter 8)
4.2 How to proceed when replacing a travel pump / axle drive motor / drum
drive motor?
• Automatic detection of surge currents in the travel system (see chapter 3.6 Fehler! Es wurde kein
Textmarkenname vergeben.)
4.3 How to proceed when replacing a steering valve (BVC)?
• Automatic detection of surge currents of the steering valve (BVC) (see chapter 3.7 Fehler! Es
wurde kein Textmarkenname vergeben.)
4.4 How to proceed when replacing a steering angle transducer?
• Teaching electric end positions of the steering angle sensors (see chapter 3.8)
4.5 How to proceed when replacing an front / rear axle sensor?
• Teaching the travel direction sensor

Author: Seis/ TE
4.6 Which components can be replaced without a subsequent

adjustment procedure?
• Display
• Data collector
• Joystick
• Electric steering wheel
• Diesel engine
• All switches in the dashboard
• Vibration motor
• Vibration pump
Note: A final function test of the complete machine is highly recommended.

Author: Seis/ TE
Service Training WZ – 4 Description of signals on the ESX control
5 Description of the signals on the ESX-control

Notes:
Wherever the value of 24 V is mentioned in the following text, it refers to the current battery voltage
under due consideration of voltage drops in the lines.

X35:1 AGND = Analogue ground: Ground potential for sensors (steering approx. 0 V measured against ground (terminal 31)
angle sensor, steering unit etc.)
X35:2 Output amplitude changeover active, i.e. high amplitude "approx.12 V
Digital output (max. 2.5 A) inactive, i.e. low amplitude " 0V
X35:3 Output warning buzzer Warning buzzer active "approx.12 V
Digital output (max. 2.5 A) Warning buzzer inactive " 0V
X35:4 Interface RS 232 RxD, not used for normal operation. Measurement not possible!
X35:5 Interface RS 232 TxD, not used for normal operation. Measurement not possible!
X35:6 Not used ---
X35:7 Not used ---
X35:8 Not used ---
X35:9 Not used ---
X35:10 Not used ---
X35:11 Not used ---
X35:12 Input axle speed Signal changes between approx. 0V and 12V, when machine is driving.
Frequency input (0....7,5kHz) Frequency with travel speed m/min
Machine type:
XX m/min "approx.XX Hz
Machine type:
Machine type:
X35:13 Not used ---
X35:14 Not used ---
Status: 06.12.04 Description of signals on the ESX control Page 18 of 46

Author: Seis/ TE

X35:15 Input seat contact switch Seat occupied " 0V
Digital input active high Seat not occupied " ?V
X35:16 Not used ---
X35:17 Input BTS brake (from travel lever) Release brake "approx.12 V
Digital input active high Apply brake " 0V
X35:18 Input steering sensor (S1/A) Signal changes between approx. 0V and 12V, when steering wheel is
Digital input active high turned.
Frequency depends on speed of rotation
X35:19 Input steering sensor (S1/B) Signal changes between approx. 0V and 12V, when steering wheel is
X35:20 Output steering left Steering left active " 0,4..1,2 A
PWM digital output (max. 4 A) Steering left inactive " 0A
X35:21 Output steering right Steering right active " 0,4..1,2 A
PWM digital output (max. 4 A) Steering right inactive " 0A
X35:22 Output vibration pump for extension plate permissible current range: approx. 0..0,6 A
PWM current output (max. 4 A) Vibration pump active " 0,0..2,0 A
Vibration pump not active " 0A
X35:23 Voltage supply for sensors Nominal voltage = 8,5 V
This output supplies steering angle sensor and steering unit. Permissible range: approx. 7,65..9,35 V
Without this voltage the control cannot work correctly and will switch to This voltage must be measured against AGND.
override mode (emergency function).
X35:24 Output Backup alarm Backup alarm inactive " 0V
Digital output (max. 2.5 A) Backup alarm active "approx.12 V
X35:25 Not used ---
X35:26 Interface CAN-Bus 1 Wire -, is used for communication with the
MESX, the data collector, the LC-Display and the BOP.
MEASUREMENT NOT POSSIBLE!
X35:27 Interface CAN-Bus 1 Wire +, is used for communication with the
MESX, the data collector, the LC-Display and the BOP.
X35:28 Input potential terminal 15 Control switched on "approx.12 V
Digital input active high Control switched off "approx.2 V
This signal must be present, so that the control can work.
X35:29 Input steering angle sensor Position steering angle sensor (measured against AGND)
Analogue input / voltage input 0..8.5 V right hand stop " 0,50..1,00 V

Author: Seis/ TE

straight ahead / neutral / middle " .. V
left hand stop " 6,80..8,70 V
X35:30 Input longitudinal inclination of machine Inclination of machine (measured against AGND)
Analogue input / voltage input 0..8.5 V -45° axle at top " 0,50..2,49 V
Neutral position " 2,50 V
maximum down " 2,51..4,50 V
X35:31 Input hydraulic pressure travel pump circuit 0 bar " approx.4 mA
Analogue input (current input 4mA..20mA) from pressure sensor on 600 bar " approx.20 mA
travel pump
X35:32 Not used ---
X35:33 Interface CAN-Bus 2 Wire -, is used for communication with travel
lever and engine EMR.
X35:34 Input drum speed Signal changes between approx. 0V and 12V, when machine is driving.
Frequency input (0....7,5kHz) Frequency with travel speed m/min
Machine type:
Machine type:
Machine type:
X35:35 Input vibration motor Frequency at vibration frequency in Hz
Frequency input (0....2,0kHz) Machine type:
Vib. frequency XX Hz "approx.XX Hz
Machine type:
Machine type:
X35:36 Input vibration motor sense of rotation Sense of rotation forward "approx.12 V
(currently not used) Sense of rotation reverse "approx.2 V

Author: Seis/ TE

X35:37 Input drum sense of rotation Sense of rotation forward "approx.12 V
Digital input active high Sense of rotation reverse "approx.2 V
X35:38 Input axle sense of rotation Sense of rotation forward "approx.12 V
Digital input active high Sense of rotation reverse "approx.2 V
X35:39 Not used ---
X35:40 Input steering sensor (S2/A) Signal changes between approx. 0V and 12V, when steering wheel is
X35:41 Input steering sensor (S2/B) Signal changes between approx. 0V and 12V, when steering wheel is
X35:42 Output emergency steering Emergency steering active "approx.12 V
Emergency steering inactive " 0V
X35:43 Not used ---
X35:44 Not used ---
X35:45 Not used ---
X35:46 Output drum drive motor permissible current range: approx. 0..0,6 A
PWM current output (max. 4 A) Drum drive motor active " 0,0..2,0 A
Drum drive motor not active " 0A
X35:47 Output axle drive motor permissible current range: approx. 0..0,6 A
PWM current output (max. 4 A) Axle motor active " 0,0..2,0 A
Axle motor not active " 0A
X35:48 Output vibration pump permissible current range: approx. 0..0,6 A
PWM current output (max. 4 A) Axle motor active " 0,0..2,0 A
Axle motor not active " 0A
X35:49 Output travel pump forward Travel forward active " 0,0..2,0 A
PWM current output (max. 4 A) Travel forward inactive " 0A
Sauer components with EDC

Travel forward active " 18..80 mA
Travel forward inactive " 0 mA
X35:50 Not used ---
X35:51 Not used ---
X35:52 Not used ---

Author: Seis/ TE

X35:53 Interface CAN-Bus 2 Wire +, is used for communication with travel
lever and engine EMR.
X35:54 Voltage supply for electronics (permanent voltage) Control running "approx.12 V
Control not running " 0V
X35:55 Ground connection electronics 0 V (measured against ground)
X35:56 Voltage supply for outputs (permanent voltage) approx. 12 V (measured against ground)
X35:61 Output brake Open brake "approx.12 V
Digital output (max. 4 A) Close brake " 0V
X35:62 Output blower coupling stage 2 (currently not used) Active "approx.12 V
Digital output (max. 4 A) Inactive " 0V
X35:63 Output blower coupling stage 3 (currently not used) Active "approx.12 V
Digital output (max. 4 A) Inactive " 0V
X35:64 Output travel pumps reverse Travel forward active " 0,0..2,0 A
PWM current output (max. 4 A) Travel forward inactive " 0A
Sauer components with EDC

Travel forward active " 18..80 mA
Travel forward inactive " 0 mA
X35:65 Test connection Baby Boards approx. 0 V

Author: Seis/ TE
Service Training WZ – 4 Description of signals on the data collector
6 Description of signals on the data collector

Notes:
Wherever the value of 12 V is mentioned in the following text it refers to the current battery voltage
PIN data Signal description Nominal values (voltage / current)

collector
X26:1 Input direction indicator right Direction indicator right active "approx.12 V
Digital input active high Direction indicator left active " 0V
X26:2 Input direction indicator left Direction indicator left active "approx.12 V
Digital input active high Direction indicator left active " 0V
X26:3 Input engine running (D+) Engine running "approx.12 V
Digital input active high Engine not running " 0V
X26:4 Not used ---
X26:5 Input differential pressure hydraulic oil filter Filter clogged " 0V
Digital input active low Filter OK " ?V
X26:6 Not used ---
X26:7 Input air conditioning Air conditioning on "approx.12 V
Digital input active high Air conditioning off " 0V
X26:8 Input engine air filter Filter clogged " 0V
Digital input active low Filter OK " ?V
X26:9 Input background illumination Illumination on "approx.12 V
Digital input active high Illumination off " 0V
X26:10 Input coolant level Coolant level too low " 0V
Digital input active low Coolant level sufficient " ?V
X26:11 Not used ---
X26:12 Ground connection 0V (measured against ground)
X27:1 Not used
X27:2 Input fuel level The voltage signals change with the fuel level in the diesel tank
Analog input Fuel tank empty " ?? V
Fuel tank full " ?? V
X27:3 Not used ---
X27:4 Voltage supply for monitoring of the water separation (PIN X27:9) Voltage supply O.K. "approx.12 V
Status: 06.12.04 Description of signals on the data collector Page 23 of 46

Author: Seis/ TE
Service Training WZ – 4 Description of signals on the data collector
PIN data Signal description Nominal values (voltage / current)

collector
No voltage supply " 0V
X27:6 Interface CAN-Bus 1 Wire +, is used for communication with the Measurement not possible!
MESX, the ESX, the LC-Display and the BOP.
X27:7 Interface CAN-Bus 1 Wire -, is used for communication with the Measurement not possible!
MESX, the ESX, the LC-Display and the BOP.
X27:8 Voltage supply (permanent voltage) Control running "approx.12 V
Control not running " 0V
X27:9 Input water separation If a sufficient amount of water has been separated a low current flows
Current input through the contacts and the water in the separator bowl. This current is
evaluated in this input.
No water separated " I= 0A
Water separated " I∗ 0,03mA
X27:10 Not used ---
X27:11 Not used ---
X27:12 Not used ---
Status: 06.12.04 Description of signals on the data collector Page 24 of 46

Author: Seis/ TE
Service Training WZ – 4 Description of signals on the travel lever
7 Description of signals on the travel lever

Notes:
PIN Travel Signal description Nominal values (voltage / current)

lever
X23:1 Voltage supply (permanent voltage) Electronics working "approx.12 V
Electronics not working " 0V
X23:3 Output BTS brake Brake opens "approx.12 V
Digital output (max. 4 A) Brake closing " 0V
X23:4 Output BTS (not used)
Digital output (max. 4 A)
X23:5 Output voltage supply for additional analog evaluations Nominal voltage = approx. 5,0 V
This output supplies the 24-stage travel speed range switch. Without Permissible range: approx. 4,8..5,2 V
this voltage no additional analogue switches can be connected to the This voltage must be measured against AGND.
travel lever and evaluated.
X23:6 Interface CAN-Bus 2 Wire +, is used for communication with the ESX Measurement not possible!
and the engine EMR.
X23:7 Interface CAN-Bus 2 Wire -, is used for communication with the ESX Measurement not possible!
and the engine EMR.
X23:8 AGND = Analogue ground: Ground potential for additional analog approx. 0 V measured against ground (terminal 31)
evaluation
Relation to PIN X23:5
X23:9 Node address addressing 1 Connection to machine ground (0V)
X23:10 Node address addressing 2 Connection to machine ground (0V)
X23:11 Input travel speed range switch The voltage signal changes with the adjusted travel range
Analog input Travel stage min. " ?? V
Travel stage max. " ?? V
X23:12 Not used ---
X24:1 Not used ---
X24:2 Input high amplitude High amplitude active "approx.12 V
Status: 06.12.04 Description of signals on the travel lever Page 25 of 46

Author: Seis/ TE
Service Training WZ – 4 Description of signals on the travel lever
PIN Travel Signal description Nominal values (voltage / current)

lever
Digital input active high High amplitude inactive " 0V
X24:3 Input low amplitude Low amplitude active "approx.12 V
Digital input active high Low amplitude inactive " 0V
X24:4 Not used ---
X24:5 Not used ---
X24:6 Input left hand armrest (not yet realized) ---
X24:7 Output voltage supply for additional digital evaluations Voltage supply active "approx.12 V
This output supplies the amplitude pre-selection switch. Without this Voltage supply inactive " 0V
voltage no additional digital switches can be connected to the travel
lever and evaluated.
X24:8 Output voltage supply ground potential 0V (measured against ground)
This output in connection with PIN X24:7 enables the control of
additional components (relay, displays etc.)
Status: 06.12.04 Description of signals on the travel lever Page 26 of 46

Author: Seis/ TE
Service Training WZ – 4 Description of signals on the LC - display
8 Description of signals on the LC - Display

Notes:
PIN Display Signal description Nominal values (voltage / current)

X28:1 Voltage supply (permanent voltage "ignition on") Electronics working "approx.12 V
X28:3 Interface CAN-Bus 1 Wire +, is used for communication with the Measurement not possible!
MESX, the ESX, the data collector and the BOP.
X28:4 Interface CAN-Bus 1 Wire -, is used for communication with the Measurement not possible!
MESX, the ESX, the data collector and the BOP.
X28:5 Voltage supply (permanent voltage "Battery +" for RTC) Electronics working "approx.12 V
X28:6 Not used ---
X29:1 Input frequency adjustment lower Adjustment active "approx.12 V
Digital input active high Adjustment inactive " 0V
X29:2 Input frequency adjustment higher Adjustment active "approx.12 V
Digital input active high Adjustment inactive " 0V
X29:3 Input engine speed high idle High idle active "approx.12 V
Digital input active high High idle inactive " 0V
X29:4 Input engine speed low idle Low idle active "approx.12 V
Digital input active high Low idle inactive " 0V
X29:5 Not used ---
X29:6 Not used ---
X29:7 Output voltage supply for additional digital evaluations Voltage supply active "approx.12 V
This output supplies the engine speed switch and the switch for Voltage supply inactive " 0V
frequency adjustment. Without this voltage no additional digital
switches can be connected to the LCD and evaluated.
X29:8 Not used ---
Status: 06.12.04 Description of signals on the LC - display Page 27 of 46

Author: Seis/ TE
Service Training WZ - 4 Description of signals on the DIOS module
9 Description of signals on the DIOS module (only with optional extension plates)
DIOS terminal Signal description Nominal values (voltage / current)

X0:1 Interface CAN-Bus 1 Wire +, is used to communicate with the ESX- Measurement not possible!
control.
X0:2 Interface CAN-Bus 1 Wire -, is used to communicate with the ESX- Measurement not possible!
control.
X0:3 Voltage supply for electronics Ignition ON: "approx.12 V
Ignition OFF: " 0V
X0:4 Input Proximity switch plates middle Plates in middle position "approx.12 V
Digital input active high Plate outside middle position " 0V
X0:5 Output plates up Lifting active "approx.12 V
Digital output (max. 4 A) Lifting inactive " 0V
X0:6 Output plates down Lowering active "approx.12 V
Digital output (max. 4 A) Lowering inactive " 0V
X0:7 Output plate left Offset left active "approx.12 V
Digital output (max. 4 A) Offset left inactive " 0V
X0:8 Output plate right Offset right active "approx.12 V
Digital output (max. 4 A) Offset right inactive " 0V
X0:9 Voltage supply for outputs Ignition ON: "approx.12 V
Ignition OFF: " 0V
X0:10 Voltage supply for outputs Ignition ON: "approx.12 V
Ignition OFF: " 0V
X0:11 Ground connection 0 V measured against ground
X0:12 Input proximity switch plates middle Plates at top lift point "approx.12 V
Digital input active high Plates lowered " 0V
X0:13 Output plates floating position Float position active "approx.12 V
Digital output (max. 4 A) Lifting inactive " 0V
X0:14 Output plates priority Priority active "approx.12 V
Digital output (max. 4 A) Priority inactive " 0V
X0:15 Not used ---
X0:16 Not used ---
Status: 06.12.04 Description of signals on the DIOS module Page 28 of 46

Author: Seis / TE
Service Training Error codes of the ESX control
10 Fault codes of the ESX control
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 - Fault of work functions (vibration, rotor, dozer blade, 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, locating system, access system,
6999 time calculation, etc.
7000 - Input of machine codes
7499
7500 - Input of measuring technology codes
7899
7900 - Operating hours, load spectrum, etc.
7999
8000 - Severe software fault
8999
9000 - Fault of external I/O-nodes (joystick, data collector, Dios-module,
9999 LCD-display, etc.)
Status: 06.12.04 Error codes of the ESX control Page 29 of 46

Author: Seis / TE
Service Training WZ – 4 Description of input codes of the control
10.2 Description of fault reactions

Fault reaction Description of fault reaction
1 Warning.
Fault code is displayed.
2 Warning.
Audible signal
3 Function affected, the faulty function is replaced by an emergency function.

Audible signal
4 Partial function faulty, the partial function cannot be overridden by an emergency function.
The machine is stopped if this fault occurs.
The machine can still be driven to a limited extent, but must be repaired by the service department as soon as possible.
Audible signal
5 Partial function faulty, the partial function cannot be overridden by an emergency function.
The machine is no longer able to drive, e.g. because parts of the travel system are defective " the diesel engine is shut
down.
Audible signal
6 Fatal fault. The function of the control can no longer be guaranteed.

Control is switched off.
The fault code is displayed, the signal light in the monitoring board is permanently on.
No audible signal!
Note: Faults with fault reaction 1 and 2 are only warnings and are NOT stored in the error log!
Status: 06.12.04 Description of input codes of the control Page 30 of 46

Author: Seis / TE
10.3 Detailed description of fault codes and their possible causes
Fault Fault description Possible causes Terminal Assignment Input Fault

Code on ESX DH-4 BVC-4 code for reaction
diagnose
500 Warning "Driving against brake“ A corresponding input code was entered X
The function "Driving against brake“ is activated
502 Warning "Simulated engine run" A corresponding input code was entered X
The function "sumulated engine run" is active
504 Warning "Anti-Slip Control (ASC) deactivated" A corresponding input code was entered X
The function "Anti-Slup Control (ASC)" is deactivated
507 Warning "Drum drive deactivated" A corresponding input code was entered X
The test mode "drum drive deactivated" was activated.
508 Warning "Axle drive deactivated" A corresponding input code was entered X
The test mode "axle drive deactivated" was activated.
560 Fault "Overvoltage 8,5V" Connection of the voltage level to operating voltage, another X
The voltage level of 8,5V range is exceeded in an voltage potential or control defective
unacceptable way
(see signal description)
561 Fault "Undervoltage 8,5V" Connection of the voltage level to ground, another voltage X
The voltage level of 8,5V range is fallen short of in an potential or control defective
unacceptable way
(see signal description)
562 Fault "Voltage override relay" X
The voltage level of the 8,5V range is...
1001 Fault brake valve The connecting line from the output of the control to the control X X
The required control power cannot be transmitted to the solenoid is interrupted, or
control solenoid. the proportional solenoid is defective
1002 Fault brake valve Cable breakage in ground line, or X X
Signal outside the valid range (see signal description) the connecting cable valve / ground connection has come loose
1003 Fault brake valve Cable breakage in supply line, or X X
Signal outside the valid range (see signal description) the connecting cable valve / supply has come loose
1004 Fault BTS brake / travel lever Hardware defect on travel lever X X
Overheating of the BTS has the effect that the travel lever
brake position is not recognized correctly

Author: Seis / TE

diagnose
1005 Fault BTS brake / plausibility Hardware defect of travel lever, input X35:17 has not the same X35:17 X X
Plausibility conflict when evaluating X- and Y-axes of the voltage as the BTS
travel lever to the brake contact signal
1040 Fault travel range switch "ground connection" Cable breakage in ground line, or X X
Signal outside the valid range (see signal description) the connecting cable switch / ground connection has come
loose
1041 Fault travel range switch "supply connection" Cable breakage in supply line, or X X
Signal outside the valid range (see signal description) the connecting cable switch / supply has come loose
1042 Fault travel range switch Increased transition resistance values on contacts may have led X X
Signal outside the valid range (see signal description) to a falsification of the signal.
The switch needs to be replaced
1070 Fault output "travel pump forward" The connecting line from the output of the control to the X X
The required control power cannot be transmitted to the
proportional solenoid is interrupted, or the proportional
proportional solenoid.
solenoid is defective
1071 Fault of current regulator forward X X
1072 Fault of current regulator forward X X
1073 Fault output "travel pump forward" Short circuit in the connecting line (control to prop valve) to X X
Supply voltage UB applied at the output to the proportional supply voltage
valve.
1074 Fault when teaching surge current forward Machine is mechanically blocked
Bypass valves in travel system are deadjusted
1080 Fault output "travel pump reverse" The connecting line from the output of the control to the X X
The required control power cannot be transmitted to the proportional solenoid is interrupted, or the proportional solenoid
proportional solenoid. is defective
1081 Fault of current regulator reverse X X
1082 Fault of current regulator reverse X X
1083 Fault output "travel pump reverse" Short circuit in the connecting line (control to prop valve) to X X
valve.
1084 Fault when teaching surge current reverse Machine is mechanically blocked
Bypass valves in travel system are deadjusted
1088 Informative message! Surge currents of travel pump Function "Learning of pump surge currents" for travel pump not X X Note
NOT YET learned. See 3.6 yet executed.
-> New machine/control change
1100 Fault output "front travel motor" The connecting line from the output of the control to the X X
The required control power cannot be transmitted to the proportional solenoid is interrupted, or the proportional
proportional solenoid. solenoid is defective

Author: Seis / TE

diagnose
1105 Fault front travel motor "speed sensor" Check connecting lines and plugs to the wheel speed sensor or X X
Faulty or non-existent signal "frequency" replace the speed sensor, if necessary
1106 Fault front travel motor "speed sensor" Check connecting lines and plugs to the wheel speed sensor or X X
Faulty or non-existent signal "direction" replace the speed sensor, if necessary
1107 Fault output "front travel motor" Short circuit in the connecting line (control to prop valve) to X X
valve.
1110 Fault output "rear travel motor" The connecting line from the output of the control to the X X
The required control power cannot be transmitted to the proportional solenoid is interrupted, or the proportional solenoid
proportional solenoid. is defective
1115 Fault rear travel motor "speed sensor" Check connecting lines and plugs to the wheel speed sensor or X X
Faulty or non-existent signal "frequency" replace the speed sensor, if necessary
1116 Fault rear travel motor "speed sensor" Check connecting lines and plugs to the wheel speed sensor or X X
Faulty or non-existent signal "direction" replace the speed sensor, if necessary
1117 Fault output "rear travel motor" Short circuit in the connecting line (control to prop valve) to X X
valve.
1140 Fault pressure switch travel system "signal" The connecting line from the output of the control to the X X
The current signal is not transmitted (see signal pressure sensor is interrupted, or
specification) The pressure sensor is defective
1141 Fault pressure switch travel system "signal range" The pressure sensor is defective X X
The current signal is outside the permissible range (see
signal specification)
1142 Fault pressure switch travel system "no pressure" No pressure connection on sensor, of X X
The current signal indicates that no permanent travel supply line clogged or
pressure is built up. no travel pressure is built up
1145 Fault inclination sensor "supply connection" Cable breakage in supply line, or X X
Signal outside the valid range (see signal description) the connecting cable sensor / voltage supply has come loose
1146 Fault inclination sensor "ground connection" Cable breakage in ground line, or X X
Signal outside the valid range (see signal description) the connecting cable sensor / ground connection has come
loose

Author: Seis / TE

diagnose
1300 Seat contact switch not occupied Cable breakage in signal line, or X X
driver's seat not occupied (driver not seated!)
1500 Warning "dangerous situation ASC" X X
2060 Fault output "steering valve right" The connecting line from the output of the control to the X
The required control power cannot be transmitted to the proportional solenoid is interrupted, or
proportional solenoid. the proportional solenoid is defective
2061 Fault output "steering valve left" The connecting line from the output of the control to the X
proportional solenoid. the proportional solenoid is defective
2065 Fault learning the surge current right hand valve Drum was not moved, maximum current reached, steering is
blocked (e.g. articulation lock applied)
2066 Fault learning the surge current left hand valve Drum was not moved, maximum current reached, steering is
blocked (e.g. articulation lock applied)
2068 Informative message! Surge currents of steering pump Function "Learning of pump surge currents" for steering pump (X) Note
NOT YET learned. See 3.7 not yet executed.
(Only machines with electric steering) -> New machine/control change
2170 Fault steering wheel "change of direction" Wiring fault or steering sensor in left hand arm rest defective X
2171 Fault steering wheel "impulse coverage" Steering sensor in left hand arm rest defective. X
Measuring value of sensor 1 and 2 difference too strong
2172 Fault steering wheel "sensor 1 pulse range" Check connecting line to steering sensor – sensor 1, X
The detected steering pulses on steering sensor 1 are if necessary change the steering sensor in the left hand arm rest
outside the valid range (see signal description)
2173 Fault steering sensor "sensor 2 pulse range" Check the connecting lines to the steering sensor – sensor 2, or X
The detected steering pulses on steering sensor 2 are replace the steering sensor in the left hand arm rest.
outside the valid range (see signal description)
2174 Fault steering wheel "sensor 1" Steering sensor in left hand arm rest defective. X
2175 Fault steering wheel "sensor 2" Steering sensor in left hand arm rest defective. X
2176 Fault steering wheel "sensor 1 cable damage" Check the connecting lines to the steering sensor – sensor 1, or X
replace the steering sensor in the left hand arm rest.
2177 Fault steering wheel "sensor 2 cable damage" Check the connecting lines to the steering sensor – sensor 2, or X
replace the steering sensor in the left hand arm rest.
2190 Fault steering "steering angle sensor... initialization" Steering angle sensor on articulated joint defective X
Fault when initializing the steering angle sensor
2191 Fault steering "steering angle sensor—ADC" Steering angle sensor on articulated joint defective X
2192 Fault steering "steering angle sensor—cable damage Voltage supply line to steering angle sensor interrupted or X
supply" Steering angle sensor on articulated joint defective
2193 Fault steering "steering angle sensor—cable damage Ground supply line to steering angle sensor interrupted or X

Author: Seis / TE

diagnose
ground" Steering angle sensor on articulated joint defective
2198 Informative message! Steering stops of the electric Function "Learning of steering stops" for electric steering not yet (X) Note
steering NOT YET learned. See 3.8 executed.
(Only machines with electric steering) -> New machine/control change
2300 Fault "driver's seat armrest lifted" Arm rest is raised or magnetic switch under left hand arm rest X
defective
2301 Fault "driver's seat armrest" Cable breakage in signal line, or X
Signal outside the valid range (see signal description) magnetic switch under left hand arm rest defective
2302 Fault "driver's seat armrest cable damage supply" Voltage supply line to magnetic switch interrupted or X
magnetic switch under left hand arm rest defective
2303 Fault "driver's seat armrest cable damage ground" Ground supply line to magnet switch interrupted or X
magnetic switch under left hand arm rest defective
3000 Fault vibration sensor "no signal" Check connecting lines and plugs to the vibration sensor X X
The sensor in the vibration motor does not detect any
or replace the sensor in the vibration motor, if
pulses.
necessary
3001 Fault vibration pump "valve for low amplitude" The connecting line from the output of the control to the X X
The required control power cannot be transmitted to the
proportional solenoid is interrupted, or the
proportional solenoid.
proportional solenoid is defective, or the changeover
relay / bridge is missing
3002 Fault vib. pump valve low amplitude "hysteresis" X X
The...
3003 Fault vib. pump valve low amplitude "current range" Fault in connecting line or connection to another potential (e.g.: X X
The current signal is outside the permissible range (see operating voltage)
3004 Fault vibration pump "valve for high amplitude" The connecting line from the output of the control to the X
proportional solenoid. the proportional solenoid is defective, or
the change-over relay / bridge is missing
3005 Fault vib. pump valve high amplitude "hysteresis" X
The...
3006 Fault vib. pump valve high amplitude "current range" Fault in connecting line or connection to another potential (e.g.: X
The current signal is outside the permissible range (see operating voltage)
5024 Fault diesel engine warning "coolant filling level" Coolant level too low or sensor defective X X

Author: Seis / TE

diagnose
5025 Fault diesel engine shut-down "coolant filling level" Coolant level too low or sensor defective X X
5026 Fault diesel engine warning "air filter" Air filter soiled or sensor defective X X
5027 Fault diesel engine shut-down "air filter" Air filter soiled or sensor defective X X
5028 Warning water separator Water or other dirt in fuel filter X X
5029 Shut-down caused by water separator Water or other dirt in fuel filter X X
5100 Fault diesel engine EMR "warning lamp" Collective warning X X

" see other fault codes for exact fault diagnose
5101 Fault diesel engine EMR "red stop light" Collective fault engine shut-down X X
" see other fault codes for exact fault diagnose
5110 Fault diesel engine EMR "nominal speed value" " CAN connection between ESX and EMR interrupted X X
" CAN connection has short circuit to ground, to +12 V or
connection between CAN+ and CAN-.
" ESX without voltage supply
" Voltage of on-board battery too low
5112 Fault diesel engine EMR "oil pressure" " Engine oil pressure too low X X
5113 Fault diesel engine EMR "charge air pressure" " Charge air pressure too low X X
5114 Fault diesel engine EMR "temperature intake pipe" " Charge air temperature too high X X
5116 Fault diesel engine EMR "coolant temperature" " Coolant temperature too high X X
5117 Fault diesel engine EMR "fuel temperature" " Fuel temperature too high X X
5118 Fault diesel engine EMR "engine speed" " Speed sensor 1 or 2 defective X X
" Connection between EMR and speed sensor 1 or 2
interrupted
5122 Fault diesel engine EMR "nominal speed value" " CAN connection between ESX and EMR interrupted
" CAN connection has short circuit to ground, to +12 V or
connection between CAN+ and CAN-.
" ESX without voltage supply
" Voltage of on-board battery too low
5123 Fault CAN communication " CAN communication between EMR and ESX X X
5130 Fault diesel engine EMR "oil pressure sensor" " sensor defective X X
" Wire breakage in current path
" Current path has short circuit to ground
5131 Fault diesel engine EMR "charge air pressure sensor" " sensor defective X X
5132 Fault diesel engine EMR "charge air temperature" " sensor defective X X

Author: Seis / TE

diagnose
5133 Fault diesel engine EMR "coolant temperature sensor" " sensor defective X X
5134 Fault diesel engine EMR "speed sensor" " Speed sensor 1 or 2 defective X X
5140 Fault diesel engine EMR "unknown fault" Fault diagnose only with DEUTZ diagnose tool (SERDIA) X X
5502 Fault warning "hydraulic oil filter" Hydraulic oil filter soiled or sensor defective X X
5503 Fault shut down "hydraulic oil filter" Hydraulic oil filter soiled or sensor defective X X
5504 Fault warning "oil temperature" Hydraulic oil temperature too high or sensor defective X X
5005 Fault shut down "oil temperature" Hydraulic oil temperature too high or sensor defective X X
7011 Fault warning "change of machine type" Only change the machine type after appropriate measures have X X
This warning appears when the machine type has been been applied; e.g. conversion from D to PD (different rolling
changed. circumference of drum)
7012 Fault "conflict machine type" The machine type was changed in a way that the type X X
This fault message is displayed if the set machines do not parameters no longer comply with the basic parameters → enter
comply with the basic parameters of the machine. the correct machine code or a basic parameter of the machine
was changed (e.g. a different axle)

Author: Seis / TE
11 Input codes for ESX control
11.1 General

0500 Activation of function "Driving against closed brake" 500 and brake control light stays on when shifting the travel
lever out of the neutral gate
0501 Deactivation of function "Driving against closed brake" O K for 3sec. then back to 0000
0555 Display of "software version" e.g.: „109" for software version 1.09
0700 Activation of function "Show stored faults" Fault codes are successively displayed
0701 Deactivation of function "Show stored faults" 0000
0710 Delete stored faults once the error log is deleted the display will return to 0000
0720 Display of "machine code" The machine code is displayed (72xx) (see chapter 3.6)
11.2 Brake

1001 Display of output voltage on output of control "brake valve" Display in V (e.g. 126 corresponds with 12,6V)

Author: Seis / TE
11.3 Travel lever / driving

1025 Display "travel lever direction" 100 = forward
0 = neutral
1 = reverse
1026 Display "movement direction" 0 = neutral
1 = forward
2 = reverse
1027 Display "travel lever enable" 1
1040 Display "speed range / gear" The display shows the travel range switch position from 1...24
1041 Display "voltage value for speed range / gear" Stages 0...4 = 4
Stages 5...9 = 3
Stages 10...14 = 2
Stages 15...19 = 1
Stages 20...24 = 0
1042 Display "voltage value for speed range / gear standardized" Stage 1 ≈ 956 Stage 2 ≈ 916 Stage 3 ≈ 875
Stage 4 ≈ 835 Stage 5 ≈ 795 Stage 6 ≈ 756
1044 Display "speed range / gear" end value Stage 1 = 417 Stage 2 = 833 Stage 3 = 1'250
Stage 4 = 1'667 Stage 5 = 2'089 Stage 6 = 2'500
1070 Display "nominal current travel pump forward“ 0 – 1200 mA

1071 Display "Actual current travel pump forward“ Display in mA

Author: Seis / TE
1080 Display "nominal current travel pump reverse“ 0 – 1200mA

1081 Display "actual current travel pump reverse“ Display in mA
1090 Activates Function "detect surge currents in travel system see chapter "Teach travel system surge currents"
automatically"
1091 Function "Determine surge current forward" (only vers.1.07 and 1.08) see chapter "Teach travel system surge currents"
1092 Function "Determine surge current reverse" (only vers.1.07 and 1.08) see chapter "Teach travel system surge currents"
1106 Display "speed sensor travel motor front / pulses" Counts the pulses up to 99'999 and then starts at 0 again
1107 Display "speed sensor travel motor front / direction signal" 2 = forward
1 = standstill and reverse
1108 Display "sense of rotation front drive" 1 = forward
0 = standstill
2 = reverse
1116 Display "speed sensor travel motor rear / pulses" Counts the pulses up to 99'999 and then starts at 0 again
1117 Display "speed sensor travel motor rear / direction signal" 2 = forward
1 = standstill and reverse
1118 display "sense of rotation rear drive" 1 = forward
0 = standstill
2 = reverse
1140 Display "travel pressure" Display in bar
1145 Display "inclination sensor" standardized Incloination display as standardized value (65540 → 0%)
1146 Display "inclination sensor" sensor input voltage Display in mV
0% ≅ 2550mV
1147 Display "inclination sensor" standardized sensor voltage Inclination display in mV
1148 Display "inclination sensor" initialization 1 corresponds with OK

Author: Seis / TE
11.4 Steering
1300 Function status arm rest contact 1= arm rest up; 2=arm rest down
1301 Voltage of arm rest contact Display in mV
1302 Travel operation status by arm rest contact 1=travel enabled; 2= travel disabled
2000 activates Function "teach steering start current" see chapter "Determine steering system surge currents"
2001 Function "teach steering start current" see chapter "Determine steering system surge currents"
2010 activates Function "teach steering potentiometer limits" see chapter "Determine steering system end stops"
2011 Deactivates Function "teach steering potentiometer limits" 0000
2012 Function "teach steering potentiometer right hand limit" see chapter "Determine steering system end stops"
2013 Function "teach steering potentiometer left hand limit" see chapter "Determine steering system end stops"
2060 Activates function „Change steering unit“ see chapter "Changing the steering unit“
2061 Activation of electric steering unit see chapter 3.6
2062 Activation of hydraulic steering unit see chapter "Changing the steering unit“
2100 Display "Nominal current value steering valve right“ 0 – 1200mA

2101 Display "Actual current value steering valve left“ Display in mA
2102 Display "Nominal current value steering valve left“ 0 – 1200mA
2103 Display "Actual current value steering valve left“ Display in mA
2110 Display of voltage value from steering angle sensor on articulated joint 0...8,5VDC
2112 Steering angle actual position -1000...0...1000
2120 Steering angle nominal position -1000...0...1000
2130 Steering wheel sensor 1 track 1 absolute pulses Number of total pulses
2132
2133 Steering wheel sensor 1 direction 1=steering wheel steers to the right; 2=steering wheel steers to
the left
2142
2143 Steering wheel sensor 2 direction 1=steering wheel steers to the right; 2=steering wheel steers to

Author: Seis / TE

the left
11.5 Vibration
3000 Display "switch vibration mode" Off = 0
On = 1
3001 Display "Status of vibration relay" 0 = Relay K43 not switched
1= Relay K43 switched
3002 Display "Vibration pump valve current" Display value = mA
The actual pump current is displayed.
11.6 Engine
5024 Display "Status engine coolant level" 0= coolant level OK; 1= coolant level too low
5026 Display "Status engine air filter" 0= air filter OK; 1= air filter soiled
5028 Display "Status water separator" 0= water separator OK; 1= water or dirt in fuel filter
11.7 Hydraulics
5002 Display "Status hydraulic oil – filter" 0= hydraulic oil filter OK; 1= hydraulic oil filter soiled
11.8 Changing the machine code

7010 Change "machine code" see chapter "Changing the machine code“

Author: Seis / TE
Service Training WZ – 4
12 Terminology in connection with ESX

Short circuit
A direct, unwanted connection between two different cables or between machine and cables.
Examples:
Two lines rub against each other until the insulation has worn off.
A conductive line rubs off the insulation at the vehicle ground.
Wire breakage
This generally means that a connection is interrupted. Possible reasons may be:
Line:
• torn (not necessarily visible from outside)
• rubbed through
• chafed mostly in connection with a short circuit to ground
Terminal, cable lug

• loosened, slipped off
• broken off,
• corroded,
• socket / plug faulty

Author: Seis / TE
Short circuit to ground

Line, terminal has direct connection to vehicle ground, often in connection with wire breakage
Digital
There are only two permissible states, e.g. switched on or off; lamp on / off; current flows /
does not flow; valve open / closed (black-white valve)
Analogue
In contrast to Digital many conditions are permitted within a certain range. For instance room
temperature 0° to 40°; current 4mA to 20mA; voltage 0V to 8,5V; resistance 100 Ω to 300 Ω;
valve 0% to 100% opened (proportional valve)

Author: Seis / TE
Control
Controlling describes the process during which an input value influences a distance (the
value to be controlled), following a fixed command. For this purpose all possible interfering
factors (e.g. temperature, humidity ...) must be known.
Closed loop control

Closed loop control is a process during which a value, the closed loop control value (e.g.
pressure), is continually measured and compared with a nominal value (guide value). The
result of this comparison will affect the closed loop control value, thereby adapting the closed
loop control value to the guide value.
This sequence occurs in a closed circuit, the co-called closed loop control circuit.
Marking Closed loop control Control

Operating path: closed open
(closed loop control circuit) (control chain)
Measurement and Value to be adjusted is Values to be controlled
comparison of value to measured and compared. are not measured and
be adjusted: compared.
Reaction to faults Counteracts to all faults Does not respond to
(generally): targeting the system to be unknown faults
controlled.
Technical expense: Low expense: High expense if many
Measurement of the value to faults have to be
be controlled, comparison of considered, low expense
nominal and actual value, if not faults occur.
power amplification
Performance in For unstable systems closed In unstable systems
unstable systems loop controls must be used. controls cannot be used.

Author: Seis / TE
Current and voltage measurement
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)
PWM – digital output

Certain outputs on the ESX are designed as so-called PWM – digital outputs. This means
that these outputs are special current outputs. Here it is possible to measure a current, but
no voltage. These outputs are used to trigger proportional valves.

Author: Seis / TE
Inhaltsverzeichnis: BW177..226DH−4
table of contents:
Blatt Nr.: Zeichnungsnummer
Funktionsgruppe function unit
sheet no.: drawing − no.
001 582 700 95 Stromlaufplan Circuit Diagram
002 582 700 95 Versorgung, Starten, Hupe supply, starting unit, signal horn
003 582 700 95 Motor Deutz EMR II engine Deutz EMR II
004 582 700 95 Fahrantrieb, Neigungssensor, Sitzkontakt driving system, slope sensor, seat contakt switch
005 582 700 95 Datensammler, LC−Display data−collector, LC−display
006 582 700 95 Lenkung, Vibration steering, vibration
007 582 700 95 Fahrhebel, Vibrationsplatten joystick, vibration−plates
008 582 700 95 Variocontrol, Messtechnik Variocontrol, measurement equipm.
009 582 700 95 Bomag Compaction Management BCM Bomag Compaction Management BCM
010 582 700 95 Beleuchtung und StvZO illumination and StvZO
011 582 700 95 Kabinenausrüstung, Beleuchtung, Radio, Tachograph cabin−equipment, headlights, radio, tachograph
012 582 700 95 Kabinenheizung, Klimaanlage, Zusatzheizung cabin−heater, air conditioning, add. heater
101 582 700 95 Bauteilliste component listing
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
X1:15E X1:16E X1:27E X1:28E X1:30E
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
S00 S01 X3:3

22 12 32 42 52 62
2 x 10qmm
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
V01 X1:3 X1:4 5:8

heating−flange
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
only acc.to air conditioning

1 1 D+ 5:2
B+ 2:11 2:6 B+
nur bei Klimaanlage
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
X1:110 X1:168 X1:123 X1:103 X1:104
31 31 3:1
Trennschalter Batter 2:8 12:7 2:16 Starter Signalhörer Steckdose

break switch battery starter warning horns socket
Heizflansch Batterie Batterie Generator Nur bei Geländer/ROPS/SD

heating−flange battery battery generator only at hand−rail/ROPS/sun−roof
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
B88 B114 B130 Y137 5 B115 B113

X34:N
Diagnosestecker EMR
diagnosis interface EMR
2:4
X1:186
31 EMR
2:20 31 31 4:1
2:2
Motordrehzahlsensor
sender engine rpm 2
Motordrehzahlsensor EMR Kühlmitteltemperatur

sender engine rpm 1 EMR coolant temperature
EMR Motoröldruck Ladeluftdruck + Temp
EMR engine oil pressure charging air pressure + temperature
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
+45_G=4,5V X1:158 X1:114 X1:121 X1:122 X1:143 X1:141

X1:171
X1:173
X1:175
X1:177
X1:176
+ −45_G=0,5V
B57 1V
400 ... 1.200mA
400 ... 1.200mA
400 ... 1.200mA
400 ... 1.200mA

bl
ws
br
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
Rückfahrwarnsummer Prop.−Pumpe Rückw. Prop.−Ventil Achsmotor

back up alarm buzzer prop−pump backwards prop.−Valve axle 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
X1:29E 2:17 F05:2 F05:2 2:17
1 4:17 CAN1+ CAN1+ 7:14

F24 ESX Fahrsteuerung DIOS Platten
15A 4:17 CAN1− CAN1− 7:14
2
X1:29A
X1:87 X1:88 X1:80 X1:86

X1:41
X1:39
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
X1:106 X1:111 X1:112 X1:107 X1:108 X1:105

BL 10:17 ECO
Low High down up
Wasserabscheider
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
X21:1 X8:1 X10:2

B21 1 B03 1 B55 B124
0 .. 67 OHM
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
X1:117 X1:94 X1:94 X1:117 X1:154 X1:149 X1:82

31 31 6:1
4:20
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
X1:60 FM5 X1:61
X1:58 FM2 X1:59
X1:56 FM1 X1:57

X1:159 X41:4 X40:4 0V S2 A X40:3 sw
B132 2 2 2 ws X22:3
VIB
Schalter Armlehne
X1:162 X41:2 X39:4 X39:3 11:6

Lenkwink.
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
400 ... 1.200mA
2:16
X1:116 X1:115 12
400 ... 1.200mA

X1:150
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
Prop.−Ventil Vibration klein Magnetventil Bremse

prop. valve vibration small solenoid valve brake
Notlenkung links Prop. Ventil lenken links Prop−Ventil Vibration groß
emerg. valve steering left prop. valve steering left prop. valve vibration big
Notlenkung rechts Prop. Ventil lenken rechts Warnsummer Störung
emrg. valve steering right prop. valve steering right warning buzzer, failure
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
S35 K0G S09 13 S64 13 S36 13 S139 X72:1

13 23 2 2 2
86 86 1 Y122 1 Y142 1 Y144 1

K48 K05 Y98
14 14 14 14
24
2 2 2 2
85 85
X72:2
X1:149 X1:211 X1:212
6:20 31
8:1
6:17 2:12 31
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
7:20 K11:87 K11:87 10:1
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
nur bei BTM+/BTM prof

only at BTM+/BTM prof
1 1 1
F148 F146 X2:56 X2:53 X2:60 X2:57 FM4
10A 15A X2:71
2 2 2
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
nur bei BTM prof

only at BTM prof
15g/bl 15g/bl
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
Aufn. hinten 20g

Aufn. vorne 15g
Aufn. vorne 20g

X4:A X4:B 120 OHM
Elektronik
Leistung
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
Prop−Ventil Erreger auf EVIB−Meter

solenoid−valve exciter up EVIB−meter
Prop−Ventil Erreger ab
solenoid valve exciter down
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
X3:4 X3:5 with cabin 30 49L 49R

STV1
11:17 A02
STV2
11:17
X1:23E X1:24E
K16 30 31 82 L R
10:9 F09 F10
15A 15A
switch, working head lights
87 87a X1:23A X1:24A

BEL 5:9 BL
5:9
13 BR
5:9
Schalter Arbeitsbele
Arbeitsscheinwerfer hinten rechts
Arbeitsscheinwerfer vorne rechts

S16 14
connection working head
Arbeitsscheinwerfer hinten links

Anschluß Arbeitsschein−
Arbeitsscheinwerfer vorne links
working head lights, front rh.

working head lights, front lh.
lights without StvZO
working head lights, rear rh.

working head lights, rear lh.
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
switches interior lights
+ 7,8,9 2 B4 2 2 2 2
Schalter Innenleuche
A01 VIB X3:18 5 3 C3

6:18
A5+A6
S45 TK −
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
11:6 Wascher hinten Wascher vorn 11:2 Arbeitsscheinwerfer vorn

washer rear washer front working head lights, front
Wischer hinten Wischer vorne Arbeitsscheinwerfer hinten Rundumkennleuchte

windscreen wiper, rear windscreen wiper, rear working head lights, rear rotary beacon
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
switch, cab add.−heater

Steuergerät 5
control unit
Schalter Kabinenlüfter 6 11 12 1 Regel aus = 0,4A 0123
E30 Kleine Stufe = 0,67A S28
switch blower cabin X54:6 X54:11 X54:12 X54:1 Zusatzheizung mittleter Stufe = 1,0A
add. heater große Stufe = 1.9A
X3:13 Power Stufe = 2,8A
6 2 1 3
Anlaufstrom beim Start = 8,3A
X53:M
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
temperature sensor heating unit

X3:11
X3:10
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
Y15 1 2
X17:4 V04 X1:168
3,5A
2 1
X1:164
11:20 31 31
Kabinenlüfter Klimakompressor Magnetventil Heizung Kraftstoffpumpe

cab ventilator air conditioning compr. solenoid valve, heating unit fuel pump heating unit
Kabinenlüfter
cab ventilator
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
B03 005 3 Unterdruckschalter Luftfilter Vacuum switch, air cleaner

B11 002 16 Signalhorn Warning horn
B11 002 18 Signalhorn Warning horn
B16 006 16 Aufnehmer Vibrationsfrequenz vorne Transducer, vibration frequency, front
B21 005 2 Differenzdruckschalter Hydr.−Oelfilter Pressure diff. switch, hydr. oil filter
B51 011 4 Lautsprecher Radio Speaker radio
B51 011 6 Lautsprecher Radio Speaker radio
B55 005 4 Kuehlmittelstand Ausgleichsbehaelter Coolant charge expansion tank
B57 004 6 Neigungssensor Stufenumschaltung Slope sensor, speed range selection
B59 004 4 Aufnehmer Bandagengeschwindigkeit Sensor, drum speed
B60 004 2 Aufnehmer Achsgeschwindigkeit Sensor, axle speed
B61 008 12 Aufnehmer Verstellzylinder Sensor, ajustable zylinder
B62 008 8 Beschleunigungsaufnehmer Acceleration sensor
B62 008 10 Beschleunigungsaufnehmer Acceleration sensor
B65 006 4 Sensor, Lenkwinkel vorn Sensor, angularity steering, front
B88 003 6 Druckgeber Motoroel Sender, engine oil pressure
B103 012 7 Temperaturschalter Klimaanlage Temperature switch, air conditioning
B104 012 7 Druckschalter Klimaanlage Pressure switch, air conditioning
B112 004 3 Druckgeber Fahrpumpe pressure sender, driving pump
B113 003 13 EMR Temperaturgeber Kuehlmittel EMR Temperature switch, collant
B114 003 7 EMR Aufnehmer, Motordrehzahl 1 EMR Trancducer, engine speed 1
B115 003 11 Geber Ladeluftdruck Sender, charging air pressure
B124 005 5 Geber Wasserstandsabscheider Diesel Sender, water separator fuel
B126 003 14 EMR Temperaturgeber Kraftstoff EMR fuel temperature sender
B130 003 8 EMR Aufnehmer, Motordrehzahl 2 EMR Trancducer, engine speed 2
B131 012 10 Temperaturschalter Heizung Temperature switch, heating
B132 006 2 Inititator Armlehne links proximity switch left arm rest
B134 007 17 Näherungsschalter Platten oben proximity switch, plate up
B135 007 16 Näherungsschalter Platten mitte proximity switch, plate middle
component listing
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
F00 002 4 Hauptsicherung Batterie Fuse, main, battery 125A

F05 002 14 Sicherung Steckdose Fuse, socket 15A
F07 010 15 Sicherung Warnblinker Fuse, hazard light 15A
F08 010 18 Sicherung Blinker u. Arbeitsscheinw. Fuse, indicators a. work. head light 15A
F09 010 6 Sicherung Park− u. Schlussl. links Fuse, parking and tail light, lh. 10A
F10 010 8 Sicherung Park− u. Schlussl. rechts Fuse, parking and tail light, rh. 10A
F11 010 2 Sicherung Scheinwerfer links Fuse, head light, lh. 15A
F13 002 10 Sicherung Startschalter Fuse, starter switch 30A
F15 012 18 Sicherung Heizgeraet Fuse, heating unit 5A
F18 010 5 Vorsicherung Arbeitsscheinw. vorne Primary fuse, work. head light, fr. 30A
F19 010 12 Sicherung Arbeitsscheinw. vorne li. Fuse, working head light, front, lh. 30A
F22 010 10 Sicherung Arbeitsscheinwerfer hinten Fuse, working head lights, rear 30A
F23 002 18 Sicherung Signalhorn Fuse, warning horn 15A
1
F24 005 2 Sicherung Ueberwachungsmodul Fuse, monitoring module 15A

F31 012 3 Sicherung Kabinenluefter Fuse, cabin ventilator 20A
F39 002 19 Hauptsicherung Kabine Main fuse, cab 15A
F40 012 13 Sicherung Kabinenheizung Fuse, heating unit cab 20A
F41 011 19 Sicherung Rundumkennleuchte Fuse, rotary beacon 10A
9
F42 011 3 Sicherung Kabineninnenleuchte Fuse, inside light cab 10A

F43 011 10 Sicherung Wischermotor hinten Fuse, wipermotor rear 15A
F44 011 13 Sicherung Wischermotor vorn Fuse, wipermotor front 15A
F48 002 3 Sicherung Gluehanlage Fuse, glow plug system 125A
582 700 95
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
101

F130 011 15 Sicherung Nachtleuchte Fuse, night lamp 10A
F143 011 2 Sicherung Heckscheibenheizung fuse rear screen heating unit 15A
F144 011 20 Sicherung Kabinensteckdose Fuse cabin−socket 15A
F145 007 18 Sicherung Anhängeplatten fuse vibration plates 15A
F146 008 5 Sicherung Steuerung MESX (Potential 30) Fuse Controller (Pot. 30) 15A
F148 008 2 Sicherung Steuerung MESX (Potential 15) Fuse Controller (Pot. 15) 10A
G01 002 3 Batterie Battery 103A

G02 002 5 Generator Generator
G03 002 4 Batterie Battery 103A
H06 010 15 Meldeleuchte Warnblinker Indicator light, hazard light LED ROT
H07 006 16 Warnsummer Betriebsstoerung Warning buzzer, breakdown 0.15A
H14 004 11 Warnsummer Rueckwaertsfahrt Back−up alarm buzzer MAX O,46A
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28.06.2004
K05 007 3 Relais Startstrom Relay, starting current BOSCHW

K06 010 4 Relais Scheinwerfer hinten Relay, head lights, rear BOSCHW
K09 002 8 Relais Klimageraet Relay, air conditioning BOSCHW
K11 002 10 Relais Klemme 30 auf 15 Relay, terminal 30 to 15 BOSCHL
K14 003 19 Relais Vorgluehen Relay, glow plug system TYCOX
K16 010 9 Relais Scheinwerfer vorne Relay, head lights, front BOSCHW
K32 011 1 Relais Kabine Relay, cabin BOSCHW
K43 006 12 Relais Vibration Relay, vibration BOSCHW
K48 007 2 Relais Fahrhebel 0−Stellung Relay, travel lever 0−position BOSCHW
K56 006 8 Relais Lenkung Relay, steering system BOSCHW
K57 006 9 Relais Lenkung Relay, steering system BOSCHW
K61 002 6 Relais Ladekontrolle Relay, charge control BOSCHW
K141 011 16 Relais Heckscheibenheizung relay, heating rear screen BOSCHW
M01 002 11 Starter Starter 2.3 KW

M04 011 12 Scheibenwischermotor vorne Windscreen wiper motor, front 4,7A
M05 011 10 Scheibenwischermotor hinten Windscreen wiper motor, rear 2,9A
M06 011 13 Scheibenwaschermotor vorne Windscreen washer motor, front MAX. 3,8A
M07 011 11 Scheibenwaschermotor hinten Windscreen washer motor, rear MAX. 3,8A
M09 012 3 Kabinenluefter Cabin ventilator
M09 012 4 Kabinenluefter Cabin ventilator
P07 008 15 Omegameter Omegameter

P09 011 8 Frequenz− und Geschwindigkeitsanzeige Frequency− and Speedometer
P11 008 14 Drucker Printer
P15 009 16 BCM 03 Bildschirm BCM 03 terminal
P16 008 16 Diagnose, Variomatic Diagnostics, varimatic
P33 008 18 Opus 21 Opus 21
component listing
R03 005 6 Geber Tankanzeige Sender, level gauge 0 .. 67 OHM

R19 002 2 Heizflansch heater flange 167A
Bauteilliste
R20 004 15 Widerstand Resistor 120 OHM

R80 011 2 Heizung Heckscheibe heating rear screen MAX. 13A
S00 002 10 Startschalter Starter switch

S01 002 16 Schalter NOT AUS Switch, emergency off NOTAUSH
S03 002 18 Taster Signalhorn Push button, warning horn
S06 004 10 Sitzkontaktschalter links Switch, seat contact, lh.
S09 007 8 Vibrationsschalter vorne Switch, vibration, front
S14 010 15 Warnblinkschalter Switch, hazard light
S15 010 4 Beleuchtungsschalter StVZO Switch, lighting StVZO
S16 010 4 Schalter Arbeitsbeleuchtung vorne Switch, working head lights, front
S20 011 13 Schalter Scheibenwischer vorne Switch, windscreen wiper, front
S21 011 10 Schalter Scheibenwischer hinten Switch, windscreen wiper, rear
S28 012 18 Schalter Kabinenheizung Switch, cabin heating
S30 002 3 Batterietrennschalter Switch, battery disconnect
S35 007 7 Vibrationsschalter klein/gross Switch, vibration low/high
S36 007 11 Vibrationsschalter Switch, vibration
S37 010 18 Schalter Blinker Switch, indicator
S38 011 19 Schalter Kennleuchte Switch, warning light
S42 007 11 Stufenumschalter schnell−langsam Speed range selector, fast−slow
S44 012 3 Schalter Kabinenluefter Switch, cabin ventilator
S45 011 3 Schalter Kabineninnenleuchte Switch, cabin inside light
S55 007 6 Schalter Fahrhebel Switch, travel control lever
S64 007 10 Schalter Schwimmstellung Switch, float position
S86 011 3 Schalter Tuer, links Switch door, lh.
S120 005 17 Schalter Motordrehzahl Switch, engine speed
S139 005 19 Schalter Frequenzverstellung Switch, frequency control
S139 007 13 Schalter Frequenzverstellung Switch, frequency control
S158 011 15 Schalter Nachtbeleuchtung Switch, cabin night lamp
S163 011 16 Schalter Heckscheibenheizung switch rear screen heating unit
2
V01 002 7 Diode Diode FE5B

9
V06 012 9 Diode Diode
X1:1 002 6 WAGO ZENTRALELEKTRIK WAGO E−BOX

582 700 95

102

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28.06.2004

component listing

Bauteilliste

3

9

582 700 95

103

X1:15A 002 10 WAGO ZENTRALELEKTRIK WAGO E−BOX
X1:15E 002 10 WAGO ZENTRALELEKTRIK WAGO E−BOX
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28.06.2004

component listing

Bauteilliste

4

9

582 700 95

104

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X2:47 008 18 WAGO−MESSTECHNIK Wago−measurement equip.
component listing

Bauteilliste

X3:1 010 11 STECKER ROPS/SD conn. ROPS/SR
X3:1 011 10 STECKER KABINE/ROPS conn. cabin/ROPS
X3:3 002 19 SETCKER KABINE/ROPS Con cabin/ROPS
X4:A 008 14 KABINENST. MESST. con. measurem.equipm.
X4:B 008 14 KABINENST. MESST. con. measurem.equipm.
X4:C 008 14 KABINENST. MESST. con. measurem.equipm.
X4:D 008 14 KABINENST. MESST. con. measurem.equipm.
X4:E 008 15 KABINENST. MESST. con. measurem.equipm.
X4:F 009 18 KABINENST. MESST. con. measurem.equipm.
X4:G 009 18 KABINENST. MESST. con. measurem.equipm.
X4:M 009 16 KABINENST. MESST. con. measurem.equipm.
X4:N 009 15 KABINENST. MESST. con. measurem.equipm.
5
X6:1 006 13 STECKER VIBRATION GRO conn. vibration big

X6:2 006 14 STECKER VIBRATION GRO conn. vibration big
X7:1 006 15 STECKER VIBRATION KLE conn. vibration small
X7:2 006 14 STECKER VIBRATION KLE conn. vibration small
X8:1 005 5 STECKER WASSERABSCHEI connector water separator
9
X8:2 005 5 STECKER WASSERABSCHEI connector water separator

X9:1 004 11 STECKER RÜCKFAHRALARM conn. backupalarm
X9:2 004 11 STECKER RÜCKFAHRALARM conn. backupalarm
XS 002 19 Steckdose Socket
582 700 95
XS 011 20 Steckdose Socket

X10:2 005 6 STECKER TAUCHROHRGEBE connector fuel level sensor
X10:3 005 6 STECKER TAUCHROHRGEBE connector fuel level sensor
X14:A 004 10 STECKER SITZKONTAKT connector seat contact switch
X14:B 004 10 STECKER SITZKONTAKT connector seat contact switch
105
X15:1 004 13 STECKER FAHRPUMPE RÜC connectoe driving pump back

X15:2 004 13 STECKER FAHRPUMPE RÜC connectoe driving pump back
X16:1 004 12 STECKER FAHRPUMPE VOR connector driving pump front
X16:2 004 12 STECKER FAHRPUMPE VOR connector driving pump front
X17:1 012 3 STECKER LÜFTER HKL conn. blower
X18:1 012 10 STECKER THERMOFÜHLER conn. sender temp.
X18:2 012 10 STECKER THERMOFÜHLER conn. sender temp.
X19:1 012 7 STECKER EISSCHUTZ HKL conn. anti−ice air−cond.
X19:2 012 7 STECKER EISSCHUTZ HKL conn. anti−ice air−cond.
X20:1 012 7 STECKER DRUCKSCH. KLI conn. pressuresitch air−cond.
X21:1 005 4 STECKER KÜHLMITTEL connector coolant sensor
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X21:2 005 4 STECKER KÜHLMITTEL connector coolant sensor

X22:1 006 16 ST. VIBRATIONSAUFNEHM connector vibration sensor
X25:2 007 11 ST. FAHRSTUFENSCHALTE connector switch speed ranges
X26:1 005 8 STECKER DATENSAMMLER connector data collector
component listing

Bauteilliste

X28:1 005 16 STECKER LC−DISPLAY 1 connector LC−display 1
X30:1 003 5 EMR−Stecker Fahrzeug EMR−connector compactor
X31:1 003 16 EMR−Stecker Motor EMR−connector engine
6

9

582 700 95

106

X32:A 003 2 EMR − Diagnose EMR−diagnosis
X32:B 003 3 EMR − Diagnose EMR−diagnosis
X32:G 003 3 EMR − Diagnose EMR−diagnosis
X32:H 003 3 EMR − Diagnose EMR−diagnosis
X32:K 003 2 EMR − Diagnose EMR−diagnosis
X32:L 003 2 EMR − Diagnose EMR−diagnosis
X33:1 003 19 Trennstelle EMR II conector EMR II
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X34:A 004 14 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:B 004 16 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:C 004 12 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:D 004 13 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:G 004 10 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:H 004 11 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:J 006 3 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:N 003 5 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:P 002 14 DIAGNOSESTECKER ESX connector diagnosis ESX
X34:R 005 2 DIAGNOSESTECKER ESX connector diagnosis ESX
X35:1 006 4 ESX STECKER esx connector
component listing

Bauteilliste

X36:A 002 4 EINSPEISUNG SCHALTKAS supply e−box
X36:B 002 5 EINSPEISUNG SCHALTKAS supply e−box
X37:A 002 10 ST. ZÜNDSCHLOSS E−KAS connector ignition switch, e−box
X37:B 002 12 ST. ZÜNDSCHLOSS E−KAS connector ignition switch, e−box
X38:A 002 12 STECKER STARTER E−KAS connector starter, e−Box
X39:1 006 9 STECKER 1 LENKRAD connector 1 steering unit
7

9
X41:1 006 8 ST. LENKRADKABELBAUM conn. steer. wire harn.

582 700 95

X42:1 008 18 STECKER OPUS21 conn. OPUS21
107

X43:1 006 2 STECKER SCHALTER ARML connector switch arm rest
X43:2 006 1 STECKER SCHALTER ARML connector switch arm rest
X44:1 008 13 MESX STECKER MESX Stecker
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X47:A 008 11 STECKER AUFN. PLEIGER conn. sender PLEIGER
component listing
X47:B 008 12 STECKER AUFN. PLEIGER conn. sender PLEIGER

X47:C 008 12 STECKER AUFN. PLEIGER conn. sender PLEIGER
Bauteilliste
X48:1 008 8 STECKER AUFN. VORNE conn. sender front

X49:1 008 10 STECKER AUFN. HINTEN conn. sender rear
X50:1 007 13 ST. PLATTENFREQ. conn. plate−freq.
X51:1 006 2 ST. 1 LENKRADKABELBAU connector 1 steering wiring
X52:1 004 3 STECKER DRUCKSENSOR connector pressure sensor
X52:2 004 3 STECKER DRUCKSENSOR connector pressure sensor
X53:B 012 3 STECKER LÜFTERSCHALTE conn. blowerswitch
X53:C 012 4 STECKER LÜFTERSCHALTE conn. blowerswitch
X53:H 012 4 STECKER LÜFTERSCHALTE conn. blowerswitch
X53:L 012 3 STECKER LÜFTERSCHALTE conn. blowerswitch
X53:M 012 3 STECKER LÜFTERSCHALTE conn. blowerswitch
X54:1 012 11 STECKER HEIZSTEUERUNG conn. heating controller
X55:1 011 11 STECKER WISCHER HINTE connector wiper rear
X56:1 011 14 STECKER WISCHER VORNE conn. wiper front
X57:1 003 15 Stecker Motor connector engine
8

9

582 700 95

108

X58:2 010 17 STECKER STVZO VL Con. STVZO FL
X59:2 010 19 STECKER STVZO VR Con. STVZO FR
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X60:1 010 18 STECKER STVZO HL Con. STVZO BL
X61:1 010 19 STECKER STVZO HR Con. STVZO BR
X62:1 007 19 STECKER DIOS PLATTEN con. DIOS−plates
X72:1 007 14 ST. PROP.−PUMPE PLATT con. plate−pump
X72:2 007 14 ST. PROP.−PUMPE PLATT con. plate−pump
X74:1 008 14 STECKER DRUCKER con. printer
component listing

Bauteilliste

X75:2 009 16 SUB−D STECKER BCM INT con. SUB−D BCM
X75:7 009 15 SUB−D STECKER BCM INT con. SUB−D BCM
X76:1 009 17 STECKER VERS. BCM con. Power−sup. BCM
X76:2 009 17 STECKER VERS. BCM con. Power−sup. BCM
Y04 006 17 Magnetventil Bremse Solenoid valve, brake MAX. 1.8A

Y07 006 15 Magnetventil Vibration vorne gross Solenoid valve, vibration, front, high 0.4 .. 1.2A
Y08 006 13 Magnetventil Vibration vorne klein Solenoid valve, vibration, front, low 0.4 .. 1.2A
Y14 012 14 Kraftstoffpumpe Heizgeraet Fuel pump, heating unit
Y15 012 7 Magnetkupplung Klimakompressor Magnetic clutch, air conditioning compr. 3,5A
Y16 004 13 Magnetventil Fahrtrichtung vorwaerts Solenoid valve, travel direction forw. 0.4 .. 1.2A
Y17 004 12 Magnetventil Fahrtrichtung rueckwaerts Solenoid valve, travel direction backw. 0.4 .. 1.2A
Y30 004 15 Magnetventil Stufenumschaltung vorn Solenoid valve, speed range sel., front 0.4 .. 1.2A
Y31 004 16 Magnetventil Stufenumschaltung hinten Solenoid valve, speed range sel., rear 0.4 .. 1.2A
Y92 006 7 Magnetventil Lenkung vorne rechts Solenoid valve, steering, front rh. 0.4 .. 1.2A
Y93 006 6 Magnetventil Lenkung vorne links Solenoid valve, steering, front lh. 0.4 .. 1.2A
Y98 007 14 Magnetventil Vibrationsfrequenz, hinten Solenoid valve, vibrat.freq.,rear 0.4 .. 1.2A
Y112 006 4 Magnetventil Lenkung (Y1) Solenoid valve, steering (Y1) MAX. 1.8A
Y113 006 3 Magnetventil Lenkung (Y2) Solenoid valve, steering (Y2) MAX. 1.8A
Y122 007 16 Magnetventil Platten heben Solenoid valve, lift plates MAX. 1.8A
Y123 007 17 Magnetventil Platten senken Solenoid valve, let down plates MAX. 1.8A
Y137 003 10 EMR Verstellung EMR adjustment
Y138 012 10 Magnetveentil Heizung Solenoid valve, heating unit 1A
Y140 008 10 Magnetventil Erreger auf solenoid valve exciter up 0.4 .. 1.2A
Y141 008 11 Magnetventil Erreger ab solenoid valve exciter down 0.4 .. 1.2A
Y142 007 18 Magnetventil Plattenverschieben Links solenoid valve, plate displace left MAX. 1.8A
Y143 007 18 Magnetventil Plattenverschieben rechts solenoid−valve, plate displace right MAX. 1.8A
Y144 007 19 Magnetventil Platten Schwimmstellung solenoid−valve, plate swimming−position MAX. 1.8A
Y145 007 20 Magnetventil Platten (Priorität) solenoid−valve, plate (priority) MAX. 1.8A
99
582 700 95
109
X38
X36 X37
X1:301…
X1:324
X1:79 … X1:214
A80
X1:1 … X1:61
Nur bei StvzO

only acc. To StvZO illumination
A02 K05
K16 K06
K11
K09 K43
K48
K61
B57
K57
K56
X32:1-12 X34:1-19
Gez.: 28.06.2004 Seite: 1 von: 2

Name: Seis Übersicht Schaltkasten BW 177...226 DH/BVC-4 page: 1 from: 2
582 700 95
Gepr.: 28.06.2004 Ers. f.: Blatt Nr.: 201
Name: Werner
overview e-box BW 177...226 DH/BVC-4 Replaces: Sheet No.: 201
X2:47 … X2:78
CAN 1
A34
Fahrsteuerung
CAN 2 EMR + Fahrhebel
LCD +
CAN 1 Datensammler
+ OPUS 21
A83
Messtechnik Steuerung
CAN 3 BCM
Gez.: 28.06.2004 Seite: 2 von: 2

Name: Seis Übersicht Schaltkasten-Tür BW 177...226 DH-4/BVC page: 2 from: 2
582 700 95
Name: Werner
overview e-box door BW 177...266 DH-4 Replaces: Sheet No.: 201
WAGO smart DESIGNER 4.0
1 05756417
2 3 x 05756540 "R" + 793-501
5 05756539 "R" + 793-501
6 05756537
7 3 x 05756540 "R" + 793-501
10 05756537
11 05756540 "R" + 793-501
12 05756535 "R" + 793-501
13 05756537
14 2 x 05756538 "R" + 793-501
16 2 x 05756539 "R" + 793-501
18 05756537
19 4 x 05756540 "R" + 793-501
23 05756537
24 4 x 05756540 "R" + 793-501
28 2 x 05756539 "R" + 793-501
30 05756537
31 05756540 "R" + 793-501
32 05756539 "R" + 793-501
33 05756537
34 4 x 05756540 "R" + 793-501
38 05756539 "R" + 793-501
39 05756537
40 4 x 05756540 "R" + 793-501
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 :
Copyright WAGO. Technische Änderungen vorbehalten.

02.07.2004 09:04:26 Seite 1
44 05756537
45 05756540 "R" + 793-501
46 05756535 "R" + 793-501
47 05756537
48 05756540 "R" + 793-501
49 05756535 "R" + 793-501
50 05756537
51 05756538 "R" + 793-501
52 2 x 05756540 "R" + 793-501
54 05756539 "R" + 793-501
55 05756537
56 3 x 05756540 "R" + 793-501
59 05756538 "R" + 793-501
60 05756537
61 3 x 05756540 "R" + 793-501
64 05756535 "R" + 793-501
65 05756537
66 2 x 05756540 "R" + 793-501
68 05756539 "R" + 793-501
69 05756537
70 3 x 05756540 "R" + 793-501
73 05756535 "R" + 793-501
74 05756537
75 2 x 05756540 "R" + 793-501
77 05756539 "R" + 793-501
78 05756537
79 05756417
Artikelnummer :
Ort :
Optional4 :
Optional7 :

02.07.2004 09:04:26 Seite 2
Artikelnummer :
Ort :
Optional4 :
Optional7 :

02.07.2004 09:16:28 Seite 6
Artikelnummer :
Ort :
Optional4 :
Optional7 :

02.07.2004 09:16:28 Seite 7
1 05756417
2 4 x 05756540 "R" + 793-501
6 05756537
7 2 x 05756540 "R" + 793-501
9 4 x 05756538 "R" + 793-501
13 2 x 05756539 "R" + 793-501
15 05756537
16 05756417
Artikelnummer :
Ort :
Optional4 :
Betriebsmittel : Optionen Beleuchtung Lieferadresse: :
Optional7 :

02.07.2004 09:19:48 Seite 1
Artikelnummer :
Ort :
Optional4 :
Betriebsmittel : Optionen Beleuchtung Lieferadresse: :
Optional7 :

02.07.2004 09:22:27 Seite 2
1 05756417
2 2 x 05756540 "R" + 793-501
4 05756539 "R" + 793-501
5 05756537
6 05756538 "R" + 793-501
7 2 x 05756540 "R" + 793-501
9 05756539 "R" + 793-501
10 05756537
11 2 x 05756540 "R" + 793-501
13 05756539 "R" + 793-501
14 05756537
15 05756540 "R" + 793-501
16 05756538 "R" + 793-501
17 05756540 "R" + 793-501
18 05756537
19 05756540 "R" + 793-501
20 05756539 "R" + 793-501
21 05756537
22 2 x 05756438 "R" + 793-501
24 05756421
25 05756417
Artikelnummer :
Ort :
Optional4 :
Betriebsmittel : Klemmenleiste X2 / Lieferadresse: :
Optional7 :

02.07.2004 09:27:03 Seite 1
Artikelnummer :
Ort :
Optional4 :
Betriebsmittel : Klemmenleiste X2 / Lieferadresse: :
Optional7 :

02.07.2004 09:29:27 Seite 2
X74 X75
X56
X55 X76 X53 X54
X29
X28 X21
X39 X23 X24 X50
X59 X40 X25 X41
X58 X42 X51 X43 X57
X20
X14
X18 X30 X72 X6 X7

X17 X52 X33
X47 X22 X19 X31 X4 X3
X8 X15 X16
X45
X48 X49 X48 X49 X10
X46 (BVC) (BVC)
X36 X26 X60
X37 X1 X27 X61 X62
X38 X2
X9
X44
X35
X32 X34
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
Gez.: 28.06.2004 Seite: 1 von: 1

Name: Seis
Steckerübersicht BW 177...226 DH/BVC-4 page: 1 from: 1
582 700 95
Name: Werner
Connector overview BW 177...226 DH/BVC-4 Replaces: Sheet No.: 301

BW177-213-226 Series 4 Service Training

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BW177-213-226 Series 4 Service Training

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Service Training

Single drum roller - 4

BW 177 / 213 / 226 BVC

Teile-Nr. 008 099 94 12/2004

Compaction measuring system D1

Working principle of the system F1

Variocontrol Single Drum Rollers Series 4

Variocontrol Single Drum Rollers Series 4

• the location of components in the machine eases maintenance work,

Variocontrol Single Drum Rollers Series 4 -A1-

BW 177 DH-4 BVC

BW 213 DH-4 BVC

BW 213 DH-4 BVC + vibratory plates

BW 226 DH-4 BVC

1. Operating and maintenance instructions

Variocontrol Single Drum Rollers Series 4 -A2-

BOMAG VARIOCONTROL (BVC)

2. fulfilment of a task according to specification

BOMAG VARIOCONTROL offers the user the following advantages:

2. Better, reproducible results on all materials

3.No jump operation and therefore no particle destruction or loosening of material

5.Low vibration loads for driver and environment

Variocontrol Single Drum Rollers Series 4 -B1-

BOP ----- Bomag Operation Panel

Variocontrol Single Drum Rollers Series 4 -B2-

The hydraulic steering is also available as an option.

Variocontrol Single Drum Rollers Series 4 -B3-

Variocontrol Single Drum Rollers Series 4 -C1-

Variocontrol Single Drum Rollers Series 4 -C2-

Variocontrol Single Drum Rollers Series 4 -C3-

Pos. Designation Pos. in wiring diagram Pos. in hydraulic Measuring values

Variocontrol Single Drum Rollers Series 4 -C4-

Pressure test port

High pressure filter

Variocontrol Single Drum Rollers Series 4 -C5-

Pos. Designation Pos. in wiring diagram Pos. in hydraulic Measuring values

Variocontrol Single Drum Rollers Series 4 -C6-

Variocontrol Single Drum Rollers Series 4 -C7-

Pos. Designation Pos. in wiring diagram Pos. in hydraulic Measuring values

Variocontrol Single Drum Rollers Series 4 -C8-

Variocontrol Single Drum Rollers Series 4 -C9-

Pos. Designation Pos. in wiring diagram Pos. in hydraulic Measuring values

Variocontrol Single Drum Rollers Series 4 - C 10 -

Variocontrol Single Drum Rollers Series 4 - C 11 -

Pos. Designation Pos. in wiring diagram Pos. in hydraulic Measuring values

Variocontrol Single Drum Rollers Series 4 - C 12 -

Variocontrol Single Drum Rollers Series 4 - C 13 -

Variocontrol Single Drum Rollers Series 4 - C 14 -

Variocontrol Single Drum Rollers Series 4 - C 15 -

Variocontrol Single Drum Rollers Series 4 - C 16 -

The display shows error codes

All electric faults are primarily displayed in the display.

Variocontrol Single Drum Rollers Series 4 - C 17 -

(Bomag E-vib Meter) for circular exciters

Variocontrol Single Drum Rollers Series 4 -D1-

(Bomag Terrameter) for circular exciters

Variocontrol Single Drum Rollers Series 4 -D2-

(Bomag Terrameter) for circular exciters

Variocontrol Single Drum Rollers Series 4 -D3-

(Bomag Variocontrol) for Vario exciters

Drehzahlsensor MESX Befehle

Variocontrol Single Drum Rollers Series 4 -D4-

The VARIOCONTROL system consists of the following primary

Variocontrol Single Drum Rollers Series 4 -E1-