Plate adjustment deactivated!
Travel lever out of brake gate:
Diagnostics mode active in foreground
Service Training WZ-4 DH Version and higher
3.3 Adjusting the machine type
Since the same control is used for all DH-4 single drum rollers with electronically controlled engine (EMR II), it is necessary to adjust the machine type after installing a new control.
This is necessary during first time commissioning as well as in case of a spare parts installation. This adjustment of machine type is necessary, because the machines may be equipped with different drum drive or axle drive motors or different tire sizes, thus resulting in different rolling circumferences, or they may be equipped with attachment plates or other options.
For simple checking the currently adjusted machine type is displayed for approx. 3 seconds on the display module when switching the ignition on. It can also be checked by entering code 0720.
The following machine types can be adjusted:
72XX
0 1 2 3 4 5 6 7 8 9
0 Default BW 177 DH-4
Service Training WZ-4 DH Version and higher
Version/Status: V2.07 / 24.06.05
Functions of ESX control
Page 12 of 67 Author: Seis / TENote: This function can only be activated / deactivated when the travel lever is locked in the brake gate. (à Input mode)
The following procedure must be used for initial start-up of a control:
• The control has been installed into the machine.
• Switch the ignition on. Approx. 4 seconds after switching on the letters C O D E are displayed for a period of approx. 3 seconds. After this the display changes and shows code 7200.
• Use the Arrow Up or Arrow Down keys to select the correct machine code from the list of codes.
• Confirm the selection with the Arrow Right key.
• After a period of approx. 7 seconds the adjusted machine code, e.g. 7 2 1 2 is displayed for approx.
3 seconds. The new parameters are loaded according to the machine type setting. Do not switch the ignition off during this time!
• After this switch the ignition off and on again to accept the configuration.
• After this 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 1 0 . This code number activates the function "Adjusting machine type“.
The display module now permanently shows the code 7 2 0 0 .
• Select the machine code from the table above and confirm it with the Arrow Right key. After operating the Arrow Right key the control switches automatically off and on again.
• After a period of approx. 7 seconds the adjusted machine code, e.g. 7 2 1 2 is displayed for approx.
3 seconds. The new parameters are loaded according to the machine type setting. Do not switch the ignition off during this time!
• After this switch the ignition off and on again to accept the configuration.
• After this the normal display will appear again.
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 enable to drive or steer the machine. It only 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 hydraulic steering option 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 the steering unit“.
• The following code numbers are available to activate the assembled 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!
Service Training WZ-4 DH Version and higher
3.5 Teaching the travel direction sensor
Teaching of the travel direction sensor is required for initial commissioning and after the replacement of a travel motor. Perform the following sequence
• Turn the speed range selector switch to "MAX"
• Shift the travel lever slowly out of neutral, until a travel speed of approx. 1 km/h is indicated.
• If one or both travel direction sensors detected a counteracting direction the error codes 1106 and/or 1116 will appear after approx. one machine length. Otherwise no error code will be displayed. The travel direction detection is now automatically set.
However, should one of the two error codes appear, this must be caused by a sebsor fault.
3.6 Automatic detection of surge currents in travel system
This function is only valid from software version 1.09!
For a sensitive and exact function of the travel system 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! First set the machine to input mode (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 speed selection switch must be in position ECO.
• If necessary enter code number 9 9 9 9 to access the service mode.
• Then enter 1 0 9 0 . This code number activates the function "Automatic detection of surge currents in
Service Training WZ-4 DH Version and higher
Version/Status: V2.07 / 24.06.05
Functions of ESX control
Page 14 of 67 Author: Seis / TE• The measurements (forward/reverse) must be started by entering a code number. The code number required to teach the travel direction is as follows:
Determination of control surge currents 1 0 9 1
• After the input of the above code number the display shows " F O R E ". Shifting the travel lever forward starts the first surge current measurement for forward travel.
• During the measurement the actual current is displayed (display value = current in mA).
• Once the surge current measurement is finished the display will show the reading O K for a period of 5 seconds.
• After this wait time the display reading changes to " B A C K ". Now shift the travel lever backward to start the surge current measurement in reverse.
• During the measurement the actual current is displayed (display value = current in mA).
• After completion of the measuring process in reverse the display will show O K again.
• The travel lever must now be returned to braking position.
• Once both surge currents have been learned correctly and the travel lever is in "braking position", the display shows the reading "D O N E", the values are saved and the function is completed. Now the machine can be operated again 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 time be aborted by operation of the emergency stop or the ignition switch.
The following procedure applies for software versions 1.07 and 1.08:
The automatic measurement of the travel system surge currents is performed as follows:
• The seat must be adjusted for travel direction forward!
• The speed selection switch must be in position ECO.
• If necessary enter code number 9 9 9 9 to access the service mode.
• Then enter 1 0 9 0 . This code number activates the function "Automatic detection of surge currents in the travel system"; the display now shows the reading 0 0 0 0 with the first digit flashing. This code number must be entered to be able to perform the following steps. From this point the machine can no longer be operated with the travel lever! The travel lever will only be in function again after the teach function has been completed or the machine 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 will only start after moving the travel lever to the respective travel direction.
ATTENTION: The ASC fault indicator light will come on during the teach process. In this case this is of no relevance. The warning will disappear when restarting the machine.
• During the measurement the actual current is displayed (display value = current in mA).
• Teaching is required for both travel directions.
• When returning the travel lever to neutral position after the two measurements, the display will show O K for 3 seconds and the averaged values will be saved.
• Once both surge currents have been measured the machine can be operated again 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 time be aborted by operation of the emergency stop or the ignition switch.
Service Training WZ-4 DH Version and higher
3.7 Teaching the electronic end stops of the steering angle sensor (BVC)
Attention: Does not apply for BVC machines with "hydraulic steering" option!
Note: During the measurement the machine should be parked on level ground.
The drum should be standing on old rubber tires or a metal plate.
Specify the engine speed -> travel lever out of braking position = neutral position (Not while entering a code).
To prevent the steering from moving all the way to the mechanical stops of the steering cylinder it is necessary to determine a defined safety distance to these end stops.
• Enter code number 9 9 9 9 to access the service mode.
• Enter code number 2 0 1 0 to activate the mode "Teach steering stops".
• Return the travel lever to neutral position (no braking function, but to relieve the machine of strain).
The display shows the standardized steering position (0..1000 → right ... left).
• Now turn the electric steering wheel clockwise, until the mechanical stop is reached The displayed value should be in the range of 100..300. Then shift the travel lever to braking position and enter code number 2 0 1 2 (press both Info-buttons first to access the input mode). In case of acceptance the value 2 2 2 2 will appear for a moment. In case of a fault the value 9 9 9 9 upon acceptance (see below).
• Return the travel lever to neutral position (no braking function, but to relieve the machine of strain).
The display shows the standardized steering position (0..1000 → right ... left).
• Now turn the electric steering wheel anti-clockwise, until the mechanical stop is reached The displayed value should be in the range of 700..900. Then shift the travel lever to braking position and enter code number 2 0 1 3 (press both Info-buttons first to access the input mode). In case of acceptance the value 3 3 3 3 will appear for a moment. In case of a fault the value 9 9 9 9 upon acceptance (see below).
• To leave the mode the machine must be switched off or code 2 0 1 1 must be entered.
Possible error causes (code 9 9 9 9 ) :
- Incorrect connection of hoses -> have checked by engineer -> correct.
- Connecting fault on potentiometer -> have checked by an electrician -> correct.
- Potentiometer faulty -> replace the potentiometer.
Service Training WZ-4 DH Version and higher
Version/Status: V2.07 / 24.06.05
Functions of ESX control
Page 16 of 67 Author: Seis / TEMachine on level ground
Tires or metal plate under drum
Turn steering wheel to the RIGHT to the STOP (PRV can be heard, cylinder full extended or retracted).
enter 2012
Travel lever in brake position
Travel lever in neutral position
Turn steering wheel to the LEFT to the STOP (PRV can be heard, cylinder full extended or retracted).
Travel lever in brake position
Switch ignition off
and on again OR enter 2011
FINISHED START
Service Training WZ-4 DH Version and higher
3.8 Automatic detection of surge currents on steering valves (BVC)
Attention: Does not apply for BVC machines with "hydraulic steering" option!
Note: Execute this function only AFTER "Teaching electronic end stops of angle sensor".
During the measurement the machine should be parked on level ground.
Before the measurement both drums should be steered to straight ahead position.
The travel motor must be moved out of braking position -> raised idle speed!
To enable a sensitive and exact function of the steering the surge currents of the two control solenoids and both steering valves must be measured. The surge currents are automatically adjusted after entering a code number, so that no electric meter is required.
The surge currents must only be adjusted during initial commissioning in the factory, after a service during which the control on a steering valve or the complete steering valve has been replaced and after the replacement of the ESX-control.
The measurement is identical for both solenoids:
Example BW 177 BVC:
After entering the respective code number the current is increased by the control solenoid in steps of 5 mA, starting from 650 mA.. After each increasing step the system waits for 2 seconds. If a change in drum angle is measured after the waiting time, the surge current is reached. In order to enhance the measuring result this measurement is performed three times. The final surge current is the mean value of these three measurements. This surge current is automatically stored and is valid from the next start of the machine.
For all other machine types the same procedure is used, however, currents and times will vary.
Before the measurement you must strictly make sure that the steering system is „bled“, because an air cushion in the steering cylinders would have a negative effect on the measurement and therefore on the steering performance of the machine. Sufficient bleeding is achieved by performing a few quick steering movements at full engine speed.
The automatic measurement of the steering valve surge currents is performed as follows:
• The engine must be operated in ECO-mode!
• Enter code number 9 9 9 9 to access the service mode.
• Travel lever in neutral position (Brake must be relieved!)
• Enter code number 2 0 0 0 . This code number activates the function "Automatic detection of steering valve surge currents"; the display now shows the reading 0 0 0 0 with the first digit flashing.
• Now code number 2 0 0 1 must be entered.
• After entering one of the above mentioned code numbers the measurement of the surge current will start immediately.
• The drum is thereby first steered to the right and then to the left.
• During the measurement the actual valve current is displayed (display value in mA).
• Attention! During the measurement the drum cannot be steered ! The steering wheel has no effect.
• During the measurement the machine should not be driven !
• Once the measurement is completed the display value OK will appear for 3 seconds, after this the code number 0000 is displayed with the first digit flashing, the next measurement can be started.
• The new surge current values are valid from the next start.
Service Training WZ-4 DH Version and higher
Version/Status: V2.07 / 24.06.05
Functions of ESX control
Page 18 of 67 Author: Seis / TE3.9 Driving against the closed brake
After entering the code number 0 5 0 0 the brake will not be released. If the travel lever is in this condition shifted out of the brake gate and moved to any travel direction, the travel pumps will be triggered according to the chosen travel direction. At the same time a warning (fault code 0 5 0 0 ) appears on the display and the warning buzzer is triggered, in order to keep the operator informed about the condition. The brake control light in the LC-display remains activated.
In order to terminate this function and release the brake you must either enter code number 0 5 0 1 or switch the ignition off. After entering code number 0 5 0 1 the function is aborted and OK is displayed as confirmation for 5 seconds. After this the code needs to be entered again.
Note: This function can only be activated / deactivated when the travel lever is locked in the brake gate. (à Input mode)
3.10 Showing stored faults
This function is only valid from software version 1.10!
Switch on function „Show stored faults“:
• Enter code number 0 7 0 0 . This code number enables the function „Show stored faults“.
The faults stored in the ESX are displayed in flashing mode. If several faults are stored, these are successively displayed in cycles of 3 second. After the last fault has been displayed, the first fault will appear again. If no faults are stored in the ESX, the display will show "- - - "
Switch off function „Show stored faults“:
• Enter code number 0 7 0 1 . This code number disables the function „Show stored faults“.
Note: Apart from the stored faults the current faults are also displayed.
Note: This function can only be activated / deactivated when the travel lever is locked in the brake gate. (à Input mode)
3.11 Delete all stored faults
This function is only valid from software version 1.10!
Execute the function „Delete all stored faults“:
• The engine must not be running!
• Enter code number 0 7 1 0 .
• Switch the ignition off and on again.
All stored faults are now deleted.
Note: The stored faults can only be deleted when the engine is not running.
Note: This function can only be activated / deactivated when the travel lever is locked in the brake gate. (à Input mode)
Service Training WZ-4 DH Version and higher
4 How to proceed when replacing components?
Each machine is adjusted individually during initial commissioning. This adjustment or teaching process is necessary to make sure that the travel and steering functions are almost identical on all machines.
Background of these adjustment procedures are the tolerances of the components used, e.g. hydraulic pump for travel system, proportional valves for steering, steering angle sensors and ESX control. These tolerances apply for both mechanical as well as electrical functions and are unavoidable for
manufacturing reasons.
To enable simple and quick adjustment procedures we have decided to do without expensive tools. All that is needed is this manual and a bit of time. By following the described procedure it is possible to take a machine back into operation after the replacement of one of the components specified above and to
To enable simple and quick adjustment procedures we have decided to do without expensive tools. All that is needed is this manual and a bit of time. By following the described procedure it is possible to take a machine back into operation after the replacement of one of the components specified above and to