Service Training BW 154/174-4 AP
Status:
25. November 2010
Page 1 of 38
Author:
H.Mueller/VK
ELECTRICS–
TRAINING
BW 154 AP-
4
B
W 174 AP-
- Version 1.01 -
P/N 008 097 67
Page 1: ...Service Training BW 154 174 4 AP Status 25 November 2010 Page 1 of 38 Author H Mueller VK ELECTRICS TRAINING BW 154 AP 4 BW 174 AP 4 Version 1 01 P N 008 097 67...
Page 2: ...nctions and operation 9 7 1 1 Calling up service mode 9 7 1 2 Entering input codes 9 7 2 Driving against the closed brake 10 7 3 Setting the machine type 11 7 4 Adjusting the EGAS actuator 13 7 5 Adju...
Page 3: ...e Training BW 154 174 4 AP Status 25 November 2010 Page 3 of 38 Author H Mueller VK 2 Confirmation of changes 2 1 Document No Date Description of changes resp 1 00 28 02 2010 Creation of version 1 00...
Page 4: ...8 Author H Mueller VK 2 2 Software Ver Date Description of changes resp 1 00 xx 03 2010 First software for series production Fondel 1 Only the most important software changes are listed here A detaile...
Page 5: ...Code output with buzzer Engine oil pressure 5020 after 5s 5021 after 10s Coolant level 5024 after 5s 5025 after 10s Engine air filter 5026 after 5s Water separator in fuel filter 5028 after 5s Coolant...
Page 6: ...ts 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 t...
Page 7: ...with the new control after a replacement Important Before performing one of the following steps you may first need to adjust the respective machine type see chapt 7 3 However if the correct machine ty...
Page 8: ...ves see chapt 7 8 6 5 How to proceed when replacing a steering angle transducer Adjustment of the angle transducers see chapt 7 7 Calibration of the angle transducers see chapt 7 4 Note Calibration of...
Page 9: ...be in locked braking position in order to activate input mode Input mode is switched on by simultaneously pressing both INFO buttons over a period of approx 3 seconds 7 1 2 Entering input codes Input...
Page 10: ...is case detect a line interruption in the current path to the brake In order to conduct this test the code number 0 5 0 0 must be entered at the display module After entering the code number the brake...
Page 11: ...on is switched on The following table shows the assignment of the various machine types to the machine codes The range of serial numbers must be strictly observed Machine type First serial number Last...
Page 12: ...s the normal display will appear again The following applies for a correction of the machine type code after it has been set Enter code number 9 9 9 9 activation of service mode Enter code number 7 0...
Page 13: ...ter entering this code move the governor rod manually to full throttle position and hold it there for about 10 seconds If the value is in the permissible range see table the actuator signalizes this a...
Page 14: ...the brake lock In order to steer to any position the travel lever must be shifted out of the brake lock Calibrating the front stops Steer the front drum against the left hand stop Once the left hand...
Page 15: ...lize the automatic neutral setting of the drums when changing the steering mode When switching over steering must be avoided and it must be assured that the automatic neutral setting of the drums has...
Page 16: ...Before the measurement you must strictly make sure that the steering system is bled because an air cushion in the steering cylinders would have a negative effect on the measurement and therefore on t...
Page 17: ...orrectly For a function test enter code number 1106 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...
Page 18: ...current is displayed display value current in mA Once the measurement is finished the display will show again O K or 1 1 1 1 1 The travel lever must now be returned to braking position Once both surge...
Page 19: ...ults are stored in the ESX the display will show Switch off function Show stored faults Enter code number 0 7 0 1 WITHOUT service code 9 9 9 9 This code number disables the function Show stored faults...
Page 20: ...chines driven by the vibration pump the machine cannot be used with vibration when working in chip spreading mode Activating the spreading beam type chip spreader Enter code number 3 1 4 2 This code n...
Page 21: ...ibration operation If the machine is equipped with two edge cutters the edge cutter to be moved must first be selected with an additional selector switch The up or down movement is then controlled wit...
Page 22: ...Interface RS232 RXD not used for normal operation Communication interface for parameter changes Measurement not possible X35 5 Interface RS232 TXD not used for normal operation Communication interfac...
Page 23: ...high Seat operated 0 V Seat not operated 0 5 V X35 16 Input Diesel engine speed sensor Digital input active low BW 170 174 with speedometer frequency between approx 2kHz at 800 rpm and approx 7 5kHz...
Page 24: ...CAN Bus 1 Wire is used for communication with MESX data collector LCD display and BOP Measurement not possible X35 28 Input D Here 12 V must be applied to be able to switch on the control X35 29 Input...
Page 25: ...relay Engine shut down approx 12 V Engine still running or not yet started 0 V X35 46 Output steering valve front left PWM digital output max 4A Permissible current range approx 0 1 8A X35 47 Output...
Page 26: ...ound X35 59 Voltage supply for outputs permanent voltage Approx 12V measured against ground X35 60 Voltage supply for outputs permanent voltage Approx 12V measured against ground X35 61 Output brake v...
Page 27: ...nput active high Engine running approx 12 V Engine not running 0 V X26 4 grey Input engine air filter Digital input active low Filter clogged 0 V Filter OK V X26 5 grey Input coolant supply Digital in...
Page 28: ...lack Voltage supply for monitoring of water separation PIN X27 9 Voltage supply O K approx 12 V No voltage supply 0 V X27 5 black Ground connection 0V measured against ground X27 6 black Interface CAN...
Page 29: ...onic modules Page 29 of 38 Author H Mueller VK PIN data collector Signal description Nominal values voltage current X27 11 black Input water level only BW 174 Analog input resistance This input is swi...
Page 30: ...onnect and evaluate further analog switches to the travel lever Nominal voltage approx 5 0 V Permissible range approx 4 8 5 2 V This voltage must be measured against AGND X23 6 Interface CAN Bus 2 Wir...
Page 31: ...ation chip spreader service mode Digital input active high Edge cutter vib approx 12 V Service chip spreader 0 V X24 6 Input selector switch edge cutter vibration chip spreader service mode Digital in...
Page 32: ...and BOP Measurement not possible X28 5 Only with LCD Voltage supply permanent voltage Battery for RTC Electronics functioning approx 12 V Electronics not working 0 V X28 6 Only with LCD Not used X29...
Page 33: ...V no consumer connected 2 9 V X22 09 Output relay K78 emulsion pump Relay on 12 V Relay off 0 V no consumer connected 2 9 V X22 10 Output hydraulic valve Y 20 edge cutter up Valve on 12 V Valve off 0...
Page 34: ...d 2 9 V X22 27 Input switch S36 drum pre selection vibration rear Vibration rear only selected 12 V Otherwise 0 V X22 28 Input voltage supply 12 V against ground X22 29 Supply ground X22 30 CAN Bus CA...
Page 35: ...spreader edge cutter or sprinkling system 4 5 0 0 4 9 9 9 Fault in measuring systems 5 0 0 0 5 4 9 9 Fault diesel engine 5 5 0 0 5 9 9 9 Fault hydraulic system 6 0 0 0 6 9 9 9 Fault anti theft warnin...
Page 36: ...iven to a limited extent but must be repaired by the service department as soon as possible Fault code is displayed Audible signal 5 Partial function faulty the partial function cannot be overridden b...
Page 37: ...ering has not yet been executed New machine replacement of control 2199 Calibration of angle transducers Teaching of steering stops for electric steering NOT yet executed See 7 4 Fehler Kein g ltiges...
Page 38: ...rent in current path 1003 Although the output is switched off voltage is present X35 61 5 1001 Current path has connection to Ub 15 or 30 FaultLocation Input BTS brake Input BTS brake Input BTS brake...
Page 39: ...sive current in current path 1017 Although the output is switched off voltage is present X22 6 3 Current path has connection to Ub 15 or 30 1015 No or too low current flow out of this output X22 6 3 L...
Page 40: ...ial error X axis Error in redundant evaluation of travel lever signal CAN 2 3 Software or hardware fault in travel lever replacement requir 1028 Direction evaluation X axis The direction of travel lev...
Page 41: ...eakage in current path 1040 Ground Connection faulty Signal outside the valid range X23 8 3 1040 1041 1042 FaultLocation Input travel stage selector switch S42 Input travel stage selector switch S42 I...
Page 42: ...Line breakage in current path Excessive current in current path Software parameter fault software update may be required 1075 Output to proportional valve shorted to ground X35 20 2 1070 1071 Short c...
Page 43: ...is applied to the proportional valve output even though the output is not switched X35 21 5 1080 1081 Current path has connection to Ub 15 or 30 1088 Initialization error output System 2 Software para...
Page 44: ...each function travel pump flow controller Teach function travel pump flow controller Teach function travel pump flow controller FCode FaultDescription Terminal Reac Diag Possible Cause 1091 Error in t...
Page 45: ...X35 32 3 1260 1262 1263 1264 Line breakage in current path 1260 Supply connection Signal outside the valid range see signal description X35 32 3 1260 1262 1263 1264 No voltage supply Ub Pot 15 or 30...
Page 46: ...lausibility error signals from switches 1 and 2 not plausible System 2 1313 1314 Line breakage in current path Hardware defect sensors replacement required Sensors not correctly installed or not adjus...
Page 47: ...braked to stop X35 13 0 FaultLocation Input arm rest switch B132 Input arm rest switch B132 Input arm rest switch B132 Input arm rest switch B132 FCode FaultDescription Terminal Reac Diag Possible Cau...
Page 48: ...to ground X35 47 2 Short circuit to ground 31 in the current path Excessive current in current path 2026 Fault current regulator X35 47 2 Line breakage in current path Excessive current in current pa...
Page 49: ...alve Y93 front right steering FCode FaultDescription Terminal Reac Diag Possible Cause 2036 Fault current regulator X35 46 2 Line breakage in current path Excessive current in current path Software pa...
Page 50: ...ent path has connection to Ub 15 or 30 2037 Fault current regulator X35 46 2 Line breakage in current path Excessive current in current path Software parameter fault software update may be required 20...
Page 51: ...2 Short circuit to ground 31 in the current path Excessive current in current path 2041 Supply voltage Ub is applied to the proportional valve output even though the output is not switched X35 49 5 C...
Page 52: ...upply voltage Ub is applied to the proportional valve output even though the output is not switched X35 48 5 Current path has connection to Ub 15 or 30 2058 Initialization error output System 2 Softwa...
Page 53: ...each function surge current steering front right Teach function surge current steering front right FCode FaultDescription Terminal Reac Diag Possible Cause 2065 Teach function aborted because current...
Page 54: ...ion for the steering valve surge currents has not yet been successfully performed see adjustment instructions System 1 Perform teach function steering valve surge currents Informative code Follow the...
Page 55: ...ion does not match X35 18 2 2200 Hardware defect sensors replacement required Pin 18 and 19 mixed up by mistake Pin 40 and 41 mixed up by mistake 2174 Sensor 1 pulse error sensor 1 delivers no or impl...
Page 56: ...mixed up by mistake 2176 Sensor 1 electronics error System 2 ESX hardware defect hardware replacement may be necessa 2171 2 2200 2170 Plausibility of the sense of rotation does not match X35 19 2 220...
Page 57: ...placement required 2186 Supply connection Connection of sensor switch faulty The voltage applied to the input is outside the specified range see signal description X35 09 2 2250 2252 Line breakage in...
Page 58: ...le sensor rear B66 Steering angle sensor rear B66 FCode FaultDescription Terminal Reac Diag Possible Cause 2194 Teach values from memory not within the permissible range System 2 2043 2044 2045 Repeat...
Page 59: ...n monitoring FCode FaultDescription Terminal Reac Diag Possible Cause 2203 The rear right hand output is triggered however the drums steers to the left or does not steer at all System 2 2203 2203 Drum...
Page 60: ...ower cannot be transmitted to the proportional solenoid X35 42 2 3021 3022 Line breakage in current path Valve coil defective 3002 Output to proportional valve shorted to ground X35 42 2 3021 3022 Sho...
Page 61: ...ent path has connection to Ub 15 or 30 FaultLocation Vibration frequency controller low amplitude Vibration frequency controller low amplitude Vibration frequency controller low amplitude Vibration fr...
Page 62: ...ration pump high amplitude Y57 Output vibration pump high amplitude Y57 Output vibration pump high amplitude Y57 FCode FaultDescription Terminal Reac Diag Possible Cause 3020 The required control powe...
Page 63: ...1 3032 Line breakage in current path Valve coil defective 3022 Output to proportional valve shorted to ground X35 42 2 3031 3032 Excessive current in current path Short circuit to ground 31 in the cur...
Page 64: ...h System 2 3031 Frequency adaptation saved control values are outside limiting values System 1 3035 Software parameter fault software update may be required 3032 Frequency adaptation controller has re...
Page 65: ...oid valve X35 51 3 3041 Line breakage in current path Valve coil defective FaultLocation Output amplitude changeover relay K43 Output amplitude changeover relay K43 Output amplitude changeover relay K...
Page 66: ...ac Diag Possible Cause 3074 Rear vibration is switched on but no pulses received by the sensor X35 35 3 3065 Line breakage in current path Hardware defect sensors replacement required No voltage suppl...
Page 67: ...valve rear Y172 Output phase synchronization valve rear Y172 Output phase synchronization valve rear Y172 FCode FaultDescription Terminal Reac Diag Possible Cause 3080 Valve 2 current regulator has r...
Page 68: ...the input is outside the specified range see signal description X23 12 3 3107 Line breakage in current path No voltage supply Ub Pot 15 or 30 3105 Ground Connection of sensor switch faulty The voltage...
Page 69: ...FaultLocation Output sprinkling valve edge cutter right Y99 Output sprinkling valve edge cutter right Y99 Output sprinkling valve edge cutter right Y99 Output sprinkling valve edge cutter right Y99 F...
Page 70: ...X22 26 3 Current path has connection to Ub 15 or 30 3135 The required control power cannot be transmitted to the valve X22 26 3 Line breakage in current path 3136 The output to the valve has ground c...
Page 71: ...in current path 3152 Supply voltage Ub is applied to the valve output even though the valve is not switched X22 10 3 Current path has connection to Ub 15 or 30 FaultLocation Output valve edge cutter r...
Page 72: ...ve chip spreader adjustment up Y131 FCode FaultDescription Terminal Reac Diag Possible Cause 3170 The required control power cannot be transmitted to the valve X22 19 3 Line breakage in current path V...
Page 73: ...to the valve X22 22 3 Line breakage in current path 3181 The output to the valve has ground contact or the output current is higher than permitted X22 22 3 Short circuit to ground 31 in the current pa...
Page 74: ...o ground 31 in the current path Excessive current in current path FaultLocation Input engine speed B92 Input engine speed B92 Input engine speed B92 Input engine speed B92 FCode FaultDescription Termi...
Page 75: ...ngine oil pressure monitoring B06 Input engine oil pressure monitoring B06 FCode FaultDescription Terminal Reac Diag Possible Cause 5021 Fault No oil pressure X26 07 5 5020 5020 Warning No oil pressur...
Page 76: ...6 3 FaultLocation Input coolant temperature switch B53 Input coolant temperature switch B53 Input coolant temperature switch B53 Input coolant temperature switch B53 FCode FaultDescription Terminal Re...
Page 77: ...ted to ground X35 64 3 Short circuit to ground 31 in the current path 5200 The required control power cannot be transmitted to the relay X35 64 3 Line breakage in current path EGAS actuator diesel eng...
Page 78: ...ltDescription Terminal Reac Diag Possible Cause 5500 Warning Hydraulic oil filter dirty X35 36 1 Check filter if necessary clean or replace as per service instr 5501 Fault Hydraulic oil filter dirty X...
Page 79: ...n Setup operating hour meter Setup operating hour meter Setup operating hour meter Setup operating hour meter FCode FaultDescription Terminal Reac Diag Possible Cause 7013 Operating hour meter not yet...
Page 80: ...lay Values for axle forward reverse 1 0 1000 Forward 0 1000 Reverse 1022 Display Values for axle right left 1 left 1000 0 1000 right i e brake gate 1025 Display Movement direction acc to travel lev 1...
Page 81: ...isplay Actual current value travel pump for 1 Display in mA 0 350 1300 1071 Display Nominal current value travel pump fo 1 Display in mA 0 350 1300 1078 Initial current value learned surge current of...
Page 82: ...eed sensor travel motor B60 FaultLocation 1105 Travel speed 1 Display in m min 100 1106 Pulses of speed sensor 1 Counts the pulses up to 99 999 and starts again at 0 Input Description Category ValueRa...
Page 83: ...avel drive B112 FaultLocation 1270 Display travel pressure 1 0 410 bar 1271 Display pressure sensor current measuring valu 1 0 0 22 0 mA 1272 Display pressure sensor measuring value stand 1 0 1000 127...
Page 84: ...ation 1314 Switching condition switch 2 outer 1 0 not switched 1 switched Input Description Category ValueRange Arm rest left FaultLocation 1320 Status arm rest left 1 1 arm rest up 2 arm rest down In...
Page 85: ...tion to learn steering valve su 1 See adjustment instructions 2001 Start teach function to learn steering valve surg 1 See adjustment instructions Input Description Category ValueRange Steering angle...
Page 86: ...0 mA Input Description Category ValueRange Input rear steering angle sensor B66 FaultLocation 2040 Shows current from input rear angle sensor 1 3000 21000 mA 2041 Show standardized actual angle value...
Page 87: ...nge steering valve front 1 1 mA Digit Input Description Category ValueRange Output steering valve Y36 rear left steering FaultLocation 2120 Rated current steering valve rear left 1 1 mA Digit 2121 Act...
Page 88: ...5 after overflow start again 0 2213 Show sense of rotation of steering sensor beari 1 000 undefined 001 turn right 002 turn left 003 error 2220 Show number of pulses sensor bearing 2 track 1 0 65535 a...
Page 89: ...ut Description Category ValueRange Input steering mode selector switch S89 FaultLocation 2260 Set stage on steering mode selector switch 1 1 5 1 Synchronous 2 Auto 3 Front 4 Rear 5 Diagonal 2261 3 226...
Page 90: ...ustment also via blue buttons 1 2327 Set crabwalk adjustment also via blue buttons 1 Input Description Category ValueRange Steering direction monitoring FaultLocation 2330 COMM_STEERING_CHANGE_PAR_CEC...
Page 91: ...a 1 mV Digit Input Description Category ValueRange Vibration frequency controller low amplitude FaultLocation 3025 Display adaptation value low amplitude singl 1 1500 4500 3026 Display adaptation valu...
Page 92: ...tegory ValueRange Input speed transducer vibration motor front B16 FaultLocation 3064 Display front vibration frequency 1 0 60 0 Hz Input Description Category ValueRange Input speed transducer vibrati...
Page 93: ...03 Display value for pressure switch only BW 15 1 0 100 Input Description Category ValueRange Water sprinkling system tank filling level FaultLocation 3102 Display switch for residual water quantity 1...
Page 94: ...edge cutters right and left activated 3 only left edge cutter activated Input Description Category ValueRange Edge cutter FaultLocation 3131 Enable changes to edge cutter parameters 1 See adjustment...
Page 95: ...led 1 Chip spreader controlled 3146 Display of push button status chip spreader on 1 0 Off 1 On 3147 Input code Set spreader to spreading beam sp 1 See adjustment instructions 3148 Input code Set spre...
Page 96: ...ine speed mode diesel engine com 1 0 Low idle speed 1 Eco mode 2 Full speed position 5003 Display engine speed mode diesel engine defa 1 0 Low idle speed 1 Eco mode 2 Full speed position 5004 Display...
Page 97: ...nt level too low Input Description Category ValueRange Input coolant temperature switch B53 FaultLocation 5022 4 does currently not exist 5023 Status of coolant temperature switch 1 0 Temperature ok 1...
Page 98: ...ation upper limit full spee 1 5103 Input code Quit this function 1 5110 Display input potentiometer measuring value E 1 0 1000 5111 Display of saved parameter for lower limit idl 1 BW 154 AP 50 300 BW...
Page 99: ...lso docu 800 4 801 4 802 4 8870 Enable parameter change fault indication BLM 3 See adjustment instructions 8871 Do not display BLM errors 3 See adjustment instructions 8872 Display BLM errors 3 See ad...
