Vous êtes sur la page 1sur 59

TEREX ELECTRIC MAINTENANCE TRAINING

BOARD CONTROL SYSTEM

TEREX BOARD CONTROL SYSTEM


BCS Notes : BCS The BCS is a passive monitoring device which monitors critical and non critical functions of the machine and its components. It delivers audible and visual warnings in the event of, any of the machines operating parameters are exceeded . If any operating parameters are exceeded e.g.. Temperature, the operator is notified immediately and the relevant information is recorded in a central memory bank known as the BCS fault storage. The BCS also advises the operator of what course of action to take in the event of a problem occurring, if the fault is not critical, the operator is advised please check. If the fault is critical and detrimental to machine operation, the BCS advises the operator to stop engine. This fault storage information can be called up at any time by all mine personnel. Because the BCS automatically notifies the operator of any abnormalities, the operator can concentrate on operating the machine without having to constantly monitor the instruments and having to make decisions in the event of an alarm. By using a laptop computer and BCS Reader programme, the entire BCS programme, or specific information, such as fault screen, can be downloaded. This can ten be saved into a selected file.

SERVICE TRAINING

TEREX BOARD CONTROL SYSTEM


BCS

SERVICE TRAINING

TEREX BOARD CONTROL SYSTEM


Start Up Screen NOTES:Board Control System As soon as the key switch is turned on the basic graphic appears in the display. This graphic shows the most important operational values in analog gauge and digital form. Further values can be checked using the up or down scroll keys to move through the alternative displays. The most critical operating values, engine oil pressure and engine water temperature are always displayed ate the top of the page on all start up screens. Operating Values Displayed: Engine Oil Pressure Water temperature Hydraulic Temperature Battery Voltage Engine RPM Ambient Temperature Pump Drive G/Box oil temperature Fuel level Grease Pressure Slew Pressures Engine Oil temperature

Additional graphics displayed at the bottom of the screen are the truck counter, time to next service and fuel level. Also at the bottom of the page are the warning indicators for alternator charge, engine temperature, engine oil pressure, idle timers active, grease system operating and servo pressure on / off. Should a operating parameter be exceeded the operator will be advised of the nature of the fault and its current value, he will also be advised of what action is to be taken, stop engine or please check. All faults are recorded in a database or fault list and can be called up or down loaded by maintenance personnel.

SERVICE TRAINING

TEREX BOARD CONTROL SYSTEM


Start Up Screen

SERVICE TRAINING

TEREX BOARD CONTROL SYSTEM


Fault Screen NOTES:Board Control System Current faults will also be displayed on the BCS screen, as well as other relevant information, eg. Travel Brake Applied

SERVICE TRAINING

TEREX BOARD CONTROL SYSTEM


Fault Screen

SERVICE TRAINING

TEREX BOARD CONTROL SYSTEM


Fault Screen NOTES:Board Control System By pressing the HELP button, recommended courses of action will be displayed, after arrowing up or down to the selected fault.

SERVICE TRAINING

TEREX BOARD CONTROL SYSTEM


Fault Screen

SERVICE TRAINING

TEREX BOARD CONTROL SYSTEM


Service Menu NOTES: Service Menu The service menu contains various sub menus and is accessed using the service key and cursor up / down key on the touch pad. The service menu lists 10 sub menus: Oil change = hours to go until engine oil change Service = hours to go until next service Engine = engine operating values Hydraulics = hydraulic operating values Device = contamination's recorded against hydraulic pumps, motors and pump drive gearboxes Operating hours = engines, travel swing and load Set time / date = change date and time setting Error list = fault storage Contrast = adjust display screen contrast Service O&K = access additional sub menus, code required. Engine In addition to important operating data for both engines and pump drive gearboxes this menu also shows the total operating hours and hours at rated load. Ambient air temperature are also displayed. To move back to the service menu screen us the back key on the touch pad.

SERVICE TRAINING

10

TEREX BOARD CONTROL SYSTEM


Service Menu

SERVICE TRAINING

11

TEREX BOARD CONTROL SYSTEM


Service Menu : Hours NOTES: Service Menu

Oil change. The display shows the number of hours operated by each engine and the number of operating hours to the next oil change.

To move back to the service menu screen us the back key on the touch pad.

SERVICE TRAINING

12

TEREX BOARD CONTROL SYSTEM


Service Menu

SERVICE TRAINING

13

TEREX BOARD CONTROL SYSTEM


Service Menu NOTES: Service Menu Service. The display shows the number of operating hours to the next service. To move back to the service menu screen us the back key on the touch pad.

SERVICE TRAINING

14

TEREX BOARD CONTROL SYSTEM


Service Menu

SERVICE TRAINING

15

TEREX BOARD CONTROL SYSTEM


Service Menu NOTES: Service Menu

Engine. 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 ambient temperature. To move back to the service menu screen us the back key on the touch pad.

SERVICE TRAINING

16

TEREX BOARD CONTROL SYSTEM


Service Menu

SERVICE TRAINING

17

TEREX BOARD CONTROL SYSTEM


Service Menu NOTES: Service Menu Hydraulics. This sub menu displays important values for the hydraulic system. Also the hydraulic oil, swing and ambient temperatures. To move back to the service menu screen us the back key on the touch pad.

SERVICE TRAINING

18

TEREX BOARD CONTROL SYSTEM


Service Menu

300 42 820 1920 25 35 25

300 225 25

600 600

SERVICE TRAINING

19

TEREX BOARD CONTROL SYSTEM


Service Menu NOTES: Service Menu

Device. This screen indicates cases of contamination in the main pumps, swing pumps and the pump transfer gearboxes. 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. To move back to the service menu screen us the back key on the touch pad.

SERVICE TRAINING

20

TEREX BOARD CONTROL SYSTEM


Service Menu

SERVICE TRAINING

21

TEREX BOARD CONTROL SYSTEM


Service Menu NOTES: Service Menu

Operating Hours. The screen displays following operating hours/load ratings: Total hours operated Hours operated under Hours operated at work Engine utilization (%) Hydraulic utilization (%) = engine running = engine running times at load rated load = hours run by the hydraulics at work, swing or travel = hours operated under load divided by total hours operated = hours operated at work divided by total hours operated.

The number of hours spent travelling or swinging the superstructure are indicated separately.

To move back to the service menu screen us the back key on the touch pad.

SERVICE TRAINING

22

TEREX BOARD CONTROL SYSTEM


Service Menu

SERVICE TRAINING

23

TEREX BOARD CONTROL SYSTEM


Service Menu NOTES: Service Menu Date / Time. The date and time are shown in each of the displays. This screen can be can be used to set / correct the date and the time. Select line to be altered with UP / DOWN Alter value with UP / DOWN To move back to the service menu screen us the back key on the touch pad.

SERVICE TRAINING

24

TEREX BOARD CONTROL SYSTEM


Service Menu

SERVICE TRAINING

25

TEREX BOARD CONTROL SYSTEM


Service Menu NOTES: Error List (fault storage) The fault storage database contains all reported faults. The database contains a maximum of 125 fault reports.If a fault occurs when the data base is full the oldest fault report is deleted make room for the new report. The database record the following information on each reported fault: No. = the fault position in the error list 1 - 125 with 1 the oldest fault reported, the fault reports can be scrolled through using the up / down keys on the touch pad. Name = is an abbreviation of the of the parameter that has been exceeded e.g. GOT1 (pump drive gearbox L/H oil temperature). Type = is a description of the fault,e.g. communication,limiting value etc. Beginning = date and time fault occurred End = date and time fault was cleared. The error list or individual fault reports can be down loaded using the printer or laptop Computer and BCS Reader Programme.

To move back to the service menu screen us the back key on the touch pad.

SERVICE TRAINING

26

TEREX BOARD CONTROL SYSTEM


Service Menu

SERVICE TRAINING

27

TEREX BOARD CONTROL SYSTEM


Service Menu NOTES: Error List (fault storage)

Should more detailed information be require on any fault report listed this can be obtained by moving the cursor through the error list using the up / down keys on the touch pad to the fault report required and press the enter key. This will display a sub menu with more information on the selected fault. To return to the error list press the enter key again. The error list or individual fault reports can be down loaded using the printer.

SERVICE TRAINING

28

TEREX BOARD CONTROL SYSTEM


Service Menu

SERVICE TRAINING

29

TEREX BOARD CONTROL SYSTEM


Service Menu NOTES: Error List Permanent

Permanent errors are stored in the BCS. These faults cannot be erased, not even by Terex personnel. To access these faults the Terex 5 digit access code is required.

SERVICE TRAINING

30

TEREX BOARD CONTROL SYSTEM


CMS Screen

SERVICE TRAINING

31

TEREX BOARD CONTROL SYSTEM


Terex Service Menu NOTES: Service Terex The Terex service menu is accessed using a 5 digit pin code. Persons entering this sub menu should only do so if authorized as display and recorded information can be altered or deleted. Proceed with caution. The service menu contains various sub menus and is accessed using the service key and cursor up / down key on the touch pad. The service menu lists 10 sub menus: Confirm Service = resets the service interval timer and adjustments to this interval can be made Confirm Oil change =resets hours to go until engine oil change and adjustments to this interval can be made Clear Error Memory = deletes all faults contained in the error list Change Operating Hours = adjust or reset all recorded operating hours Check Engine Performance = load test engines Change Service Data = Configure display information, change display language, printer type, units of measurement etc. Sensors DER (analog) = view operating parameters of each DER card and inputs from sensors analog which are connected to each card Sensors DER (digital) =view each DER card and inputs from switches digital which are connected to each card Process Data PMS = operational settings of PMS master / slave boxes for hydraulics and engines, adjustments can be made. CMS Check = operational settings of CMS functions for hydraulics and engines. Adjustments can be made, and all mA values of proportional valves can be accessed. Configure Device = access additional sub menus, code required. Note: Menus that are access and have the ability to change information within will always display a warning when exiting asking for conformation of any changes by pressing the enter key or exit without change by pressing the back key. If in doubt press the back key to exit without change to information

SERVICE TRAINING

32

TEREX BOARD CONTROL SYSTEM


Terex Service Menu

SERVICE TRAINING

33

TEREX BOARD CONTROL SYSTEM


Terex Service Menu NOTES: Service Terex Confirm Service.

SERVICE TRAINING

34

TEREX BOARD CONTROL SYSTEM


Terex Service Menu

SERVICE TRAINING

35

TEREX BOARD CONTROL SYSTEM


Terex Service Menu NOTES: Service Terex Confirm Oil Change.

SERVICE TRAINING

36

TEREX BOARD CONTROL SYSTEM


Terex Service Menu

SERVICE TRAINING

37

TEREX BOARD CONTROL SYSTEM


Terex Service Menu NOTES: Service Terex Change Operating Hours. Use this screen to change component operating, eg, after changing out an engine.

SERVICE TRAINING

38

TEREX BOARD CONTROL SYSTEM


Terex Service Menu

SERVICE TRAINING

39

TEREX BOARD CONTROL SYSTEM


Terex Service Menu

NOTES: Service Terex


Engine Performance. Use this screen to check engine performance..

SERVICE TRAINING

40

TEREX BOARD CONTROL SYSTEM


Terex Service Menu

SERVICE TRAINING

41

TEREX BOARD CONTROL SYSTEM


Terex Service Menu

NOTES: Service Terex


Engine Fault Codes. Use this screen to check engine active fault codes.

SERVICE TRAINING

42

TEREX BOARD CONTROL SYSTEM


Terex Service Menu

SERVICE TRAINING

43

TEREX BOARD CONTROL SYSTEM


Terex Service Menu NOTES: Service Terex

NOTES: Service Data Device Type = machine model (RH120) Device Number = machine serial number (40064) Service Interval = service hour setting Oil Change Interval = engine oil change interval setting CMS Present = Yes / No if machine is fitted with central management system (electronic joysticks and pedals) Change Language = English, Spanish or German Speaker = Yes / No audible warning sounded on occurrence of fault DTS Functionality = Yes /No telemetry fitted Printer No = printer type used to download information (Seiko, Epson or data shuttle) System Of Unit = metric or imperial Confirm Oil Change / Service = Yes / No reset oil change and service interval Suppress Message BUS OFF = Yes / No suppress communication (BUS) fault warnings. Can Baudrate = controller area network (CAN) data communication speed. Note: Menus that are access and have the ability to change information within will always display a warning when exiting asking for conformation of any changes by pressing the enter key or exit without change by pressing the back key. If in doubt press the back key to exit without change to information

SERVICE TRAINING

44

TEREX BOARD CONTROL SYSTEM


Terex Service Menu

SERVICE TRAINING

45

TEREX BOARD CONTROL SYSTEM


Sensors : Analog

NOTES: Sensors DER Analog

Each of the 2 data acquisition processor cards (DER) can be accessed and the operating values of each of the sensors which is connected to the card. Usually DER 1 processes the sensor information from the left side of the machine or position 1. DER card 2 process information from the right side of the machine or position 2 and lastly DER card 2 processes information for the machine which can not be identified left or right. All cards and sensors can be view by pressing the up /down key on the touch pad.
Information displayed: Adr. = address port of the sensor Name = abbreviated name of sensor Measured Value = current operating pressure or temperature Limiting Value = the maximum or minimum preset operating parameter Current = mA signal being received by the card for the sensor. Error = 0 if no fault is present or 1 if a fault is present.

SERVICE TRAINING

46

TEREX BOARD CONTROL SYSTEM


Sensors : Analog

SERVICE TRAINING

47

TEREX BOARD CONTROL SYSTEM


Sensors : Analog NOTES: Sensors DER Analog To access a full name description of the sensors connect to the current DER card being displayed press the help key on the touch pad are the sub menu displaying full sensor name will appear. To exit and return to the DER card display press the back key.

SERVICE TRAINING

48

TEREX BOARD CONTROL SYSTEM


Sensors : Analog

SERVICE TRAINING

49

TEREX BOARD CONTROL SYSTEM


DER Cards NOTES: Each of the 2 data acquisition processor cards (DER) can be accessed and the current status of each of the digital switches connected to the card checked. Usually DER 1 processes the switch information from the left side of the machine or position 1. DER card 2 process information from the right side of the machine or position 2 and lastly DER card 2 processes information for the machine which can not be identified left or right. All cards and switches can be view by pressing the up / down key on the touch pad. Information displayed: Adr. = address port of the switch Name = abbreviated name of switch and current status indicator (open / closed) Error = 0 if no fault is present or 1 if a fault is present.

SERVICE TRAINING

50

TEREX BOARD CONTROL SYSTEM


Sensors : Digital

SERVICE TRAINING

51

TEREX BOARD CONTROL SYSTEM


Sensors : Digital

NOTES:Sensors DER Digital (switches) To access a full name description of the sensors connect to the current DER car being displayed press the help key on the touch pad are the sub menu displaying full sensor name will appear. To exit and return to the DER card display press the back key.

SERVICE TRAINING

52

TEREX BOARD CONTROL SYSTEM


Sensors : Digital

SERVICE TRAINING

53

TEREX BOARD CONTROL SYSTEM


Process data PMS

NOTES: Process Data PMS Process parameters which have been set in the Configure Device menu or set in the factory for the pump management system (PMS) master and slave . Engine On Load Speed = current engine speed Nominal Speed = pump regulation speed normally 12% lower than high idle speed setting High Idle Speed = engine speed at the time the load switch closes. Water Temperature = current engine coolant temperature GLR Current = governor load limit regulation current (PMS current) 250 - 850 mA Load DSL = current status of load switch for working equipment functions Driving DSF = current status of load switch for travel function Lifting Force DSS = for special attachments e.g. hammer, grab etc.. Clam DSH = current status of clam function Lower FSA = engine auto rev reduction activated.

SERVICE TRAINING

54

TEREX BOARD CONTROL SYSTEM


Process data PMS

SERVICE TRAINING

55

TEREX BOARD CONTROL SYSTEM


CMS Screen NOTES: : CMS Central Unit The operating values of the Joysticks and Pedals can be accessed from this screen. When a function is operated, eg. L/H joystick, the actual and set mA values are displayed, the indicater bar for the safety valve moves, and if the float valves are bypassed, (Power Down), this is indicated. Other functions are displayed, including travel brake, slew brake, 2nd stage travel, Load Sensing pressure and which engines are running.

SERVICE TRAINING

56

TEREX BOARD CONTROL SYSTEM


CMS Screen

SERVICE TRAINING

57

TEREX BOARD CONTROL SYSTEM


CMS Screen NOTES: : Configure Device Access to this screen is reserved for Terex personal or authorised dealer representatives only. Non Permanent errors can be erased and lubrication cycle times can be set from this screen,

SERVICE TRAINING

58

TEREX BOARD CONTROL SYSTEM


CMS Screen

SERVICE TRAINING

59