Bw177 213-226 series-4_service_training

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

Service Training
Variocontrol Single Drum Rollers Series 4
Table of contents
Foreword A 1
Documentation A 2
General B 1
Peculiarities B 3
Electric steering C 1
Steering circuit C 2
Steering pump C 4
Steering wheel C 5
Steering valve C 6
Steering angle sensor C12
Trouble shooting C15
Compaction measuring system D 1
BEM D 1
BTM plus D 2
BTM prof. D 3
BVC D 4
BVC - System E 1
Exciter system E 4
Gear pump E 5
Valve block E 7
Swashing motor E 9
Acceleration transducer E 10
MESX-control E 11
BOP E 12
Working principle of the system F 1

Service Training
Variocontrol Single Drum Rollers Series 4
Repair and adjustments G 1
Replacement of swashing motor G 2
Replacement of potentiometer G 3
Potentiometer adjustment G 4
Trouble shooting H 1
Electrics I 1
Service Training
MESX - Service Training
Wiring diagram
Hydraulic diagrams

Service Training
Variocontrol Single Drum Rollers Series 4 - A 1 -
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.

Service Training
Variocontrol Single Drum Rollers Series 4 - A 2 -
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.

Service Training
Variocontrol Single Drum Rollers Series 4 - B 1 -
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.

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
Variocontrol Single Drum Rollers Series 4 - C 1 -
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.

Service Training

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

Service Training
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.
Pos. Designation Pos. in wiring diagram Pos. in hydraulic
diagram
Measuring values
05 one steering cylinder on BW 177 05
05 two steering cylinders
on BW 213 and 226
05
06 Steering valve with 2 proportional
solenoids and an integrated
accumulator
Y92 / Y93
Page 006
06
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
BW 177 BVC
17 / MG 80 bar
17 additional gear pump 8 cm³ on BW
213 and 226 BVC
17 / MG 120 bar
20 High pressure line filter for
Variocontrol 100 µm
20
21 Optional emergency steering valve
with 2 B/W solenoids
Y112 / Y113
Page 006
21

Service Training
Steering pump with filter
Steering pressure
Steering pump
Pressure test port
12 µm with
Steering circuit
High pressure filter
Pressure differential switc
3,5 bar
Filter outlet
Filter inlet

Service Training
Steering wheel
The small steering wheel is located in the left hand armrest of the driver's seat
diagram
Measuring values
Electric steering wheel A 45
Page 006
VCC 8,5 V

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
to the charge
system
pump

Service Training
Steering valve
diagram
Measuring values
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
solenoid
Y 113 Page 006 0/12 V
10 Emergency steering valve B/W
solenoid
Y 112 Page 006 0/12 V
1 2
3
4
5
6
7 8

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

Service Training
BW 177 BVC
diagram
Measuring values
1 Steering valve Y92 / Y93 06
2 Optional emergency steering valve Y112 / Y113 21
3 High pressure line filter 100µm in
Vario-circuit
20
1
23

Service Training
Piping BW 177

Service Training
BW 213 and 226 BVC
diagram
Measuring values
1 Steering valve Y92 / Y93 06
2 Optional emergency steering valve Y112 / Y113 21
3 Pressure retaining valve,
Variocontrol circuit
22 110 / 99 bar
4 Accumulator for Variocontrol circuit 23 Accumulator
pressure 85bar
5 High pressure line filter 100µm in
Vario-circuit
20
5
4
2
1
3

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
Adetaileddescriptionofhowtoreadouttheerrorcodesandonthedisplay
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
SYMPTOME
KeineLenkfunktion
Endanschlägewerdennichterreicht
Lenkungschwergängig
MÖGLICHE URSACHEN
Lenkventil 2 2 1
Lenk- Speisepumpe 1 1 2
Lenkzylinder 3 3 3
Knickgelenk 3 3 2
F E H L E R S U C H E

Service Training
Variocontrol Single Drum Rollers Series 4 - D 1 -
Compaction measuring system for single drum rollers:
BEM
(Bomag E-vib Meter) for circular exciters
!
MESX
Bedienfunktionen
E vib
0
50
150
200
250E VIB
MN/mm²
BMFSA
Beschleunigung
VV / VL 15g
Beschleunigung
VH / VL 15g
Befehle
Neutral
Pos.
D+ Signal
Vibrationspumpe
Stromsignal
Signale
CANBusI

Service Training
BTM prof
(Bomag Terrameter) for circular exciters
!
MESX
Bedienfunktionen
RS232
Drucker
BOP
Beschleunigung
VV / VL 15g
Beschleunigung
VH / VL 15g
Drehzahlsensor
hinten
Neutral
Pos.
D+ Signal
Vibrationspumpe
Stromsignal
Signale
CANBusI

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

Service Training
BVC
(Bomag Variocontrol) for Vario exciters
!
MESX
Bedienfunktionen
RS232
Drucker
BOP
Lageregelung
Ventil 1 vorn
Lageregelung
Ventil 2 vorn
Beschleunigung
VV / VL 15g
Beschleunigung
VH / VL 15g
Befehle
Erreger
Position vorn
Drehzahlsensor
hinten
Neutral
Pos.
D+ Signal
Vibrationspumpe
Stromsignal
Signale
CANBusI

Service Training
Variocontrol Single Drum Rollers Series 4 - E 1 -
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

Service Training
BVC Circuit diagram for BW 177 DH-4
Legend from the hydraulic
diagram:
17) External gear pump
5.5 cm³
18) Valve block with 80
bar pressure relief valve
19) Swivel drive, variable
displacement motor
20) High pressure line
filter
20
to filter
to steering system
from
tank
to the
tank
rearfront
Y141 Y140

Service Training
BVC Circuit diagram for BW 213 / 226 DH-4
Legend from the hydraulic diagram:
17) External gear pump 8cm³
18) Valve block with pressure relief valve (120 bar)
19) Swivel drive, variable displacement motor
20) High pressure line filter
22) Pressure override valve (99-110 bar)
23) Accumulator (1.4l, 85bar)
to filter
from
tank
to
Emergency
steering
to the
tank
Steering valve
Y141 Y140
front rear

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
BW 177 BVC
additional
gear pump
for Variocontrol system
Test port input
Variocontrol system
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.
diagram
Measuring values
1 P3 Input 22
2 P5 to valve block 22
3 T 22
4 T 22
5 Pressure retaining valve, opens and
closes
22 110 bar / 99 bar
6 P6 to accumulator 23 Preload pressure
85bar
7 High pressure line filter 22
8 T1 22
9 P4 22
1
2
3
4
6
5
8
9
7

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
diagram
Measuring values
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
1
2
3
4
5
6
7
8
9
10
8
11

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

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)

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 213and226 BVC signal blue15g
see wiring diagram, page 008, path 8 and10, B62

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
Variocontrol Single Drum Rollers Series 4 - F 1 -
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.

Service Training
Variocontrol Single Drum Rollers Series 4 - F 2 -
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
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
0 1 2 3 4 5 6 7
Hochleistungswalze
große Amplitude
Standardwalze
Übergänge

Service Training
Variocontrol Single Drum Rollers Series 4 - G 1 -
Repair and adjustments
Replacement of swashing motor and potentiometer
Swashing motor
Potentiometer
Fastening
screws
Potentiometer

Service Training
Locking screw
horizontal
Locking screw
vertical reverse

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.
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.
Wiring diagram Bl 008, Pf 11, B61

Service Training
Exciter lock in vertical reverse
Exciter lock in horizontal

Service Training
Variocontrol Single Drum Rollers Series 4 - H 1 -
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“
For detail info on reading out fault codes please refer to the chapter "Electrics, Training MESX".
Red fault light
Button „F5“
Button „?“

Status: 06.12.2004 Page 1 of 48
Author: T.Löw / TE
Dateiname: p:schulungwz-4elektrikenglisch06_12_04mesx_schulung_v3.00_berndnick_gb.doc
Service Training
Electrics
MESX
Version 3.00

Service Training MESX
Status:06.12.2004 Page 2 of 48
Author: T.Löw / TE
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

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
! Description of display module extended
! "Software updating record" included
Löw
1.01 23.07.2004 ! Description of BOP display pages added. Löw
2.00 31.08.04 ! Input code 4602 replaced by code 4606
! Machine type BW219D added
Löw
3.00 15.10.2004 ! Subject "How to proceed when replacing components?"
added
! Description for ESX Pin 0:35 added
! Description of error code 4601 and 4606 corrected
! Description of software version 3.00 added
Löw

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
! Amplitude limitation Automatic limited to 0,3 mm
! Default settings in Automatic changed to "MAX"
Löw
1.02 13.04.2004 ! BW213 BVC implemented
! Printer control modified (Xon, Xoff protocol)
! Software version and revision documented on printout
! Finished criterion extended (2 m of weak spots are
checked)
! Bmfsa code input for DH machines modified
Löw
1.03 05.05.2004 ! Teach mode for travel distance modified (value range
check)
! Finished criterion for polygonal drum deactivated
! 2-stage jump information included
! Self-latching of control at shut down implemented
! Storage of the current adjustment values at shut-down
implemented
! Bmfsa code input for DH machines modified
! BW211 D, BW213 D and BW213 DH implemented
! Interrogation of BOP software version implemented
Löw
1.04 16.04.2004 ! BW226 BVC Polygon implemented
! Max. swashing angle limited to 80°
! Max valve current for BW177 limited to 1000mA
Löw
1.05 26.07.2004 ! BW219DH and BW213 BVC Polygon implemented
! Cancellation criterion for while loops added in Evib
calculations
Löw
2.00 31.08.2004 ! Number of machine variants extended to 25 (BW219D)
! Problem with sporadic software crashes eliminated
Löw
3.00 15.10.2004 ! Distance impulse changed to 10m for BW226
! Amplitude limitation in automatic mode realized
! Simulation mode realized
! Change-over metric/imperial realized
! minimum required OPUS version changed to 3.00 (always
the same version as MESX)
Löw

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

Status: 06.12.2004 Functions of the ESX control Page 8 of 48
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).
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.
15/54
Vorzeichen
05766772

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.
• Switch the ignition off and on again.
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!

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

Service Training MESX Block diagram
Status: 06.12.2004 Block diagram Page 28 of 48
8 Block diagram BTMplus / VARIOCONTROL

Service Training MESX Description of signals
Status: 06.12.2004 Description of signals Page 29 of 48
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
joystick, speed range switch etc.)
approx. 0 V measured against ground (terminal 31)
X0:2
X0:3 Output Evib display
PWM (max. 2.5 A)
PWM signal (100Hz): " approx. 0..6 V
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
Analogue input / voltage input 0..8.5 V
Acceleration signal (measured against AGND)
Open-circuit voltage (vibration off): " 4,2..4,3 V
X0:8
X0:9 Input exciter position front
Position exciter front (measured against AGND)
Bottom stop " approx. 2,2 V
Neutral position " approx. 4,25 V
Top stop " approx. 6,6 V

X0:10
X0:11
X0:12
X0:13
X0:14
X0:15 Input vibration 1 On
Digital input active high
Vibration on " > 6 V
Vibration off: "approx.0 V
X0:16 Input "START" button (option)
Push button pressed " 12 V
Push button not pressed " 2 V
X0:17 Input "STOP" button (option)
X0:18 Input "PRINT" button (option)
X0:19 Input "CLEAR" button (option)
X0:20
X0:21
X0:22
X0:23 Output voltage supply for sensors
This output supplies steering joystick, travel speed range switch, etc.
Without this voltage the control cannot work correctly and will switch to
override condition (emergency operation).
Nominal voltage = 8,5 V
Permissible range: approx. 7,65..9,35 V
This voltage must be measured against AGND.
X0:24

X0:25
X0:26 Interface CAN-Bus1 Wire -, is used to communicate with the BOP-
operating panel.
Measurement not possible!
X0:27 Interface CAN-Bus1 Wire +, is used to communicate with the BOP-
operating panel.
Measurement not possible!
X0:28 Input potential terminal 15
This signal must be present, so that the control can work.
Control switched on " 12 V
Control switched off "approx.2 V
X0:29 Input acceleration transducer VV/VL15g
X0:30 Input acceleration transducer VH/VR15g
X0:31 Input acceleration transducer VV20g/HR15g
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.

X0:36
X0:37 Input D+ generator
Engine running / engine is started " 12 V
Engine not running " 0 V
X0:38 Input vibration 2 On
Vibration on " > 6 V
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
PWM digital output (max. 4 A)
permissible current range: approx. 0..1,5 A
X0:47 Output valve 2 front
PWM digital output (max. 4 A)
permissible current range: approx. 0..1,5 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 " 0 V
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
Status: 06.12.2004 Error codes of the ESX control Page 34 of 48
Author: T.Löw / TE
10 Error codes of the ESX control
10.1 Overview
Error code Description of error
4 5 0 1 -
4 5 4 0
Position controller (exciter potentiometer, valves)
4 6 0 1 -
4 6 2 0
8 0 0 0 -
8 2 5 0
Internal software error

Service Training MESX Description of error codes on the ESX control
Status: 06.12.2004 Description of error codes on the ESX control Page 35 of 48
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!

10.3 Detailed description of fault codes and their possible causes
Error
code
Description of error Possible cause Terminal
on ESX
Input
code for
diagnose
Error
reaction
4 5 0
1
Input exciter potentiometer front
The voltage applied to the input is below the
specified range (see signal description).
" Wire breakage in current path
" Current path has short circuit to ground
" No voltage supply to potentiometer
" Fuse FM ? has tripped or wire breakage in voltage supply
current path
" Potentiometer defective
X0:09 5
4 5 0
2
Input exciter potentiometer front
The voltage applied to the input is above the
" Current path connected to +12 V / +8,5 V
" Potentiometer not connected to ground
" Potentiometer defective
X0:09 5

Error
code
on ESX
Input
code for
diagnose
Error
reaction
4 5 2
1
Output proportional solenoid front
Valve exciter up
Output current too low.
" Current path has short circuit to voltage supply
" Current path has non-permitted connection to another current
path
" Current path is interrupted
X0:46 2
4 5 2
2
Valve exciter up
Output current too high.
path
X0:46 2
4 5 2
3
Valve exciter up
Fault when calibrating the valve
" Current path has unpermitted connection to another current
path / ground
X0:46 2
4 5 2
6
Valve exciter down
Output current too low.
" Current path has short circuit to voltage supply
path
X0:47 2
4 5 2
7
Valve exciter down
Output current too high.
path
X0:47 2
4 5 2
8
Valve exciter down
Fault when calibrating the valve
" Current path has impermissible connection to another current
path / ground
X0:47 2

Error
code
on ESX
Input
code for
diagnose
Error
reaction
4 5 3
1
Position controller has reached positive limit
The exciter does not move to the desired
direction or does not move at all.
" Supply and ground terminals on exciter potentiometer mixed
up+
" Valves "exciter up" and "exciter down" mixed up
" MD+ input has 12 V potential, even though the engine is not
running
X0:09
X0:37
5 0 0 0 2
4 5 3
2
Position controller has reached negative limit
The exciter does not move to the desired
direction or does not move at all.
" Supply and ground terminals on exciter potentiometer mixed
up+
" Valves "exciter up" and "exciter down" mixed up
" MD+ input has 12 V potential, even though the engine is not
running
X0:09
X0:37
5 0 0 0 2
4 6 0
1
Input acceleration transducer 1
" Current path has no connection to +12 V / +8,5 V
" Current path connected to ground
" Transducer defective
X0:29,
or
X0:31
4 6 0 1 2
4 6 0
2
" Current path not connected to ground
X0:29,
or
X0:31
4 6 0 1 2
4 6 0
6
" Current path has no connection to +12 V / +8,5 V
" Current path connected to ground
X0:30,
or
X0:07
4 6 0 6 2
4 6 0
7
" Current path not connected to ground
X0:30,
or
X0:07
4 6 0 6 2

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

Service Training MESX Description of input codes for the control
Status: 06.12.2004 Description of input codes for the control Page 40 of 48
11 Input codes for ESX control (only via BEM display module)
11.1 Travel system
Input code Description of display function Display values
1 0 0 0 Travel direction sensor
Displays the status of sensor.
0 0 0 0 " 0 V
0 0 0 1 " 12 V
1 0 0 1 Travel direction
Displays the travel direction derived from the "Travel direction sensor"
by the control.
1 0 0 0 " Forward travel detected
0 0 0 0 " Neutral position
0 0 0 I " Reverse travel detected
1 0 0 2 Distance impulse sensor
The accumulated distance impulses since starting the machine are
displayed. If the machine has travelled a greater distance in reverse
than in forward, the displayed value will be negative.
Display value = travel distance in 10 cm
1 0 0 3 Travel speed
Displays the actual speed.
Display value = speed in km/h
1 0 1 0 Parameter "Display distance impulses per 10m"
Eeprom parameter is displayed
Depending on selected machine type, e.g. 5896 at BW177 BVC
1 0 1 1 Parameter "Invert travel direction"
Eeprom parameter is displayed
0 0 0 0 " Direction signal is not inverted
0 0 0 I " Direction signal is inverted

11.2 Vibration
3 0 0 0 Vibration status general
The status of vibration is displayed.
0 0 0 0 " Vibration OFF
0 0 0 1 " Vibration ON
3 0 0 1 Vibration status low amplitude
The status of vibration with low amplitude is displayed.
3 0 0 2 Vibration status high amplitude
The status of vibration with high amplitude is displayed.
11.3 Light
3 0 1 0 Input light switch
The status of the lighting system is displayed.
0 0 0 0 " Light OFF
0 0 0 1 " Light ON

11.4 Acceleration transducer
4 6 0 1 Acceleration transducer 1
Displays voltage for transducer 1.
Display value = voltage in V
4 6 0 6 Acceleration transducer 2
Displays voltage for transducer 2.
Display value = voltage in V
11.5 Diesel engine
5 0 0 0 Input MD+
Displays the status of the diesel engine.
0 0 0 0 " Engine OFF
0 0 0 1 " Engine ON

11.6 Setting the machine type
7 0 0 0 Displays the set machine type see adjustment instructions (page Fehler! Textmarke nicht
definiert.)!
7 0 1 0 Switches on function „Set machine type“ see adjustment instructions (page Fehler! Textmarke nicht
definiert.)!
7 0 1 1 Confirms entered machine type see adjustment instructions (page Fehler! Textmarke nicht
definiert.)!
7 5 0 0 . . 7 5
9 9
Preselection of machine type see adjustment instructions (page Fehler! Textmarke nicht
definiert.)!

11.7 Parameter change
7 6 0 0 Switches on function "Invert travel direction" Display value 7 6 0 0
7 6 0 1 Inverts the actually set travel direction see adjustment instructions (page Fehler! Textmarke nicht
definiert.)!

Status: 06.12.2004 General terminology Page 45 of 48
Author: T.Löw / TE
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

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

Status: 06.12.04 Page 1 of 46
Author: Seis / TE
Dateiname: p:schulungwz-4elektrikenglischdez04esx_schulung_wz4 v1.03_gb.doc
Service Training
Electrics
Single Drum Rollers – 4
From -DH Version 1.10
Version 1.03

Service Training WZ-4 from version DH
Author: Seis / TE
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
⇒ Known faults
⇒ Fault - codes revised
⇒ Deactivation of electric steering on BVC machines
⇒ How to proceed when replacing components?
Schroeder,
Fondel

Author: Seis / TE
2 Selected fault reactions of the ESX control
Symbol in fault
message display
Warning
Code output
without buzzer
Warning
Code output
with buzzer
Engine stop
Code output
with buzzer
Engine oil pressure
(from EMR) 5100
5112
1)
5101
5112
2)
after 10s
Coolant temperature
(from EMR)
5100
5116
1)
5101
5116
2)
after 15s
Coolant level
5024
after 5s
5025
after 10s
Engine air filter
5026
after 5s
5027
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
after 5s
5503
after 2min
Water separator on fuel
filter 5028
after 5s
5029
after 2min
Theft warning system
(Option)
Seat contact
(Option)
Fault in air conditioning
(Option)
1)
After reaching the warning limit! 3)
Shut-down currently deactivated by parameter
2)
After reaching the shut-down limit!
Reaktion
Signal

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

Status: 06.12.04 Functions of ESX control Page 7 of 46
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.
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.
Navigieren
(blau)
Werte ändern
(grün)
Navigieren
(blau)
Werte ändern
(grün)INFO 1 Taste
(gelb)
INFO 2 Taste
(gelb)

Author: Seis/ TE
„Eingabe“ - Modus:
Umschaltung Displayfunktion
Einstellungen Display
Plattenverstellung inaktiv!Betätigen INFO 1
+ INFO 2 ca. 3s
Eingabe
Zugangangscode
9999
Bet. INFO 1 +
INFO 2 ca. 3s
oder Fahrhebel
aus Bremsr.
Normalmodus (Fahrhebel in Bremsraste!)
Aufruf optionaler Anzeigen über INFO - Taste 1
und INFO - Taste 2
CODE - Eingabe „0000" oder
Zündung aus
„Service“- Modus:
Eingabe Diagnosecodes
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:
72XX
0 1 2 3 4 5 6 7 8 9
0 Default BW 177
DH-4
(Dozer
blade)
BW 177
PDH-4
BW 179
DH-4
BW 179
PDH-4
BW 213
DH-4
BW 213
PDH-4
BW 213
DH-4
USA
BW 213
PDH-4
USA
BW 216
DH-4
DH
1 BW 216
PDH-4
BW 219
DH-4
BW 219
PDH-4
BW 226
DH-4
147kW
BW 226
PDH-4
147kW
BW 226
DH-4
174kW
BW 226
PDH-4
174kW
DH
2 DH
3 DH
4 DH
5 BW 177
DH-4
BVC
BW 213
DH-4
BVC
BW 213
DH-4
BVC w.
plates
BW 226
DH-4
BVC
147 kW
BW 226
DH-4
BVC
174 kW
BVC
6 BVC
7 BVC
8 BVC
9 BVC
EXAMPLE: Machine code for BW 219 PDH-4: 7212
Note: This function can only be activated / deactivated when the travel lever is in brake lock
position. (!!!! Input mode)
The following method must be used for initial start-up of a control:

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.

Bw177 213-226 series-4_service_training

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