Service Training Electric

BMP 8500
with
Safety System
BOSS

P/N 008 097 61

Author: VKS
Status: 12.01.2010
 Table of contents

Table of contents

TABLE OF CONTENTS ............................................................................................. 2

1 CONFIRMATION OF CHANGES ......................................................................... 4

2 FUNCTIONS OF THE BLM CONTROL ............................................................... 5

2.1 Description of the Display Module ........................................................................................ 5

2.2 Input of code numbers ........................................................................................................... 5

NOTE: To verify work- and driving funktion with codes, the horn button needs to be pushed
once. ....................................................................................................................................................... 5

2.3 Display CtO.............................................................................................................................. 6

2.4 Checking and setting the transfer rate ................................................................................. 6

2.5 Showing stored faults ............................................................................................................ 6

2.6 Delete all stored faults............................................................................................................ 6

2.7 Setting the machine type ....................................................................................................... 7

2.8 Adjusting the type of remote control .................................................................................... 8

2.9 Driving against the brake ....................................................................................................... 8

3 DESCRIPTION OF THE SIGNALS ON THE BML CONTROL ............................ 9

4 FAULT CODES AND WARNING MESSAGES OF THE BMP 8500 CONTROL 11

4.1 Overview ................................................................................................................................ 11

4.2 Fault codes of travel functions............................................................................................ 12

4.3 Fault codes of work functions ............................................................................................. 14

4.4 Fault codes steering ............................................................................................................. 15

4.5 Fault codes of remote control ............................................................................................. 16

4.6 General fault codes diesel engine, machine ...................................................................... 17

4.7 Fault codes safety system BOSS ........................................................................................ 21

4.8 Faults in parameterization ................................................................................................... 22

5 INPUT CODES FOR BLM CONTROL ............................................................... 23

5.1 Outputs for travel functions................................................................................................. 23

5.2 Outputs for work functions.................................................................................................. 25

5.3 Inputs logic and power module ........................................................................................... 26

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 Table of contents
5.4 Diesel engine, machine electrics......................................................................................... 27

5.5 Checking the function of the remote controls ................................................................... 29

5.6 Driving against the brake ..................................................................................................... 30

5.7 System information .............................................................................................................. 30

5.8 Setting the remote control type........................................................................................... 30

5.9 Fault log ................................................................................................................................. 30

5.10 Safety system BOSS............................................................................................................. 31

5.11 Reading out the operating hour meter ............................................................................... 31

5.12 Setting the machine type ..................................................................................................... 31

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 Confirmation of changes

1 Confirmation of changes
No. Date Description of changes resp.
1 19.06.2002 Creation of version 1.00 Ch. Fondel
2 09.10.2002 Revision of version 1.00 Ch. Fondel
3 31.05.2005 Version 1.03 from software version 1.11 Ch. Fondel
4 07.12.2006 Version 1.04 from software version 1.21 Ch. Fondel
5 11.01.2010 BMP 8500 with safety bars J.Kob
6 15.09.2010 BMP 8500 with BOSS Version 2.0, P/N 724 002 33 J.Kob

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 Functions of the BLM control

2 Functions of the BLM control

During normal and trouble-free operation the so-called BMFSA display module informs about the
operating hours the machine has performed with the engine running. During the first 2 seconds after
starting the machine the so-called machine type code (7101 for BMP 851)is displayed. Then the
display automatically changes to the operating hours. The operating hours are registered in the central
control and cannot be deleted or manipulated.

2.1 Description of the Display Module

The display module consists of a 4-digit display and two keys, F1 and F2.
The display module is used for the output of fault codes and display values as well as for the input of
code numbers.
An occurring fault is indicated by flashing. If several faults are detected, the displayed fault codes will
change in a 3 second cycle.
Display values such as machine type code and operating hours are permanently displayed.
Values ranging from 0 0 0 0 ...9 9 9 9 can be displayed. Higher values will trigger the display "9999".
Negative values are indicated by the "Minus LED" lighting up. The display module can only show
values when the potential 15 (relay K11) in the machine is switched. If the ignition is switched
on, the warning horn sounds in intervals and the module remains dark, potential 15 is not
applied. See also fault 5060 ff.
The following description describes the input of code numbers.
Vorzeichen

057 667 72
15/54

2.2 Input of code numbers

For the display of operating states and for the diagnose of control inputs and outputs various code
numbers must be entered on 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 display module for 2 seconds.
) The value 0 0 0 0 will be 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.

NOTE: To verify work- and driving funktion with codes, the horn button needs to be pushed
once.

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 Functions of the BLM control

2.3 Display CtO

If the display module shows the inscription 0 C t O , there is a fault in CAN Bus communication
between BLM-control and display module. The display value 0 C t O is not generated by the BLM-
control, but by the display itself.
This may have one of two possible reasons:
1. The CAN Bus communication line between display module and BLM-control is faulty, has been
mixed up by mistake or is interrupted. Refer to the wiring diagram.
2. The value for the transfer rate has been incorrectly set in the display module. In this case check
the transfer rate and, if necessary, set it to 100 KBaud.

2.4 Checking and setting the transfer rate

Switch off the ignition to check the transfer rate. Press both control buttons together before switching
the ignition back on Switch the ignition on with the buttons depressed. The currently set baud rate is
displayed. For correct operation the value 0 1 0 0 should be displayed. The value can be changed by
pressing the right hand button. All possible values are displayed one after the other. Keep pressing the
right hand button until the display shows 0 1 0 0 . This process is quit by pressing the left hand button.

2.5 Showing stored faults

The ten latest faults are stored in the central control.

Switch on function „Show stored faults“:
Enter code number 0 7 0 0 . This code number enables the function „Show stored faults“.

Switch off function „Show stored faults“:

Enter code number 0 7 0 I . This code number disables the function „Show stored faults“.

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

2.6 Delete all stored faults

Execute the function „Delete all stored faults“:

The engine must not be running!
Enter code number 0 7 1 0 . This code number deletes all stored faults.
Switch the ignition off

Note: The stored faults can only be deleted when the engine is not running.

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 Functions of the BLM control

2.7 Setting the machine type

Since this control is used on two machines with CAN - Bus remote control it is necessary to adjust the
central control to the corresponding machine type or remote control when switching it on for the first
time. On new machine this adjustment is made during production. This adjustment is only required
when replacing a central control unit in the field.
The machine type can be checked by entering the code 7010. If no machine type is adjusted the fault
code 7011 will be displayed when switching on the first time.

The following machine types can be adjusted:

Machine type Machine type code

BMP 8500 with safety bars 7103
BMP 8500 without safety bar 7104

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 1 0 1 )

Enter code number 7 0 1 1 . This code number confirms the entered machine type.

After confirming the machine type the control switches off and back on again. The machine type is
thereby displayed for 3 seconds (e.g. 7 1 0 1 ). Hereafter the machine type is always displayed for 3
seconds when switching on the ignition.

Attention: A machine must not be operated with a wrong type setting, because in such a
case the correct function of the control cannot be assured!

On new controls the machine type is not adjusted. The warning 7010 appears in the display.

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 Functions of the BLM control

2.8 Adjusting the type of remote control

Since this machine may be equipped with two different types of wireless remote controls the machine
control needs to be informed about the control type presently used
The remote control type can be checked by entering the code 0665.

The following machine types can be adjusted:

Remote control type Type code

Radio remote control 0662

Note: Parameter adjustments can only be performed when the engine is not running!

Enter code number 0660. This code number activates the function "Adjusting remote control type“.

The display module now permanently shows the code 0 6 6 0 .

select and enter the remote control type from the table above.

The display module now permanently shows the entered code. (e.g. 0662)

Enter code number 0 6 6 1 . This code number confirms the entered remote control type.

After confirming the remote control type the control switches off. The control automatically switches on
again is now ready for starting.

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!

On new controls the remote control type 0662 (radio remote control) is set as default.

2.9 Driving against the brake

After entering code 5 0 0 the brake will not be opened any more. When moving a travel lever forward
or reverse, the travel motors will be activated and the machine drives against the brake. At the same
time the display shows code 500 and the warning buzzer is activated.

To desactivate this function and to open the brake again you have to enter code 501 or shutt off the
ignition once.

Note: This function can only be activated / desactivated when the travel lever is in
neutral position.

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 Description of the signals on the BML control

3 Description of the signals on the BML control

Notes:

Wherever the value of 12 V is mentioned in the following text, it refers to the current battery
voltage under due consideration of voltage drops in the lines.

BML terminal Signal description Nominal values (voltage / current)

X3:01 Supply, ground
X3:02 Input signal L from generator regulator, active low Regulator switches to potential free when machine is running,
otherwise to ground
X3:03 Input oil pressure switch, active low, B 06 The ground signal is applied as long as no oil pressure is present
X3:04 Input signal Aux from solenoid for rotary speed regulation The Aux signal (ground) is applied when the pin is fully retracted.
X3:05 Input cooling water temperature sensor B 53 When temperature is too high, connected to ground.
(on +115°C, off +108 °C)
X3:06 Output relay K39, starter Relay on ) 12 V
Relay off ) 0 V, no consumer connected 2.9 V
X3:07 Output relay K11, changeover potential 30 to 15 Relay on ) 12 V
Relay off ) 0 V, no consumer connected 2.9 V
X3:08 Output 1 horn, see also X3:36, H 07 Horn on ) 12 V
Horn off ) 0 V, no consumer connected 2.9 V
X3:09 Output relay K 114, solenoid for rotary speed regulation Relay on ) 12 V
Relay off ) 0 V, no consumer connected 2.9 V
X3:10 Output, holding coil shut off solenoid, Y 13 solenoid on ) 12 V
solenoid off ) 0 V, no consumer connected 2.9 V
X3:11 Output hydraulic valve 2nd gear, Y 03 Valve on ) 12 V
Valve off ) 0 V, no consumer connected 2.9 V
X3:12 Output small amplitude vibration, Y 56 Valve on ) 12 V
Valve off ) 0 V, no consumer connected 2.9 V
X3:13 Output big amplitude vibration, Y 57 Valve on ) 12 V
Valve off ) 0 V, no consumer connected 2.9 V
X3:14 Input voltage supply 12 V against ground
X3:15 Supply, ground
X3:16 Serial interface RS 232 RxD Measurement not possible!!
X3:17 Serial interface RS 232 TxD Measurement not possible!!
X3:18 not used
X3:19 Output hydraulic valve steering right, Y 237 Valve on ) 12 V
Valve off ) 0 V, no consumer connected 2.9 V

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 Description of the signals on the BML control

BML terminal Signal description Nominal values (voltage / current)

X3:20 Control potential 15
X3:21 Output hydraulic valve steering left, Y 238 Valve on ) 12 V
Valve off ) 0 V, no consumer connected 2.9 V
X3:22 Output hydraulic valve driving forward, Y 16 Valve on ) 12 V
Valve off ) 0 V, no consumer connected 2.9 V
X3:23 Input inclination sensor, active high, B 56 Positive signal (+12V) , is applied when machine is not inclined.
X3:24 Output hydraulic valve driving reverse, Y 17 Valve on ) 12 V
Valve off ) 0 V, no consumer connected 2.9 V

X3:28 Input voltage supply 12 V against ground

X3:29 Serial interface RS 232 BSL Measurement not possible!
X3:30 CAN - Bus, CAN - Measurement not possible!
X3:31 CAN - Bus, CAN + Measurement not possible!
X3:32 Serial interface RS 232 BSL Measurement not possible!

X3:36 Output 2 horn, see also X3:08, H 07 Horn on ) 12 V

Horn off ) 0 V, no consumer connected 2.9 V
X3:37 Activation input, cable remote control, S 101 Set selector switch for remote control type to cable, switch on remote
control, switch on ignition, emergency stop not operated ) 12 V
X3:38 Output relay K 14, pre-glow Relay on ) 12 V
Relay off ) 0 V, no consumer connected 2.9 V
X3:39 Activation input, IR- or radio remote control, S 101 Set selector switch for remote control type to wireless, switch on
remote control, switch on ignition, emergency stop not operated ) 12
V
X3:40 Output hydraulic valve brake Y 04 Valve on ) 12 V
Valve off ) 0 V, no consumer connected 2.9 V
X3:41 Input engine speed Measurement not possible!
X3:42 Input voltage supply 12 V against ground

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 Fault codes and warning messages of the BMP 8500 control

4 Fault codes and warning messages of the BMP 8500 control

4.1 Overview

Fault code : Function Group : Remark:

1000 – Travel system only 4-digit
1999
2000 – Steering only 4-digit
2499
2500 – Remote controls only 4-digit
2999
5000 – Diesel engine only 4-digit
5499
7000 – Input codes for machine parameterization only 4-digit
7499
7500 - Operating hour meter, load spectrum (input codes) only 4-digit
7999
8000 – severe software fault only 4-digit
8999
9000 - External IO nodes, joysticks, data collectors (CAN communication and hardware defects ) only 4-digit
9998
9999 Unknown fault, display value higher than +- 10000, is automatically displayed by the BMFSA only 4-digit

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 Fault codes and warning messages of the BMP 8500 control

4.2 Fault codes of travel functions

Code Fault reaction Fault description Possible cause Terminal Input-

on BLM code for
diagnose
1030 Output is switched off, function no Output valve driving forward, Y 16 ) Excessive current flow in current path, X3:22 -
longer possible The current flow from this output is too high probably because of a defective coil or
output ) was switched off! a short circuit to ground
1031 Output is switched off, function no Output valve driving forward, Y 16 ) Short circuit to ground in current path X3:22 -
longer possible Short circuit current flowing from this output ) Lines rubbed through
) output was switched off ! ) Valve defective
1032 Output is switched off, function no Output valve driving forward, Y 16 ) Wire breakage in current path X3:22 1030
longer possible No or too low current flow out of this output ) Current path connected to +12V 1031
1032
1033 Engine is shut down Output valve driving forward, Y 16 ) Current path connected to +12V X3:22 1030
Although the output is switched off, voltage 1031
is present 1032
1040 Output is switched off, function no Output valve driving reverse, Y 17 ) Excessive current flow in current path, X3:24 -
longer possible The current flow from this output is too high probably because of a defective coil or
output ) was switched off! a short circuit to ground
1041 Output is switched off, function no Output valve driving reverse, Y 17 ) Short circuit to ground in current path X3:24 -
longer possible Short circuit current flowing from this output ) Lines rubbed through
) output was switched off ! ) Valve defective
1042 Output is switched off, function no Output valve driving reverse, Y 17 ) Wire breakage in current path X3:24 1040
longer possible No or too low current flow out of this output ) Current path connected to +12V 1041
1042
1043 Engine is shut down Output valve driving reverse, Y 17 ) Current path connected to +12V X3:24 1040
Although the output is switched off, voltage 1041
is present 1042

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 Fault codes and warning messages of the BMP 8500 control

Code Fault reaction Fault description Possible cause Terminal Input-

on BLM code for
diagnose
1050 Output is switched off, function no Output valve 2nd gear, Y 03 ) Excessive current flow in current path, X3:11 -
longer possible The current flow from this output is too high probably because of a defective coil or
output ) was switched off! a short circuit to ground
1051 Output is switched off, function no Output valve 2nd gear, Y 03 ) Short circuit to ground in current path X3:11 -
longer possible Short circuit current flowing from this output ) Lines rubbed through
) output was switched off ! ) Valve defective
1052 Output is switched off, function no Output valve 2nd gear, Y 03 ) Wire breakage in current path X3:11 1050
longer possible No or too low current flow out of this output ) Current path connected to +12V 1051
1052
1053 Output is switched off, engine runs Output valve 2nd gear, Y 03 ) Current path connected to +12V X3:11 1050
only with idle speed Although the output is switched off, voltage 1051
is present 1052
1060 Output is switched off, function no Output braking valve, Y 04 Excessive current flow in current path, X3:40
longer possible The current flow from this output is too high probably because of a defective coil or
output ) was switched off! a short circuit to ground
1061 Output is switched off, function no Output brakingvalve, Y 04 ) Short circuit to ground in current path X3:40
longer possible Short circuit current flowing from this output ) Lines rubbed through
) output was switched off ! ) Valve defective
1062 Output is switched off, function no Output braking valve, Y 04 ) Wire breakage in current path X3:40 1060
longer possible No or too low current flow out of this output ) Current path connected to +12V 1061
1062
1063 Output is switched off, engine runs Output braking valve, Y 04 ) Current path connected to +12V X3:40 1060
only with idle speed Although the output is switched off, voltage 1061
is present 1062

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 Fault codes and warning messages of the BMP 8500 control

4.3 Fault codes of work functions

Code Fault reaction Fault description Possible cause Terminal Input-

on BLM code for
diagnose
1305 Output is switched off, function no Output vibration small amplitude, Y 56 ) Excessive current flow in current path, X3:12 -
longer possible The current flow from this output is too high probably because of a defective coil or
output ) was switched off! a short circuit to ground
1306 Output is switched off, function no Output valve small amplitude, Y 56 ) Short circuit to ground in current path X3:12 -
longer possible Short circuit current flowing from this output ) Lines rubbed through
) output was switched off ! ) Valve defective
1307 Output is switched off, function no Output small amplitude, Y 56 ) Wire breakage in current path X3:12 1305
longer possible No or too low current flow out of this output ) Current path connected to +12V 1306
1307
1308 Output is switched off, engine runs Output small amplitude, Y 56 ) Current path connected to +12V X3:12 1305
only with idle speed, 2nd gear is Although the output is switched off, voltage 1306
locked is present 1307
1310 Output is switched off, function no Output big amplitude, Y 57 ) Excessive current flow in current path, X3:13 -
longer possible The current flow from this output is too high probably because of a defective coil or
output ) was switched off! a short circuit to ground
1311 Output is switched off, function no Output big amplitude, Y 57 ) Short circuit to ground in current path X3:13 -
longer possible Short circuit current flowing from this output ) Lines rubbed through
) output was switched off ! ) Valve defective
1312 Output is switched off, function no Output big amplitude, Y 57 ) Wire breakage in current path X3:13 1310
longer possible No or too low current flow out of this output ) Current path connected to +12V 1311
1312
1313 Output is switched off, engine runs Output big amplitude, Y 57 ) Current path connected to +12V X3:13 1310
only with idle speed, 2nd gear is Although the output is switched off, voltage 1311
locked is present 1312

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 Fault codes and warning messages of the BMP 8500 control

4.4 Fault codes steering

Code Fault reaction Fault description Possible cause Terminal Input-

on BLM code for
diagnose
20I0 Output is switched off, function no Output valve steering right, ) Excessive current flow in current path, X3:21 -
longer possible Y 237 probably because of a defective coil or
The current flow from this output is too high a short circuit to ground
)output was switched off!
2011 Output is switched off, function no Output valve steering right, ) Short circuit to ground in current path X3:21 -
longer possible Y 237 ) Lines rubbed through
Short circuit current flowing from this output ) Valve defective
) output was switched off!
2012 Output is switched off, function no Output valve steering right, ) Wire breakage in current path X3:21 1020
longer possible Y 237 ) Current path connected to +12V 1021
No or too low current flow out of this output 1022
2013 Engine is shut down Output valve steering right, Y 237 ) Current path connected to +12V X3:21 1020
Although the output is switched off, voltage 1021
is present 1022
2020 Output is switched off, function no Output valve steering left, ) Excessive current flow in current path, X3:19 -
longer possible Y 238 probably because of a defective coil or
The current flow from this output is too high a short circuit to ground
)output was switched off!
2021 Output is switched off, function no Output valve steering left, ) Short circuit to ground in current path X3:19 -
longer possible Y 238 ) Lines rubbed through
Short circuit current flowing from this output ) Valve defective
) output was switched off!
2022 Output is switched off, function no Output valve steering left, ) Wire breakage in current path X3:19 1010
longer possible Y 238 ) Current path connected to +12V 1011
No or too low current flow out of this output 1012
2023 Engine is shut down Output valve steering left, ) Current path connected to +12V X3:19 1010
Y 238 1011
Although the output is switched off, voltage 1012
is present

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 Fault codes and warning messages of the BMP 8500 control

4.5 Fault codes of remote control

Code Fault reaction Fault description Possible cause Terminal Input-

on BLM code for
diagnose
2500 Engine is stopped, all functions are Operation of two remote control system ) A remote control with cable and a
locked, horn sounds at the same time wireless remote control are operated at
the same time.

2600 Engine stopped, emergency stop
relay in the control is switched off, all
outputs on control are switched off
2601 Engine stopped, emergency stop
relay in the control is switched off, all
outputs on control are switched off
2605 Engine stopped, emergency stop
relay in the control is switched off, all
outputs on control are switched off
2611 Engine is shut down.
2612 Engine is shut down
2613 Engine is shut down
Remote control emergency stop
Fault in data transfer between remote
control sender and receiver
Receive signal too weak
CANopen – fault in bus communication
CANopen – fault in bus communication
CANopen – fault in bus communication
) Emergency stop on remote control
operated
) Battery empty
) Radio or infrared transmission
disturbed
) Distance between sender an machine
too big
) Radio or infrared transmission
disturbed
) Distance between sender an machine
too big
CANopen Slave cable control has not
sent a node guarding answer
CANopen Slave radio remote control has
not sent a node guarding answer
CANopen Slave infrared remote control
has not sent a node guarding answer

Output of error code 2605 only with software version older than 1.11!

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 Fault codes and warning messages of the BMP 8500 control

4.6 General fault codes diesel engine, machine

Code Fault reaction Fault description Possible cause Terminal Input-

on BLM code for
diagnose
5015 Only warning, horn sounds, display Potential 15 missing ) Fuse F 103 defective X3:20 not
module is dark Control has switched relay K11, no voltage ) Relay K11 defective possible
) Cable breakage in wiring loom
5016 Only warning Battery voltage too low ) Battery acid level too low 0561
Battery voltage already below 11 Volt when ) Battery defective
switching on ) Battery discharged
5020 Only warning, horn sounds Input engine oil pressure, B 06 ) The oil pressure switch has measured X3:03 5020
Oil pressure switch delivers the signal „no a too low oil pressure. The engine may
engine oil pressure“ be shut down.

Should this message be displayed

even though the engine is not running,
the following faults should be
examined:
) Current path has short circuit to ground
) Engine oil level not correct
) Engine oil pump defective
) Pressure relief valve after engine oil
filter soiled
) Oil pressure switch defective
5021 Engine shut down by too low oil Input engine oil pressure, B 06 ) see fault code 5 0 2 0 X3:03 5020
pressure Fault 5 0 2 0 present longer than 8 seconds
) Engine is shut down
Faults or warning 5020 and 5021 are only evaluated and displayed when the engine is running.

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 Fault codes and warning messages of the BMP 8500 control
Code Fault reaction Fault description Possible cause Terminal Input-
on BLM code for
diagnose
5025 Engine running No rotary speed signal from the ) Generator regulator defective X3:41 5010
generator regulator ) Line between regulator and control
Only warning interrupted
5031 Machine standing Engine stopped or stalled ) Lack of fuel
) Engine stopped even though the BLM
control did not submit a corresponding
command
5040 Output is switched off, engine stops Output holding coil shut off solenoid, ) Excessive current flow in current path, X3:10 -
Y 13 probably because of a defective coil or
The current flow from this output is too high a short circuit to ground
output ) was switched off!
5041 Output is switched off, engine stops Output holding coil shut off solenoid, ) Short circuit to ground in current path X3:10 -
Y 13 ) Lines rubbed through
Short circuit current flowing from this output ) Valve defective
) output was switched off !
5042 Output is switched off, engine stops Output holding coil shut off solenoid, ) Wire breakage in current path X3:10 5040
Y 13 ) Current path connected to +12V 5041
No or too low current flow out of this output 5042
5043 Output is switched off, engine stops Output holding coil shut off solenoid, ) Current path connected to +12V X3:10 5040
Y 13 5041
Although the output is switched off, voltage 5042
is present
5050 Output is switched off, engine runs Output relay K 114, ) Excessive current flow in current path, X3:09 -
only with idle speed Engine speed solenoid probably because of a defective coil or
The current flow from this output is too high a short circuit to ground
output ) was switched off!
5051 Output is switched off, engine runs Output relay K 114, ) Short circuit to ground in current path X3:09 -
only with idle speed Engine speed solenoid ) Lines rubbed through
Short circuit current flowing from this output
) output was switched off !
5052 Output is switched off, engine runs Output relay K 114, ) Wire breakage in current path X3:09 5050
only with idle speed Engine speed solenoid ) Current path connected to +12V 5051
No or too low current flow out of this output 5052
5053 Output is switched off, engine runs Output relay K 114, ) Current path connected to +12V X3:09 5050
only with idle speed Engine speed solenoid 51051
output is switched off, but voltage present 5052

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 Fault codes and warning messages of the BMP 8500 control
Code Fault reaction Fault description Possible cause Terminal Input-
on BLM code for
diagnose
5054 Input Aux – Signal rpm solenoid Y 13 ) Wire breakage in current path X3:04
5060 Output switched off, no potential 15 Output relay K 11, changeover of ) Excessive current flow in current path, X3:07 -
on machine, control is working, engine potential 15 probably because of a defective coil or
is stopped or cannot be started The current flow from this output is too high a short circuit to ground
output ) was switched off!
5061 Output switched off, no potential 15 Output relay K 11, changeover of ) Short circuit to ground in current path X3:07 -
on machine, control is working, engine potential 15 ) Lines rubbed through
is stopped or cannot be started Short circuit current flowing from this output
) output was switched off !
5062 Output switched off, no potential 15 Output relay K 11, changeover of ) Wire breakage in current path X3:07 5060
on machine, control is working, engine potential 15 ) Current path connected to +12V 5061
is stopped or cannot be started No or too low current flow out of this output 5062

5063 Output switched off, no potential 15 Output relay K 11, changeover of ) Current path connected to +12V X3:07 5060
on machine, control is working, engine potential 15 5061
is stopped or cannot be started Although the output is switched off, voltage 5062
is present
5070 Output switched off, engine cannot be Output relay K 39, starter ) Excessive current flow in current path, X3:06 -
started The current flow from this output is too high probably because of a defective coil or
output ) was switched off! a short circuit to ground
5071 Output switched off, engine cannot be Output relay K 39, starter ) Wire breakage in current path X3:06 -
started Short circuit current flowing from this output ) Current path connected to +12V
) output was switched off ! ) Lines rubbed through

5072 Output switched off, engine cannot be Output relay K 39, starter ) Wire breakage in current path X3:06 5070
started No or too low current flow out of this output ) Current path connected to +12V 5071
5072
5 0 7 3 All outputs switched off, engine Output relay K 39, starter ) Current path connected to +12V X3:06 5070
stopped, safety relay switched off Although the output is switched off, voltage 5071
is present 5072
No display for fault codes 5060 to 5063, because the display module is not supplied with voltage. The horn sounds if these faults occur. These faults are only
stored and serve only for internal processing in the control.

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 Fault codes and warning messages of the BMP 8500 control
Code Fault reaction Fault description Possible cause Terminal Input-
on BLM code for
diagnose
5080 Output switched off, horn cannot Output horn, H 07 ) Excessive current flow in current path, X3:08 -
5085 sound The current flow from this output is too high probably because of a defective coil or X3:36
output ) was switched off! a short circuit to ground
5081 Output switched off, horn cannot Output horn, H 07 ) Short circuit to ground in current path X3:08 -
5086 sound Short circuit current flowing from this output ) Lines rubbed through X3:36
) output was switched off ! ) Horn defective
5082 Output switched off, horn cannot Output horn, H 07 ) Wire breakage in current path X3:08 5080
5087 sound No or too low current flow out of this output ) Current path connected to +12V X3:36 5081
5082

5083 Horn may sound continuously Output horn, H 07 ) Current path connected to +12V X3:08 5085
5088 Although the output is switched off, voltage X3:36 5086
is present 5087
5090 Machine does not start Input inclination switch B56 ) Wire breakage in current path X3:23 1405
The machine cannot be started, because ) Switch defective
the input does not receive a signal from the ) The switch is in actuated state
inclination switch (incorrect installation position)
5091 Shut down of diesel engine Input inclination switch B 56 ) Wire breakage in current path X3:23 1405
The diesel engine is shut down because the ) Switch defective
input on the control does not receive a ) The switch is in actuated state
signal from the inclination sensor (machine has turned over) The
machine must first be shut down after it
has been placed in correct position.
5100 Horn sounds, just warning Input cooling water temperature B 53 ) deficit of cooling water X3:05 5100
Cooling water temperature is too high ) cooler broken
) sensor broken
5101 2nd gear and vibration is stopped Input cooling water temperature B 53 ) deficit of cooling water X3:05 5100
Cooling water temperature is too high for a ) cooler broken
longer period ) sensor broken

Due to the higher operating current two outputs are switched parallel for operation of the horn.

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 Fault codes and warning messages of the BMP 8500 control

4.7 Fault codes safety system BOSS

Code Fault reaction Fault description Possible cause Terminal Input-

on BLM code for
diagnose
Machine drives without safety system Servicemode ) Servicemode through input code -
6001 BOSS for 15 min. Attention: Only for active active.
service purposes!
6010 No travel functions, only steering Defective BOSS antenna front (W12) ) Wire breakage in current path. -
Defective BOSS antenna in the
frontfront
6011 No travel functions, only steering Defective BOSS antenna rear (W13) ) Wire breakage in current path
Defective BOSS antenna in the rear
6012 No travel functions, only steering Defective transponder (no answer back) ) Radio transmission of transponder in
transmitter does not work.
6013 No travel functions, only steering Defective transponder in transmitter ) Internal defect of transponder
6014 No travel functions, only steering Defective BOSS control (A115) ) Internal defect of BOSS control.
6015 No travel functions, only steering CAN bus communication between ) Wire breakage in current path
transponder and BOSS control does not
work.
6016 Quality of reception safety system

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 Fault codes and warning messages of the BMP 8500 control

4.8 Faults in parameterization

Code Fault reaction Fault description Possible cause Terminal Input-

on BLM code for
diagnose
7010 Machine cannot be started, module is No machine type set Module is new, parameters were deleted 0725
not completely initialized

When reading out the error log this error is usually present.

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 Input codes for BLM control

5 Input codes for BLM control

5.1 Outputs for travel functions

Input code Description of display function Display values

1010 Output valve steering right, Y 237 Display value = output voltage in Volt
Voltage at output
1011 Output valve steering right, Y 237 Display value = output current in Amperè
Current at output
1012 Output valve steering right, Y 237 0000 = Output not triggered
Logic level of control 0001 = Output triggered
1015 Valve control, steering 0100 = steering, left
0010 = valve not triggered
0011 = steering, right
1020 Output valve steering left, Y 238 Display value = output voltage in Volt
Voltage at output
1021 Output valve steering left, Y 238 Display value = output current in Amperè
Current at output
1022 Output valve steering left, Y 238 0000 = Output not triggered
Logic level of control 0001 = Output triggered
1030 Output valve driving forward, Y 16 Display value = output voltage in Volt
Voltage at output
1031 Output valve driving forward, Y 16 Display value = output current in Amperè
Current at output
1032 Output valve driving forward, Y 16 0000 = Output not triggered
Logic level of control 0001 = Output triggered
1035 Valve control, driving forward 0100 = Driving, forward
0010 = Drum stopped
0011 = Driving, reverse
1040 Output valve driving reverse, Y 17 Display value = output voltage in Volt
Voltage at output
1041 Output valve driving reverse, Y 17 Display value = output current in Amperè
Current at output
1042 Output valve driving reverse, Y 17 0000 = Output not triggered
Logic level of control 0001 = Output triggered

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 Input codes for BLM control

Input code Description of display function Display values

1050 Output valve 2nd gear, Y 03 Display value = output voltage in Volt
Voltage at output
1051 Output valve 2nd gear, Y 03 Display value = output current in Amperè
Current at output
1052 Output valve 2nd gear, Y 03 0000 = Output not triggered
Logic level of control 0001 = Output triggered
1060 Brake valve Y 04 Display value = output voltage in Volt
Voltage at output
1061 Brake valve Y 04 Display value = output current in Amperè
Current at output
1062 Brake valve Y 04 0000 = Output not triggered
Logic level of control 0001 = Output triggered

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 Input codes for BLM control

5.2 Outputs for work functions

Input code Description of display function Display values

1305 Output valve vibration small amplitude, Y 56 Display value = output voltage in Volt
Voltage at output
1306 Output valve vibration small amplitude, Y 56 Display value = output current in Amperè
Current at output
1307 Output valve vibration small amplitude, Y 56 0000 = Output not triggered
Logic level of control 0001 = Output triggered
1310 Output valve vibration big amplitude, Y 57 Display value = output voltage in Volt
Voltage at output
1311 Output valve vibration big amplitude, Y 57 Display value = output current in Amperè
Current at output
1312 Output valve vibration big amplitude, Y 57 0000 = Output not triggered
Logic level of control 0001 = Output triggered

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 Input codes for BLM control

5.3 Inputs logic and power module

Input code Description of display function Display values

1400 Input signal L from generator regulator 12 V > Generator stopped
Ground, 0 V > Generator running
1401 Input oil pressure switch, B 06 12 V > No oil pressure
Ground, 0 V > Oil pressure
1402 Input limit switch engine speed solenoid, Aux 12 V > Solenoid retracted
0V Ground > Solenoid not in end position
1405 Input inclination sensor, B 56 12 V > Inclination less than 45°
0V Ground > Inclination higher than 45°
1407 Input limit switch for safety bow, backward, B 41 12 V > Bow not operated
Ground , 0V > Bow operated
1408 Input limit switch for safety bow, forward, B189 12 V > Bow not operated
Ground, 0V > Bow operated
1409 Activation input, cable remote control, S 101 12 V > Operating mode cable remote control
1410 Activation input radio or infrared remote control, S 101 12 V > Operating mode wireless

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 Input codes for BLM control

5.4 Diesel engine, machine electrics

Input code Description of display function Display values

5010 Engine speed Display value = revolutions per minute (rpm)
5020 Engine oil pressure, B 06 0000 = No engine oil pressure
Shows status of input engine oil pressure 0001 = Engine oil pressure OK
5030 Inclination sensor, B 56 0000 = No signal, machine inclined more than 45°, or switch
Shows the switching state of the inclination switch defective
0001 = OK, inclination of machine less than 45°
5040 Output holding coil shut off solenoid, Y 13 Display value = output voltage in Volt
Voltage at output
5041 Output holding coil shut off solenoid, Y 13 Display value = output current in Amperè
Current at output
5042 Output holding coil shut off solenoid, Y 13 0000 = Output not triggered
Logic level of control 0001 = Output triggered
5050 Output relay K 114, engine speed solenoid Display value = output voltage in Volt
Voltage at output
5051 Output relay K 114, engine speed solenoid Display value = output current in Amperè
Current at output
5052 Output relay K 114, engine speed solenoid 0000 = Output not triggered
Logic level of control 0001 = Output triggered
5055 ECO mode deactivation temporarily ECO mode is deactivated as long as the engine is running
5056 Change ECO mode constantly
5057 ECO mode off Type in 5056 before !
5058 ECO mode on Type in 5056 before !
5053 Status diesel engine 0000 = Engine OFF
Shows the status of the diesel engine. The state is determined on 0001 = Engine ON
basis of signal L from generator, oil pressure and engine speed
signal
5060 Output relay K 11, potential changeover Display value = output voltage in Volt
Voltage at output
5061 Output relay K 11, potential changeover Display value = output current in Amperè
Current at output
5062 Output relay K 11, potential changeover 0000 = Output not triggered
Logic level of control 0001 = Output triggered

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 Input codes for BLM control
Input code Description of display function Display values
5070 Output relay K 39, starter Display value = output voltage in Volt
Voltage at output
5071 Output relay K 39, starter Display value = output current in Amperè
Current at output
5072 Output relay K 39, starter 0000 = Output not triggered
Logic level of control 0001 = Output triggered
5080 Output horn, H 07 Display value = output voltage in Volt
Voltage at output
5081 Output horn, H 07 Display value = output current in Amperè
Current at output
5082 Output horn, H 07 0000 = Output not triggered
Logic level of control 0001 = Output triggered
5085 Output 2 horn, H 07 Display value = output voltage in Volt
Voltage at output
5086 Output 2 horn, H 07 Display value = output current in Amperè
Current at output
5087 Output 2 horn, H 07 0000 = Output not triggered
Logic level of control 0001 = Output triggered
5100 Cooling water temperature B 53 0000 = excess temperature
0001 = temperature alright

Due to the higher operating current two outputs are switched parallel for operation of the horn.

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 Input codes for BLM control

5.5 Checking the function of the remote controls

Input code Description of display function Display values

2500 Actuation of hand travel lever on remote control, S 138 0100 = Travel lever shifted forward
0010 = Travel lever not moved
0001 = Travel lever shifted backward
2501 Actuation of joystick steering on remote control, S 137 0100 = Joystick shifted left
0010 = Joystick not moved
0001 = Joystick shifted right
2502 Position of switch for vibration, S 36 0100 = Switch operated to forward, vibration big amplitude
0010 = Switch not operated
0001 = Switch operated to backward, vibration small amplitude
2503 Position of switch for type of vibration, S 132 0100 = Switch operated to forward, automatic vibration
0010 = Switch not operated, manual operation
2504 Position of switch for fast speed, S 133 0100 = Switch operated to forward, fast speed selected
0010 = Switch not operated, fast speed disabled
2505 Position of switch for engine speed, S 134 0100 = Switch operated to forward, high speed
0010 = Switch not operated, idle speed
2506 Position of button for horn, S 03 0000 = Button not operated
0001 = Button operated

With the input codes listed above it is possible to check the transfer of the individual switching signals from the remote controls to the central control unit. For this
purpose start the machine or press the horn button to bring the remote control sender in operating mode for this function test.

For testing the spiral cable switch the operating mode switch to cable operation, connect the spiral cable to the sender and start the machine. If the engine starts,
the spiral cable is OK!

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 Input codes for BLM control

5.6 Driving against the brake

Input code Description of display function Display values

0500 Driving against the brake Input code 500 desactivates the brake. The display shows code 500
to remind that the function „driving against the brake“ is active. To
desactivate this function and to open the brake again you have to
enter code 501 or shutt off the ignition once.

5.7 System information

Input code Description of display function Display values

0555 Software Version 3-digit version number
Shows the software version number.
056I Supply voltage Display value = voltage in V
Shows the voltage value

5.8 Setting the remote control type

Input code Description of display function Display values

0660 Switches on function "Set remote control type" see adjustment instructions (page 7)!
0661 confirms the entered remote control type see adjustment instructions (page 7)!
0662 Preselect radio remote control, default setting see adjustment instructions (page 7)!
0663 Preselect infrared remote control see adjustment instructions (page 7)!

5.9 Fault log

Input code Description of display function Display values

0700 Switch on function „Show stored faults“ see adjustment instructions (page 6)
0701 Switch off function "Show stored faults" see adjustment instructions (page 6)
0710 Delete all stored faults see adjustment instructions (page 6)

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 Input codes for BLM control

5.10 Safety system BOSS

Input code Description of display function Display values

6000 Switch on service mode 6000
6001 Service mode active. Machine drives without safety system 6001 = Service mode active.
BOSS for 15 min.
6002 Switch off service mode

5.11 Reading out the operating hour meter

Input code Description of display function Display values

7500 Display of hours, operating hour meter The full hours are displayed
7501 Display of minutes, operating hour meter The minute digits of the operating hour meter are displayed

5.12 Setting the machine type

Input code Description of display function Display values

7101 Preselect machine type BMP 851 see adjustment instructions (page 7)!
7102 Preselect machine type BPH 80/65s see adjustment instructions (page 7)!
7010 Switches on function "Set machine type" see adjustment instructions (page 7)!
7011 Confirms entered machine type see adjustment instructions (page 7)!
7103 Preselect machine type BMP 8500 See adjustment instructions (page 7)!

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