Service Training 2012 - Electrics

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 Service Training 2012 - Electrics

Summary
Page Topic
03 – 17 New EGD
18 – 19 Electrical modifications
20 – 22 New Safety Switch RFIT
23 Suction/Return Filter Pressure Sensor
24 - 26 Central Lubrication 2011
27 – 28 New Step Relay
29 - 31 New Sensors for Rotary, Pressure and Angle
32 Chassis Standby Current
33 Autocor Oman

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 Service Training 2012 - Electrics
ZMS-EPS, 24 VDC, FFH 20, Gen. 4

Control Box KS 532319

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 Service Training 2012 - Electrics
Startup screen ca 5 sec. long

Function key “Home“

Function key “Help“

F4
Service area

Password

Function key F 1 Function key F 2 Function key F 3 Function key F 4

Pump status Pump settings Pump flow meter with Rotate / press to select symbols
engine menu and fault log and set numerical values.

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 Service Training 2012 - Electrics
EGD Colour Representation

Symbol colours:

Green: Function active, e.g. central lubrication, fan

switched on.

Red: Error message, important function impaired

with pumping discontinued e.g. E-stop, RSA,
over temperature ..
F4
Yellow: Pump output limited, e.g. oil too cold, too hot,
power limit..

Bar graphs:

Green: Normal range of values

Blue: Value too low, e.g. under temperature,

under speed..

Red: Value too high, e.g. over temperature..

F4

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 Service Training 2012 - Electrics
“HOME“ Menu

F4

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 Service Training 2012 - Electrics
Pump Status

F4

By rotating function switch F4 you can select the sensors.

F4 rotate to select a function, the symbol will be indicated by a

thick red outline.
F4 press and the symbol flashes.
F4 rotate until the symbol is crossed out.
F4 press and the sensor is deselected.

After turning the ignition off, settings revert to the default values.

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 Service Training 2012 - Electrics
Pump Settings

F4

Functions can be switched on or off by rotating function switch F4 .

Rotate F4 to select a function, the symbol is indicated by a thick red outline.

Press F4 and the symbol flashes or for the central lubrication the symbol turns green
and an additional lubrication cycle is triggered.
Rotate F4 until the symbol shows the desired setting.
Press F4 to save the setting.

After turning the ignition off, settings revert to the default values.

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 Service Training 2012 - Electrics
Pump Flowmeter

F4

Rotate function switch F4 until the desired value is shown in reverse.

1. Press F4 and the first digit of the set point flashes.
2. Rotate F4 to alter the first digit.
3. Pess F4 to store the first digit. The second digit flashes and can can be set.
Repeat steps 1 – 3 until the set-point has been achieved.

After turning the ignition off, settings revert to the default values.

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 Service Training 2012 - Electrics
Pump Flowmeter

In the Pump Flowmeter menu there are sub menus for

engine diagnostics and the error log.

The EBC menu only appears when Service Mode is active.

F4

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 Service Training 2012 - Electrics
Engine Diagnostics

F4

Bar charts and error messaging are only active for engines with electronic motor control (EMR).

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 Service Training 2012 - Electrics
Fault Log
Fault Code Meaning
1 Agitator safety cut-out
2 Emergency sto
4 „Pumpstop“ switch
8 Engine speed
16 Low level probe
32 Pump central lubrication
F4
64 Over temperature
128 External stop
256 Short circuit
If for example code 108 is shown, this means that 512 Transfer tube sensor
several faults exist. 64 + 32 + 8 + 4 = 108
1024 Pressure sensor
The last 10 faults are always shown. 2048 Gate valve closed
4096 Stroke count reached

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 Service Training 2012 - Electrics
Service Menu

In the Service Menu note the following !

You can return to the basic screen by pressing the „HOME“ button, but the control stays
in Service Mode. Return to the service screen by press button F4.

00123

F4 F4
F4

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 Service Training 2012 - Electrics
Service Menu

The Service Menu is accessed as follows.

In the base menu press rotary - / push button F4 2 x.

Then you are in a field for entering the password.
Enter the password by turning and pressing F4.
Customer menu 02011. Service menu 00123

Then the PM-Service Menu appears.

In this menu various functions can be turned on and off
F4 for test purposes with the rotary / push button F4.
In addition three more menu items are displayed.

00123

F4

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 Service Training 2012 - Electrics
Service Menu

00123

F4

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 Service Training 2012 - Electrics
Setup Menu
Programming the Pump and /or S-tube:
Select and activate the symbol in the Learn row / Pump or
S-Valve column by rotating/pressing F4. Whilst programming
the pump note the boundary conditions (pump on, full
throttle, 100% output setting, oil > 45°C).

Saving/ restoring factory settings:

Select the symbol in the Flash row by rotating, and activate
by pressing F4.
F4
View/change parameters:
Enter values in the Parameter row by rotation/pressing,
activate via the “Save“ icon.

The “Land Einheit Zeit“ field

Allows the choice of language for the help pages, the
preselection of units (bar/psi and/or °C/°F) and time format
(12/24h) selection.

Preselection of EQV, EOC....

These settings will remain after the ignition is turned off.
EPM = Ergonic Pump Management. EPM1, long distance
pumping; EPM2, high rise pumping; EPM3, half POH-time.
Parameterization, P340-369.

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 Service Training 2012 - Electrics
Setup Menu

F4

1 Display the basic settings from the test field.

2 Display failures and/or monitoring times.

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 Service Training 2012 - Electrics
Innovations in the Electrical Field

I/O Modules eliminated by the new EGD

F4

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 Service Training 2012 - Electrics
Innovations in the Electrical Field

Possibility of replugging the

receiver in the cab in the future.

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 Service Training 2012 - Electrics
Safety switch with RFID technology

New RSA and boom rest switches

No holes in the hopper.

Complies with the Machinery Directive, as the
agitator does not start after closing the grille.
Activated via switch on control box.

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 Service Training 2012 - Electrics
Safety switch with RFID technology

Memorising a new actuator

1. Apply the operating voltage to the safety switch.

The green LED flashes rapidly (ca. 10 Hz). During this time (ca. 3 s) a self-test is carried out. Then the LED
flashes three times to indicate it is ready for teaching, this state persists for ca. 3 minutes.
2. Bring the new actuator to the reading head.
The memorising process starts, and the green LED flashes (ca. 1 Hz). During this process the safety switch
checks whether actuator is blocked. If not, the process is completed in ca. 60 seconds, the green LED goes
out, the new code is stored and the old code is blocked.
3. To activate the newly-learned actuator code in the safety switch, the operating voltage supply to the safety
switch must be removed for a minimum of 3 seconds.

If a new actuator has been learned, the safety switch blocks the code of the previous unit. This cannot be
reinstated by a new memorising process. The blocked security code will only be cleared from the switch after
a third code has been learned.
The safety switch can only be operated by the last actuator learned. If the switch recognises a previously
learned actuator during the memorising preparation period, the process stops immediately and the switch
goes into normal operation.
If it does not find the actuator to be learned in the response zone in less than 60 s, it is not activated.

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 Service Training 2012 - Electrics
Safety Switches

Conformity with proposed EN 12001

Prepared for monitoring the covers on the emergency operating levers on
the boom and pump controls. Dual operationg mode no longer possible.

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 Service Training 2012 - Electrics
New BSF M 42

Pressure sensor on suction/return filter

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 Service Training 2012 - Electrics
BSF M 42 New Central Lubrication

New grease pot.

Both pumps are controlled by the CCU/EPS.

1 The boom lubrication is time controlled. A

lubrication cycle is performed every 4 hours. The
1 last grease distribution block has a limit switch.

2 Pump lubrication is initiated after ca. 60 strokes

and continues until a signal is given by the limit
switch on the grease distribution block.
After that the pump has a lubrication cycle ca.
every 60 strokes.
Intermediate lubrication is possible via the EGD.

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 Service Training 2012 - Electrics
Central Lubrication 2011

KS 532817

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 Service Training 2012 - Electrics
Central Lubrication 2011

New 12 way grease distributor

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 Service Training 2012 - Electrics
New Stepping Relay

Kuhnke 24V : Part No. 063516007 Replaced Stepping relay 12 / 24V

Kuhnke 12V : Part No. 063515008 by Size 2 Part No. 543660

The pins correspond one-to-one

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 Service Training 2012 - Electrics
New Stepping Relay

Note the following after installation:

If the pistons block in the end position, on machines with a switch fork the pump should
be switched off and then on again.
On machines with inductive switches, pumping can be re-established by means of the
changeover switch.

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 Service Training 2012 - Electrics
Transfer Tube Rotary Encoder Part No. 439690

Installing the new encoder.

The connecting cable for the old encoder has 3 cores, the new encoder has 4 cores.
On the new encoder the yellow core has no function and should not be connected.

Note when installing a new encoder that the shaft marking is rotated through 180°.
If this is not observed, the transfer tube cannot be programmed in.

Old shaft marking New shaft marking

Old New

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 Service Training 2012 - Electrics
New pressure sensor 420220

Pressure sensor 0 - 600 Bar

previous version new version

compatible

Electronic pressure transducer Electronic pressure transducer

Modification: Putzmeister Standard

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 Service Training 2012 - Electrics
New space angle senor for EBC

Requirements for refitting / usage of DIS angle sensors

- EBC software V 23.08 or higher.

- setup of the parameters „Sensor Location Selection“ (116, 156, 196, 236, 276, 316)
Prolec-sensor = 0 or 1
DIS-sensor = 12 or 13
- changing from Prolec to DIS needed adapter plate part-no: 513752.

Prolec basis: DIS basis:

431 348 507 018

ID part no. ID part no.

2 = Arm 1 480 099 2 = Arm 1 533 593
3 = Arm 2 480 101 3 = Arm 2 533 594
4 = Arm 3 480 102 4 = Arm 3 533 595
5 = Arm 4 480 103 5 = Arm 4 533 596
6 = Arm 5 480 104 6 = Arm 5 533 597
7 = Arm 6 480 147 7 = Arm 6 533 598
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 Service Training 2012 - Electrics
Standby current on PM truck mounted pumps

Actros M62 with ZMS-EPS

Chassis (without PM) 100 -120 mA

PM total and radio with conservation charging (no Daisy) 310 mA

PM total and radio with normal charging (no Daisy) 580 mA

PM total without radio (no Daisy) 220 mA

Daisy in sleep mode approx. 300 mA

Daisy switched off 0 mA

Total consumption without Daisy approx. 500 mA.

220 Ah batteries will be discharged after a time of 400 hrs.

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 Service Training 2012 - Electrics
Information about Autocor projects

MX 28 with BSA 1408E in Oman. Both units are installed in a building The BSA is equipped with a ZMS-
EPS control box and radio contral. The MX has a separate control box. Both machines can be controlled
by radio.

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