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OPERATING INSTRUCTIONS RH 170-B

BCS

Board Control - System


RH 170-B

No.

Terex GmbH

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OPERATING INSTRUCTIONS RH 170-B


BCS

______________________________________________________________________________________
Published by:

Terex GmbH
Department 340 - Documentation
D-44149 Dortmund, Karl-Funke-Strae 36
Tel. 49 (0) 231 922-4340
Fax 49 (0) 231 922-5340

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CONTENTS
DESCRIPTION ________________________________________________________________________ 1
FUNCTIONS ________________________________________________________________________ 1
COMPONENTS _____________________________________________________________________ 1
DISPLAYS : USING BCS ________________________________________________________________ 2
DISPLAY AND KEYBOARD ____________________________________________________________ 4
Indicator lights _____________________________________________________________________ 5
Buttons __________________________________________________________________________ 5
INSTRUMENTS _____________________________________________________________________ 6
SERVICE MENU _____________________________________________________________________ 6
Program 1: Oil change ______________________________________________________________ 7
Program 2 to 6_____________________________________________________________________ 7
The programs (Fig. 15) ______________________________________________________________ 7
Program 2: Service _________________________________________________________________ 7
Program 3: Engine _________________________________________________________________ 8
Program 4: Hydraulics (Fig. 19) _______________________________________________________ 8
Program 5: Excavator _______________________________________________________________ 9
Program 6: Operating hours __________________________________________________________ 9
HOLD function____________________________________________________________________ 10
Program 7: Setting date and time _____________________________________________________ 11
Program 8: Complete fault list ________________________________________________________ 12
Program 9: Service Terex ___________________________________________________________ 12
FAULT REPORTS___________________________________________________________________ 13
SERVICE DATA & FAULT STORAGE: PRINT-OUT OR TRANSFER INTO BUFFER ______________ 14
APPENDIX __________________________________________________________________________ 15
PRINT-OUT________________________________________________________________________ 15
DATA ACQUISITION COMPUTER DER 1__________________________________________________ 17
SENSOR ANALOGUE INPUTS ________________________________________________________ 17
DATA ACQUISITION COMPUTER DER 1__________________________________________________ 18
SENSOR DIGITAL INPUTS ___________________________________________________________ 18
DATA ACQUISITION COMPUTER DER 2__________________________________________________ 19
SENSOR ANALOGUE INPUTS ________________________________________________________ 19
DATA ACQUISITION COMPUTER DER 2__________________________________________________ 20
SENSOR DIGITAL INPUTS ___________________________________________________________ 20
DATA ACQUISITION COMPUTER DER 3__________________________________________________ 21
SENSOR ANALOGUE INPUTS ________________________________________________________ 21
DATA ACQUISITION COMPUTER DER 3__________________________________________________ 22
SENSOR DIGITAL INPUTS ___________________________________________________________ 22

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OPERATING INSTRUCTIONS RH 170-B


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DESCRIPTION

Components

Functions

Fig. 1 shows BCS and various modules. The main


parts of the BCS are:

The Board Control System, abbreviated to BCS,


monitors essential functions of the excavator and
its components. It releases an appropriate signal if
any maximum value is exceeded and also sends a
report to be archived in the memory bank. If a
normal operating status can be reached by
temporarily reducing the excavator's output, then
this is monitored by BCS and done by PMS. If it is
necessary for the operator to take certain action,
e.g. to stop one of the engines a relevant
command is sent to the BCS display screen.

Pos.
1
2
3

Function
Computer and Display
Keyboard
Printer
Data acquisition computers, sensors
and switches are mounted on several
positions on the machine.

BCS also gives information on sevicing and


trouble- shooting.
Sensors installed at various points on the
excavator constantly transmit their readings to the
BCS computer. All essential pieces of operating
data are displayed on the screen in the form of
simulated instruments. Other values, e.g. the
number of hours operated by the excavator, its
engines or, its travel or swing gears, are archived
and can be called up as and when required.
The data shown in the figures are examples. The
instruments on the screen indicate the actual
operating conditions.
Because BCS automatically warns of any
abnormal conditions that require a corrective
action, the operator can concentrate fully on the
work in hand, and is not distracted by constantly
having to keep an eye on many instruments or by
having to decide
upon appropriate actions to be taken in case of
limit values being exceeded.

Fig. 1

The operator and the servicing crew also have the


means of calling up particular background
information from the BCS archive.
This Technical Handbook (THB) has been
compiled to provide the necessary information for
working with the BCS.

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DISPLAYS : USING BCS


BCS contains several sub-programs:
"Instrument" display.
The basic display (Fig. 2) appears
automatically. Three further displays (Figs. 3, 4
& 5) can be called up when required.

Fig. 4

Fig. 2

Fig. 5

Fig. 3

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Instructions when BCS discovers a fault.
Instructions appear automatically in block
(2, Fig. 6). These instructions are to be carried
out immediately.
Status reports.
If an operating status requires a cut-back in
excavator functions, a relevant report is displayed in block (2, Fig. 6).

Service menu.
The programs listed in (Fig. 7), or the program
"Service - Terex" can be called up as needed.
Instructions for trouble-shooting (HELP blocks).
Information can be called up to help in
localizing and remedying a particular fault.

Fig. 7
Fig. 6

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Display and keyboard


(Fig. 8)

The top display line always shows the same


"instruments" (Fig. 9 - 12).

The display screen is divided into 3 blocks.

Oil pressure and coolant temperatures for,


LH & RH engines.

1. Graphic display

The "instruments" in the bottom line are:

- Graphics
- Fault reports
- HELP blocks for trouble-shooting

In the basic graphic (Fig. 9):


Hydraulic oil temperature, battery charge,
rev. settings for LH & RH engines.

2. Status block
Indicators lights (11 - 22)
The buttons (31 - 40) are arranged underneath the
display.

Fig. 9

Fig. 8

Fig. 10

In alternative 1 (Fig. 10):


Pump gearbox temperature and fuel levels for
LH & RH engines.

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Indicator lights
(Fig. 13)
Pos.
11
12
13
14
15
16
17
18
19
20
21
22

Function
Battery charge monitoring
Cooling liquid temperature
Engine oil pressure
Idle Timer
Cooling liquid min.
Battery charge monitoring
Cooling liquid temperature
Engine oil pressure
Idle Timer
Cooling liquid min.
Lubrication ON
Electronic excavator control ON

Fig. 11

In alternative 2 (Fig. 11):


Lube system grease pressure; Fuel system
pressure

Fig. 13

Buttons

Fig. 12

In alternative 3 (Fig. 12):


main pumps pressure P1+P4, P2+P3;
battery charge, ambient temperature.
Scroll through alternatives with
Return to basic graphic (Fig. 9) with

UP/DOWN
BACK

(Fig. 13)
Pos. Function
31 UP, select BCS program, positions
the cursor
select
BCS
program,
32 DOWN,
positions the cursor
confirms
a
program;
33 ENTER,
activates a desired program
34 BACK, recalls the service program
35 HOLD, freezes actual service data
36 PRINT, recalls the Print Menue
37 SERV. recalls the Service Menue
38 HELP, recalls the Help Menue
39 BL+, adjusts BCS monitor background
lighting (bright)
40 BL-, adjusts BCS monitor background
lighting (dark)

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Instruments

Service menu

As soon as the electrics are switched on, the basic


graphic (Fig. 14) appears in the display.

The service menu contains various sub-programs


and the menu "Service - Terex".

This graphic shows the most important operational


values in analog and digital form.

Call up service menu with


Return to basic graphic with

Three further displays (Figs. 10, 11 & 12) can be


called up when required.
The top display line always shows the same
"instruments".

The service menu (Fig. 15) lists 8 programs.


Program 9 is reserved for Terex|O&K service
personnel.

SERVICE
BACK

Fig. 15
Fig. 14

Select a program with

UP/DOWN

The cursor > indicates the program to be


called up.
Enter the required program with
Return to service menu with

ENTER
BACK

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Program 1: Oil change

Program 2 to 6

(Fig. 16)

The programs (Fig. 15)

The display shows the number of hours operated


by each engine and the number of operating hours
to the next oil change.
Return to service menu with

BACK

2. Service
3. Engine
4. Hydraulics
5. Excavator
6. Operating hours
can be used to call up important system data.

Program 2: Service
(Fig. 17)
Shows important data for the service
Return to service menu with

BACK

Fig. 16

Fig. 17

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Program 3: Engine

Program 4: Hydraulics (Fig. 19)

(Fig. 18)

The program displays important values for the


hydraulic system. Also hyd. oil temperature, swing
circuit temperature and ambient temperature.

In addition to important data for both engines and


pump transfer gearboxes, this program also shows
the total hours operated and the number of hours
at rated load (LOAD). It also shows the
compressed air pressure and the ambient
temperature.
Return to main menu with

Return to main menu with

BACK

BACK

Fig. 19

Fig. 19

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Program 5: Excavator

Program 6: Operating hours

(Fig. 20)

(Fig. 21)

The screen shows the number of reported cases of


contamination in the main, swing and charge
pumps and in the pump transfer gearboxes since
commissioning. It also shows fuel levels for LH and
RH engines, the number of hours to the next oil
change, the board voltage and the ambient
temperature.

The screen displays following operating hours/load


ratings:

Return to main menu with

Hours operated at work = hours run by the


hydraulics at work,
swingl or travel

BACK

Total hours operated

= engines running

Hours operated under


load

= engines running time


at rated load

Engines utilization % = hours operated under load


total hours operated
Hydraulic utilization (%) = hours operated at work
total hours operated.
The number of hours spent travelling or swinging
the superstructure are indicated separately.
Return to main menu with

BACK

Fig. 20

Fig. 21

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HOLD function

IMPORTANT

Any of the values on display in programs 2 - 6


(Figs. 17 - 21) can be "frozen" and then printed out
(Fig. 22).

The printer must be connected beforehand.


The screen otherwise displays "Printer not
connected". See directions in printer manual.
The print-out contains only the "frozen" values
from menus 2, 3, 4, 5 or 6 (Fig. 23).
Return to main menu with

BACK

Fig. 22

"Freeze" the display with

HOLD

The values frozen with the HOLD button are stored


(archived) until

Fig. 23

the function if cancelled by pressing HOLD


again
the basic graphic is recalled with the BACK
button
the print-out is finished
No fresh data or faults are displayed while the
screen is "frozen".
Start print-out with

PRINT

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Program 7: Setting date and time


(Fig. 24 und 25)
The date and time are shown in each of the
displays.
Program 7 can be used to set / correct the date
and the time.
Select line to be altered with
Alter value with

ENTER
UP / DOWN

After leaving the program a window appears on the


screen with the question "Take over data"
Take over data
Return without change

ENTER
BACK

Fig. 25

Fig. 24

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Program 8: Complete fault list

Program 9: Service Terex

(Fig. 26 und 27)

(Fig. 28)

The fault storage archive contains all reported


faults.
The archive contains a maximum of 125 fault
reports. If a fault occurs when the archive is full,
thescreen diplays fault storage archive is full

Scroll through archive with

This menu is reserved for Terex|O&K Service. It is


only accessible after a Code No. has been
entered. It is therefore not described here.

UP/DOWN

Change from fault list to fault description ENTER

Fig. 28

Fig. 26

Fig. 27

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Fault reports

Examples: Stop engine and/or


Engine output reduced

Any faults occurring during operation are shown in


the lower part of the graphic display (Fig. 29).

If more than 125 faults are present, information on


action to be taken concerning less-important faults
can only appear on the display when faults
with higher priorities have been remedied (or
action taken).

IMPORTANT
Programs or menus can be changed
even if a fault is being indicated.
The fault reports are always listed in their
respective order or priority. The most important
fault appears in the top line.
If a fault occurs in one of the components which
has an "instrument", then the instrument also
appears at the left of the display (Fig. 30).
If several faults are present, the cursor indicates
the fault to which the instrument belongs.

Information on remedying faults can be called up


with the HELP button.
Any fault (even if only 1 is listed) can be selected
with the cursor and HELP information called up
(Fig. 29).
HELP information appears in the upper sector of
the display (Fig. 30).
Select fault with

UP/DOWN

Call up information with

HELP

Cancel HELP information with

BACK

Fig. 29

The bottom sector of the display lists the action to


be taken by the operator, or the action that has
been taken automatically by the BCS system.

Fig. 30

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Service data & fault storage:


print-out or transfer into Buffer
Necessary are:
Select basic graphic with:
(press several times if necessary)

BACK

Connect printer. Otherwise BCS reports:


"Printer not connected"
Print with

PRINT

Select a desired program shown on the display


(Fig. 31).

Fig. 31

Select sub-menu with cursor >


Start print-out with
Back to the basic menu with

UP/DOWN
ENTER
BACK

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APPENDIX
Print-out
Fault storage print-out
Terex
>>> BOARD CONTROL SYSTEM RH 170-B <<<
Serial No.:

170070

Print out no.. 5


Last print out

22.09.08
19.09.08

13.42
18.41

Hours operated:

LH engine :

835

RH engine

848

Contamination:

MAIN PUMP
MAIN PUMP
MAIN PUMP
MAIN PUMP

GEARBOX
GEARBOX

1
2
3
4

2
2
2
2

1 1
2 0

SWING PUMP
SWING PUMP

1 0
2 0

Fault storage

No. 1 of 5
LH engine, oil pressure too low
First occurence :
22.09.08
Last occurence :
22.09.08
Cases
:
Metered value :
Speed
:

13.13
13.28
2
2,0 bar
1800 rpm

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Fig. 1

DATA ACQUISITION COMPUTER DER 1


Sensor analogue inputs
Item
1
2
3
4
5
6
7
8
9
10
11
12

Terminal
no.
5
7
9
11
13
15
17
19
21
23
25
26

Diagram
ident.
B 40.1
B 39.1
B 128
B 17
B1
B 29
B 107.1
B4
B2
B3
R1

Function

Sensor type

Oil pressure engine LH


Oil temperature engine LH
Oil pressure feed pump swing circuit 1
Oil temperature gearbox LH
PMS regulator pressure LH
PMS regulator pressure RH
Fuel pressure LH
Pressure servo control system
Oil pressure main pumps 1 + 3
Oil pressure main pumps 2 + 4
Fuel tank LH

4 20 mA
4 20 mA
4 20 mA
4 20 mA
4 20 mA
4 20 mA
4 20 mA
4 20 mA
4 20 mA
4 20 mA
0 90

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Fig. 2

DATA ACQUISITION COMPUTER DER 1


Sensor digital inputs
Item
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36

Terminal
no.
27
29
31
33
35
37
39
41
43
45
47
49
51
53
55
57

Diagram
ident.
B 12
S 177
S 65
S 60
B 14.1

S 62
S 61
S 59
S 64
S 63
S 56
SPS

Function

Sensor type

Min. coolant level engin LH


not used
not used
Contamination gearbox LH
Housing temperature slewing pump 1
Min. hydraulic oil level
not used
not used
Contamination slewing pump 1
Housing temperature slewing pump 2
Contamination slewing pump 2
not used
Contamination main pump 1
Contamination main pump 2
Hydraulic oil filter
Grease line A activated

GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
+ 27 V
+ 27 V

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Fig. 3

DATA ACQUISITION COMPUTER DER 2


Sensor analogue inputs
Item
41
42
43
44
45
46
47
48
49
50
51
52

Terminal
no.
5
7
9
11
13
15
17
19
21
23
25
26

Diagram
ident.
B 40.2
B 39.2
B 129
B 22
B 38.1
B 37.1
B 38.2
B5
B 107.2
R2

Function

Sensor type

Oil pressure engine RH


Oil temperature engine RH
Oil pressure feed pump swing circuit 2
Oil temperature gearbox RH
Pressure slewing motor 1
Temperature slewing circuit 1
Pressure slewing motor 2
not used
Outside temperature
Fuel pressure RH
Fuel tank RH
not used

4 20 mA
4 20 mA
4 20 mA
4 20 mA
4 20 mA
4 20 mA
4 20 mA
4 20 mA
4 20 mA
0 90
0- 30 V

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Fig. 4

DATA ACQUISITION COMPUTER DER 2


Sensor digital inputs
Item
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76

Terminal
no.
27
29
31
33
35
37
39
41
43
45
47
49
51
53
55
57

Diagram
ident.
B 20
S 179
S 75
S 70

S 72
S 69
S 71
S 74
S 73
SPS

Function

Sensor type

Min. coolant level engin RH


not used
not used
Contamination gearbox RH
Housing temperature slewing pump 3

GND
GND
GND
GND
GND

not used
not used
Contamination slewing pump 3
Housing temperature slewing pump 4
Contamination slewing pump 4
not used
Contamination main pump 3
Contamination main pump 4
not used
Grease line B activated

GND
GND
GND
GND
GND
GND
GND
GND
+ 27 V
+ 27 V

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Fig. 5

DATA ACQUISITION COMPUTER DER 3


Sensor analogue inputs
Item
81
82
83
84
85
86
87
88
89
90
91
92

Terminal
no.
5
7
9
11
13
15
17
19
21
23
25
26

Diagram
ident.
B 125
B 36

S 212

Function

Sensor type

Grease drum level - drum full


Greasing pressure

4 20 mA
4 20 mA
4 20 mA

not used
not used
not used
not used
Shutoff valve closed
V)

(dig.

4 20 mA
4 20 mA
4 20 mA
0 90
+27 0- 30 V

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Fig. 6

DATA ACQUISITION COMPUTER DER 3


Sensor digital inputs
Item
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116

Terminal
no.
27
29
31
33
35
37
39
41
43
45
47
49
51
53
55
57

Diagram
ident.
SPS
S 193
SPS
SPS
S 57
CMS
S 26
SPS
Relais
Relais
S 216.1
S 216.2
K 137
S 67
SPS
SPS

Function

Sensor type

not used
not used
Greasing ON
Greasing malfunction
Air filter engine LH
Travel 2nd stage
Superstructure brake
Parking brake
Relay contact engine LH
Relay contact engine RH
Dumper counter
Dumper reset
Electronic excavator control (seat contact)
Air filter engine RH
Idle timer engine LH
Idle timer engine RH

GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
+ 27 V
+ 27 V

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INDEX
Instruments ............................................................................6

A
Appendix ............................................................................. 15

B
Buttons .................................................................................. 5

C
Components........................................................................... 1

D
DESCRIPTION ..................................................................... 1
Display and keyboard............................................................ 4

F
Fault reports......................................................................... 13
Functions ............................................................................... 1

H
HOLD function.................................................................... 10

P
Print-out ...............................................................................15
Program 1
Oil change .........................................................................7
Program 2
Service ..............................................................................7
Program 2 to 6 .......................................................................7
Program 3
Engine ...............................................................................8
Program 5
Excavator ..........................................................................9
Program 6
Operating hours.................................................................9
Program 7
Setting date and time.......................................................11
Program 8
Complete fault list,..........................................................12
Program 9
Service Terex ..................................................................12

S
Service data & fault storage
print-out or transfer into buffer .......................................14
Service menu .........................................................................6

I
Indicator lights....................................................................... 5

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