Service Training Electric BF800

Service Training
Electrics
BF800
Version 1.40
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Table of contents
1 Confirmation of changes__________________________________________ 4
1.1 Document______________________________________________________________________ 4
1.2 Glossary _______________________________________________________________________ 4
1.3 Software _______________________________________________________________________ 5
2 The main display ________________________________________________ 6

2.1 General display functions and operation ____________________________________________ 6
2.1.1 Entering input codes ______________________________________________________ 6
2.1.2 Calling up service mode ___________________________________________________ 6
3 Settings________________________________________________________ 7
3.1 General ________________________________________________________________________ 7
3.1.1 Machine type ____________________________________________________________ 7
3.2 Tractor control (TCU) ____________________________________________________________ 8
3.2.1 Propel system ___________________________________________________________ 8
3.2.1.1 Learn function for the start currents of the propel pumps (BF800 C only) ___________________8
3.2.1.2 Teach the forward and backward start currents of the propel pumps (BF800 C only) __________9
3.2.1.3 Learn function for the start currents of the front wheel drive proportioning valves (BF800 P) ___10
3.2.1.4 Speed command by Boost button in case of a broken speed potentiometer ________________11
3.2.1.5 Steer with spin switch in case of a broken steering wheel transducer (BF800 C only) ________11
3.2.1.6 Change speed potentiometer type ________________________________________________12
3.2.1.7 Drive against closed brake ______________________________________________________12
3.2.1.8 Block screed extensions during transport (BF800P with road homologation only) ____________12
3.2.2 Miscellaneous __________________________________________________________ 13
3.2.2.1 Enable / disable force heating in LOW idle __________________________________________13
3.2.2.2 Enable / disable cleaning function_________________________________________________13
3.2.2.3 Store settings ________________________________________________________________13
3.2.2.4 Restore settings ______________________________________________________________13
3.2.2.5 Return to the default values _____________________________________________________14
3.3 Screed control (SCU) ___________________________________________________________ 15
3.3.1 Teach L.C.S. potentiometers max. values _____________________________________ 15
3.3.2 Adjust currents for the tamper pump _________________________________________ 16
3.3.3 Adjust tamper ramps _____________________________________________________ 16
3.3.4 Adjust currents for the vibration pump ________________________________________ 18
3.3.5 Miscellaneous __________________________________________________________ 19
3.3.5.1 Store settings ________________________________________________________________19
3.4 Material flow control (MCU) ______________________________________________________ 20
3.4.1 Enable/disable hoppers front flap ___________________________________________ 20
3.4.2 Adjust maximum current for augers pumps ____________________________________ 20
3.4.3 Adjust augers ramps _____________________________________________________ 21
3.4.4 Adjust maximum current for conveyor pumps __________________________________ 22
3.4.5 Enable / disable lifting auger box with screed __________________________________ 23
3.4.6 Miscellaneous __________________________________________________________ 23
3.4.6.1 Store settings ________________________________________________________________23
3.5 Store / Restore settings _________________________________________________________ 24
4 Fault log display and delete _____________________________________ 25

4.1 Showing stored faults ___________________________________________________________ 25
4.2 Showing saved faults with operating hours _________________________________________ 25
4.3 Delete all stored faults __________________________________________________________ 25
5 How to proceed when updating controller software __________________ 27
6 How to proceed when replacing components _______________________ 28
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6.1 Replacement of an electronic control unit __________________________________________ 28
6.2 Replacement of a propel pump ___________________________________________________ 28
6.3 Replacement of front wheel drive proportioning valve block ___________________________ 28
6.4 Replacement of an auger or conveyor pump ________________________________________ 28
6.5 Replacement of a tamper or vibration pump ________________________________________ 28
6.6 Which components can be replaced without an adjustment procedure? _________________ 29
7 Fault codes ____________________________________________________ 30

7.1 Overview _____________________________________________________________________ 30
7.2 Description of fault reactions_____________________________________________________ 31
7.3 Detailed description of fault codes and their possible causes __________________________ 32
7.3.1 General _______________________________________________________________ 32
7.3.2 Relay engine shutdown ___________________________________________________ 32
7.3.3 Brake valve ____________________________________________________________ 32
8 Input codes____________________________________________________ 34
8.1 Command codes _______________________________________________________________ 34
8.1.1 Fault log _______________________________________________________________ 34
8.1.2 Changing the machine code _______________________________________________ 34
8.2 Display codes _________________________________________________________________ 35
8.2.1 General _______________________________________________________________ 35
8.2.2 Brake _________________________________________________________________ 35
8.2.3 Hydraulics _____________________________________________________________ 35
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1 Confirmation of changes
1.1 Document
Version Date Description of changes Resp.

1.00 15.05.2011 Initial version. M. Nick
1.10 11.10.2011 3.2.4 Teach L.C.S. potentiometers max. values, display M. Nick
codes updated.
1.20 23.03.2012 3.2.3.2 Adjust tamper ramps. M. Nick
1.30 02.10.2012 Chapter Enable/disable hoppers front flap added. M. Peri
Chapter Block screed extensions during transport (BF800P
with road homologation only) added.
Chapter Adjustments added.
1.40 05.12.2012 Chapters added: M. Peri /
Steer with spin switch, M. Nick
Change speed potentiometer type,
Enable / disable force heating in LOW idle,
Enable / disable lifting auger box with screed,
Enable / disable cleaning function (SCU and MCU),
Return to the default values (SCU and MCU),
Store / Restore settings,
How to proceed when updating controller software,
Replacement of a auger or conveyor pump,
Replacement of a tamper or vibration pump,
Command Codes,
Display Codes
1.2 Glossary
Description
MCU Material flow control unit
SCU Screed control unit
TCU Tractor control unit
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1.3 Software
Control Version Start Version End Software Part Number Comment

Unit
Support BF800 P and
0.19
TCU, A34 05767318 BF800 P with stage IIIA
(Setup_19_17)
and stage IIIB engines
SCU, A121 0.17
05767319
MCU, A121 (Setup_19_17)
The TCU and its dedicated software basically supports the propel systems of crawler and wheel
machines.
The MCU and SCU are using the same software, in doing so the MCU controls the material flow
functions and the SCU the screed functions.
The software for a BF800 machine always consists of compatible setup, named Setup_xx_xx,
containing a TCU software and common software for SCU and MCU.
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2 The main display
Button 1
Button 2
14
2.1 General display functions and operation

Apart from its normal display function the LC display is also able to show error codes.
Currently existing faults and warnings are displayed by flashing. If several faults are detected, the
displayed fault codes will change in a 3 second cycle.
Display values are permanently displayed, whereby values from 0000...9999 are possible. Negative
values are identified by a "minus sign".
The following chapter describes the operation of the LC display with the dedicated buttons.
2.1.1 Entering input codes
Note: The brake has to be engaged (indicated by LED 14) to get in input mode.
For this purpose the display must be switched in the input mode. This is accomplished by pressing
Button 1 and Button 2 simultaneously for at least 2 sec. When the input mode is active 0000 is shown
in the display and the most left digit is blinking.
2.1.2 Calling up service mode

In order to call the service mode the input mode has to be reached before. Here service code 0001
provides the possibility to change to the service mode. The Button 1 can be used to increase the value
of the corresponding digit. By operating Button 2 the next right will start to flash. If the most right digit
is reached and Button 2 is pressed again the selected code is entered. The service mode is indicated
by a wrench symbol.
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3 Settings
3.1 General
3.1.1 Machine type

Since the same control can be used for different pavers (option) with different traction systems, 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
type adjustment is necessary, because the machines may e.g. be equipped with different valves,
propel pumps, etc.
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:
Machine type First serial number Last serial number Code Available from
version
Default - - 7870 0.01
BF 800 P TCU XXX XXXX XXXXX XXX XXXX XXXXX 7873 0.22
BF 800 C TCU XXX XXXX XXXXX XXX XXXX XXXXX 7878 0.10
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3.2 Tractor control (TCU)
3.2.1 Propel system
3.2.1.1 Learn function for the start currents of the propel pumps (BF800 C only)
For a sensitive and exact function of the propel system the start currents of the propel pumps must be
determined for both propel directions and for both tracks. The start currents are determined after
entering a code number, so that no electric meter is required.
The start currents must only be determined during initial commissioning in the factory, after the control
on a propel pump or the complete propel pump has been replaced during service or after the
replacement of the TCU.
The learn process is identical for both tracks: After entering the respective code number the current for
a control solenoid of the propel pump is increased in steps of 5mA, starting from the default value for
the minimum current (e.g. 185mA). After each current increase the system waits for 3 seconds. If a
considerable movement of a track is performed the related current value is memorised. In order to
enhance the result this measurement is performed five times. The final start current is the mean value
of these measurements. This start 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 teaching process.
Attention!
During learning the machine will move when the start current is reached!
Do not leave the machine while the teach function is progressing!
During learning keep an eye on your environment!
To stop the machine reset the travel lever to neutral position or press the park-brake-button!
How to perform the learning of the start currents of the propel pumps?
Note: At first the machine has to be moved with min. half speed and high gear (rabbit) in order
to ensure that the speed signals are validated!
Start the engine

The engine speed selection switch must be in ECO position.
The gear selection switch must be in Low (turtle) position.
If necessary enter code number 0001 to access the service mode.
The travel lever has to be in neutral position.
Then enter 1090. This code number activates the function "Learn start currents of the propel
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 learn function has been completed or the machine has been restarted.
The learning (forward/backward) must be started by entering a code number. The code number
required to learn the left side start currents is as follows: Determination of control start currents left
1091
After the input of the above code number the display shows "F O R E". Shifting the travel lever to
the forward position starts the first start current learning for the forward travel of the left track.
During the learning process the actual current is displayed (display value = current in mA). As soon
as the machine starts moving, a current value is memorised.
Once the start current learning is finished the display will show the O K.
After a wait time the display changes to "B A C K". Now shift the travel lever to the backward
position to start the start current learning for the backward travel of the left track.
During the measurement the actual current is displayed (display value = current in mA). As soon
After completion of the backward learning process the display will show O K.
The travel lever must now be returned to neutral position.
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Now the display will show 0 0 0 0. In order to continue with learn procedure of the right-side the
following code number is required: Determination of control start currents right 1092
the forward position starts the first start current learning for forward travel of the right track.
During the learning process the actual current is displayed (display value = current in mA). As soon
Once the start current learning is finished the display will show the O K.
After a wait time the display reading changes to "B A C K ". Now shift the travel lever to the
backward position to start the start current learning in backward. During the learning the actual
current is displayed (display value = current in mA). As soon as the machine starts moving, a
current value is memorised.
After completion of the backward learning process the display will show O K.
The travel lever must now be returned to neutral position.
Once all start currents have been learned correctly and the travel lever is in "neutral position", the
display shows "D O N E" then E X I T, the values are saved and the function is completed. Now
the machine can be operated again with the travel lever.
The new start current values for the propel system are valid from the next start.
The learn function can at any time be aborted by operation of the emergency stop or the ignition
switch.
3.2.1.2 Teach the forward and backward start currents of the propel pumps (BF800 C only)
Start the engine

If necessary enter code number 0001 to access the service mode.
Then enter 1095. This code number activates the function "Teach start currents of the propel
system "; the display now shows the reading 0 0 0 0 with the first digit flashing.
In this condition also the steer direction LEDs are flashing. From this point the machine can no
longer be operated with the steering wheel!
The teaching must be started by entering a code number. The code number required to teach the
forward start currents is as follows: 1096
Attention!
During teaching the machine will move in straight line direction!
Do not leave the machine while the teach function is progressing!
During teaching keep an eye on your environment!
the forward position and applying a speed command with the speed potentiometer starts the start
current teaching for the forward travel of both crawlers. During the teaching process the actual
current offset is displayed (display value = current offset in mA). Depending on the steering wheel
position the displayed offset value is added to base value on the one side and subtracted from the
base value on the other side.
Note: To stop the machine reset the travel lever to neutral position or press the park-brake-
button!
Once the desired offset value is adjusted the travel lever must be returned to the neutral position
and speed potentiometer has to be returned to the zero position. Keep the position of the steering
wheel!
The display will show O K and the adjusted value is memorised.
Then the display now shows the reading 0 0 0 0 with the first digit flashing.
Now the steering wheel should be returned to the neutral position.
Enter the code number 1097 to teach the backward start currents is as follows:
After the input of the above code number the display shows "B A C K". Shifting the travel lever to
the backward position and applying a speed command with the speed potentiometer starts the
start current teaching for the backward travel of both crawlers. During the teaching process the
actual current offset is displayed (display value = current offset in mA). Depending on the steering
wheel position the displayed offset value is added to base value on the one side and subtracted
from the base value on the other side.
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Once the desired offset value is adjusted the travel lever must be returned to the neutral position
and speed potentiometer has to be returned to the zero position.
The display will show O K and the adjusted value is memorised.
The display will show D O N E.
The steering wheel must now be returned to the neutral position.
Then E X I T will be shown in the display, the offset value will be saved and the function is
completed. The steer direction LEDs stop flashing. Now the machine can be operated again with
the steering wheel.
3.2.1.3 Learn function for the start currents of the front wheel drive proportioning valves (BF800 P
only)
This learning function determines the start currents for the four front wheel drive proportioning valves.
A suitable start current is detected and stored as soon as a good pressure level at proportional valve
output is present.
The learning procedure works with following order: 1. front left, 2. front right, 3. mid left, 4. mid right.
Start the engine

The engine speed selection switch must be in ECO position.
The hydraulic gear selection switch must be in Low (turtle) position.
The mechanical gear selection switch must be in Low (L) position.
The speed potentiometer must be set to position 0.5.
The wheel torque front traction potentiometer must be set to position 50.
Then front wheel drive must be switch on.
Enter code number 0001 to access the service mode.
Then enter 1095. This code number activates the learn function. The display now shows the
reading 0 0 0 0 with the first digit flashing.
Enter code 1096 to start the learning function.
Attention!
During learning procedure machine will move!
Do not leave the machine while the learning function is progressing!
During learning keep an eye on your environment!
After the input of the above code number the display shows "F O R E".
Shift the travel lever to the forward position.
The display shows "R U N".
The actual front left current is displayed (display value = current in mA).
button!
Once the start current for the front left proportioning valve is learned the display will show O K.
The actual front right current is displayed (display value = current in mA).
Once the start current for the front right proportioning valve is learned the display will show O K.
The actual mid left current is displayed (display value = current in mA).
Once the start current for the mid left proportioning valve is learned the display will show O K.
The actual mid right current is displayed (display value = current in mA).
Once the start current for the mid right proportioning valve is learned the display will show O K.
The display will show D O N E.
Return the travel lever to the neutral position.
Then E X I T will be shown in the display, the learned start current values will be saved and the
function is completed
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3.2.1.4 Speed command by Boost button in case of a broken speed potentiometer
This override mode for speed the potentiometer is only available if an error related to speed
potentiometer is present (fault codes: 1020, 1021, 1022, 1025,1026).
With a P-machine the work mode has to be selected additionally.
As long as the speed command by Boost button mode is active the Boost function of the L.C.S. is not
available.
Proceed the following steps to enable the speed command by Boost button mode:
Switch ignition on. Dont start the engine!
Enter code 0001 with the display buttons in order to get in the service mode (wrench symbol).
Enter code 1100 with the display buttons in order to allow changes of parameters related to the
propel system.
Enter code 1121 with the display buttons in order to enable the speed command by Boost button
mode.
Enter the code 0000 in order to leave the service mode.
From now on a speed command can be applied if the operator brings the travel lever to the forward or
backward position and keeps the Boost button pressed. The machine will accelerated in the requested
direction as long as the operator keeps the Boost button pressed until the maximum speed is reached.
As soon as the operated brings the travel lever back to neutral position the machine stops.
button!
In order start again the operator has to bring the travel lever out of the neutral position and keep the
boost button pressed until the desired speed is reached.
Once the potentiometer fault is not present anymore, e.g. after a repair, the speed command by Boost
button mode is disabled automatically in next ignition cycle. If the speed command by Boost button
mode has to be disabled manually the following steps have to be executed:
propel system.
Enter code 1122 with the display buttons in order to disable the speed command by Boost button
mode. Enter the code 0000 in order to leave the service mode.
3.2.1.5 Steer with spin switch in case of a broken steering wheel transducer (BF800 C only)
This override mode for the steering wheel transducer is only available if at least one error related to
steering wheel transducer is present (fault codes: 2010 to 2017).
As long as the steer with spin switch mode is active the Boost function of the L.C.S. is not available.

propel system.
Enter code 2021 with the display buttons in order to enable the steer with spin switch mode. Enter
the code 0000 in order to leave the service mode.
From now on a fixed steer command can be applied by using the spin switch for steering to the left or
by using the spin switch + Boost button for steering to the right.
The steering emergency mode works only if the travel lever is in neutral position.
Once the steering wheel transducer fault is not present anymore, e.g. after a repair, the steer with spin
switch mode is disabled automatically in next ignition cycle. If the steer with spin switch mode has to be
disabled manually the following steps have to be executed:
propel system.
Enter code 2022 with the display buttons in order to disable the steer with spin switch mode.
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3.2.1.6 Change speed potentiometer type
BF800 machines were equipped with speed potentiometers with parallel output signals as well as with
speed potentiometers with cross output signals. The TCU software supports both types of
potentiometers. Follow the procedures below to do the correct setting:
Speed potentiometer with parallel output signals:

propel system.
Enter code 1131 to enable the monitoring of a potentiometer with parallel output signals (older
machines).
Switch ignition off/on.
Speed potentiometer with cross output signals:

propel system.
Enter code 1130 to enable the monitoring of a potentiometer with cross output signals.
3.2.1.7 Drive against closed brake
Start the engine.

Enter the code 0001 with display buttons in order to get in the service mode (wrench symbol).
Enter the code 0500 in order to start the mode drive against closed brake. From now on the brake
LED 11 is blinking.
Shift the travel lever to the forward or backward position and apply a speed command with the
speed potentiometer in order to control the propel pump.
Bring the travel lever back to neutral and enter the code 0501 in order to quit the mode drive
against closed brake. The brake LED 11 stops blinking and will be lightened permanently.
The display will show the reading 0 0 0 0 with the first digit flashing.
3.2.1.8 Block screed extensions during transport (BF800P with road homologation only)
If the BF800P is equipped with road homologation kit, it is necessary, for safety reasons, to inhibit the
movement of the screed extension when in transport mode.
Switch ignition. Dont start the engine.
First get into the to service mode (code 0001).
Enter 3175 to enable road homologation.
Enter 3176 to disable road homologation.
Switch ignition off /on
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3.2.2 Miscellaneous
3.2.2.1 Enable / disable force heating in LOW idle
Starting from software version 0.24 / 0.21, any screed heating request - when no further power request
is present - will accelerate engine up to 1300rpm, independently from the position of the engine speed
switch.
Attention!
In case of screed width greater than 8m, it necessary to disable the heating in LOW idle
function!
To disable heating in LOW idle:

Enter 5041.
Enter the code 0000 in order to leave the service mode
To enable back heating in LOW idle:

Enter 5040.
3.2.2.2 Enable / disable cleaning function
Starting from software version 0.24 / 0.21, it has been introduced the possibility to activate the cleaning
function on BF800 by triple-click from the load switch.
Note: The function is enabled by default!
To disable the cleaning function:

Enter 5614.
To enable the cleaning function:

Enter 5613.
3.2.2.3 Store settings
Switch ignition on. Dont start the engine.

Enter 8887 to enable storing.
Enter 8889 for storing the settings.
Wait! The store process can take time up to 10 seconds.
O K is shown in the display to confirm that the settings were successfully stored.
3.2.2.4 Restore settings

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Wait! The restore process can take time up to 10 seconds.
Switch ignition off/on
3.2.2.5 Return to the default values

Enter 7010.
Confirm the machine type 7 8 7 0 with the Button 2. Wait for the reset the TCU will perform.
Check that the machine type code 7 8 7 0 is shown at the start-up.
Get into the to service mode (code 0001).
Enter 7010.
Select the machine type 7 8 7 3 or 7 8 7 8 with the Button 1 and confirm this code with the
Button 2. Wait for the reset the TCU will perform.
Check that the selected machine type code is shown at the next start-up.
Attention!
It is not possible to move the machine as long as the machine type code 7870 is present.
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3.3 Screed control (SCU)
3.3.1 Teach L.C.S. potentiometers max. values
Note: During teaching procedure the travel lever has to stay in neutral position!
Start the engine.

Turn all potentiometers to the min. position.
Enter the code 0001 with display buttons in order to get in the service mode (wrench symbol).
Enter the code 3018 in order to start the teaching procedure.
Enter the code 3019 in order to teach the WORK max. pressure.
After the input of the above code number the display shows "F O R E".
Now use the WORK potentiometer to set the requested max. pressure. At the same time the
potentiometer position (range: 0 -1000) shown in the display.
Turn the TIMELOCK potentiometer from the min. position to the max. position and back to the min.
position in order to confirm the pressure setting.
The display will show O K then D O N E.
Turn the WORK potentiometer to the min. position.
Wait until the display shows E X I T.
After a while the display shows the reading 0 0 0 0 with the first digit flashing.
If you dont want to teach the stop pressure, enter the code 0000 in order to leave the service
mode. Otherwise proceed as follows in order to teach the stop pressure.
Enter the code 3018 again in order to start the teaching procedure.
Enter the code 3020 in order to teach the STOP max. pressure.
Use the STOP potentiometer to set requested max. pressure. At the same time the potentiometer
position (range: 0 -1000) shown in the display.
Turn the TIMELOCK potentiometer from the min. position to the max. position and back to the min.
position in order to confirm the pressure setting.
The display will show O K then D O N E.
Turn the STOP potentiometer to min. position.
Wait until the display shows E X I T.
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3.3.2 Adjust currents for the tamper pump
Adjusting the currents for the tamper pump it is necessary to have an accurate correlation between the
set frequency on the display and the actual frequency of the tamper.
To achieve this result it is necessary to manually measure the rotation frequency of the shaft of the
tamper with an RPM-meter.
Note: Enter command 5611 in advance in order to increase the engine rpm (HIGH idle) with
the travel lever while park brake button is pressed!
The start current for the tamper pump has to be set in order to have 60 rpm on the shaft when 1 Hz is
set and the engine is in HIGH idle.
To adjust the start current of the tamper pump:
Start the engine
Enter 3120.
The display now shows the value in mA of the start current for the pump.
By pressing Button 1 it is possible to increase this value.
By pressing Button 2 it is possible to decrease this value.
When the desired current has been set, press both Button 1 and Button 2 simultaneously.
Enter 3121 to memorize the new value.
The display will show the new memorized value and then D O N E.
The maximum current for the tamper pump has to be set in order to have 1800 rpm on the shaft
when 30 Hz is set and the engine is in HIGH idle.
To adjust the start current of the tamper pump:
Start the engine
Enter 3122.
The display now shows the value in mA of the maximum current for the pump.
Note: Enter command 5612 to ensure normal working mode operation!
3.3.3 Adjust tamper ramps
There are two possible settings for the control:
1. Automatic variable ramps: the starting ramp is fixed, the stopping ramp depends on the
decelerating ramp of the machine
2. Adjustable manual ramps
By default automatic variable ramps are enabled. They can be disabled/ enabled through input codes:
Start the engine
Enter the code 0001 with display buttons in order to get in the service mode (wrench symbol)
3102 to enable
3103 to disable
To manually adjust starting and stopping ramps (faster or slower) a procedure has been introduced:
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Note: The bigger is the value, the faster is the ramp.
The smaller is the value, the slower is the ramp.
To adjust the starting ramp for the tamper:

Start the engine.
Enter 3104 to start modifying the start ramp
The display will show the actual value of the ramp
The value of the ramp can be modified from 10 to 2000 with a step of 10
Button 1 increases the value, Button 2 decreases it
When the right value has been found, by pressing for few moments Button 1 and Button 2
simultaneously, the display will show 0000 with the first figure blinking
Enter 3105 to finish modifying the start ramp
To adjust the stopping ramp for the tamper:

Start the engine.
Enter 3106 to start modifying the stop ramp
The display will show the actual value of the ramp
The value of the ramp can be modified from 10 to 2000 with a step of 10
Button 1 increases the value, Button 2 decreases it
When the right value has been found, by pressing for few moments Button 1 and Button 2
simultaneously, the display will show 0000 with the first figure blinking
Enter 3107 to finish modifying the stop ramp
So if the operator is not satisfied by the ramps of the tamper, the variable ramps should be disabled
first, then manually adjust them.
It is also possible to use a manually adjusted starting ramp and leave the stopping ramp automatic.
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3.3.4 Adjust currents for the vibration pump
Adjusting the currents for the vibration pump it is necessary to have an accurate correlation between
the set frequency on the display and the actual frequency of the vibration.
To achieve this result it is necessary to manually measure the rotation frequency of the shaft of the
vibration with an RPM-meter.
The start current for the vibration pump has to be set in order to have 60 rpm on the shaft when 1 Hz
is set and the engine is in HIGH idle.
To adjust the start current of the vibration pump:
Start the engine.
Enter 3164.
The display now shows the value in mA of the start current for the pump.
The maximum current for the vibration pump has to be set in order to have 3600 rpm on the shaft
when 60 Hz is set and the engine is in HIGH idle.
To adjust the maximum current of the tamper pump:
Start the engine.
Enter 3166.
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3.3.5 Miscellaneous



Enter 3003.
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3.4 Material flow control (MCU)
3.4.1 Enable/disable hoppers front flap

Enter 4160 to enable hoppers front flap (if available as option on the machine).
Enter 4161 to disable hoppers front flap (if not available on the machine).
3.4.2 Adjust maximum current for augers pumps
By adjusting the maximum current to the pumps it is possible to adjust the maximum speed of the
augers.
The maximum current has to be set in order to have 104 rpm (+/-4 rpm) on the augers shaft.
To adjust the maximum current of the left auger pump:

Start the engine.
Enter 4060.
To adjust the maximum current of the right auger pump:

Start the engine.
Enter 4062.
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3.4.3 Adjust augers ramps
Note: The bigger is the value, the faster is the ramp.

The smaller is the value, the slower is the ramp.
To adjust the starting ramp for the augers when manually operated:
Start the engine.
Enter 4070.
The display now shows the value of the ramp.
When the desired value has been set, press both Button 1 and Button 2 simultaneously.
To adjust the stopping ramp for the augers when manually operated:
Start the engine.
Enter 4072.
To adjust the starting ramp for the augers when automatically operated:
Start the engine.
Enter 4074.
To adjust the stopping ramp for the augers when automatically operated:
Start the engine.
Enter 4076.
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3.4.4 Adjust maximum current for conveyor pumps
By adjusting the maximum current to the pumps it is possible to adjust the maximum speed of the
conveyors.
The maximum current has to be set in order to have 62 rpm (+2 / -1 rpm) on the shaft of the conveyor
motor.
To adjust the maximum current of the left conveyor pump:

Start the engine.
Enter 4140.
To adjust the maximum current of the right conveyor pump:

Start the engine.
Enter 4142.
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3.4.5 Enable / disable lifting auger box with screed
To enable the possibility of lifting the auger box when the screed is lifted:
Enter 4056
To disable the possibility of lifting the auger box when the screed is lifted:
First get into the to service mode (code 0001)
Enter 4057
3.4.6 Miscellaneous



Enter 4003
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3.5 Store / Restore settings
In order to store individual settings of a machine it is possible to store these settings.

It is recommended to store the settings especially if adjustment procedures for ramps or start /
maximum current values have been executed. See: 3.2.2.3, 3.2.2.4, 3.3.5.1, 3.3.5.2, 3.4.6.1, 3.4.6.2.
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4 Fault log display and delete
4.1 Showing stored faults
Switch on function Show stored faults:

Switch ignition on. Dont start the engine
Enter code number 0700 (! WITHOUT service code 0001). This code number enables the function
Show stored faults
The faults stored in the controllers (TCU, MCU, SCU) 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 controllers, the display will show
"- - - - - ". In this case the function Show stored faults will terminate automatically after 4 seconds.
Switch off function Show stored faults:

Enter code number 0701 (! WITHOUT service code 0001). 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 brake is engaged (see
chapter 3.1.1).
4.2 Showing saved faults with operating hours
Switch on function "Show stored faults with operating hours":

Enter code number 0705 (! WITHOUT service code 0001). This code number enables the function
Show stored faults with operating hours
The faults stored in the controllers (TCU, MCU, SCU) are displayed in a flashing mode. If several faults
are saved, you can select these one after the other with the Button 1. Pressing the Button 2 displays
the operating hour at which the fault code occurred last.
By pressing the Button 2 again the number of occurrences of the fault since the last reset of the fault
memory can be displayed. After the last fault has been displayed, the first fault will appear again. If no
faults are stored in the controllers, the display will show "- - - - - ". In this case the function Show
stored faults will terminate automatically after 4 seconds.
Switch off function "Show stored faults with operating hours":

Enter code number 0706 (! WITHOUT service code 0001). This code number disables the function
Show stored faults.
Note: Apart from the stored faults the current faults are also displayed.
chapter 2.1.1).
4.3 Delete all stored faults
Execute the function Delete all stored faults:

Enter code number 0710 (! WITHOUT service code 0001)
Switch the ignition off and on again
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All stored faults are now deleted.
chapter 2.1.1).
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5 How to proceed when updating controller software
Actually it is possible to update the software of the TCU, MCU and SCU. In case of a software update it
has to be taken into consideration that all controllers have to be updated with compatible software
version. Therefore software setups are available.
Before a software update is executed it is recommended to store the settings of TCU, MCU and
SCU. See: 3.2.2.3, 3.3.5.1, 3.4.6.1.
After a software update (new version) default parameters are selected. Individual are not available
anymore. In order to restore individual setting use the procedures described in 3.2.2.4, 3.3.5.2, 3.4.6.2.
Note: If the fault code 5100 occurs after a TCU software update switch ignition off and wait for
20 seconds. This time is needed by electronic engine control to perform a shutdown.
Note: If the fault code 1022 occurs after a TCU software update use the procedure described
in 3.2.1.6 to enable the correct setting
Note: If the indication of voltage or frequency does not work as expected after a TCU software
update use Button 2 to correct the display setting.
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6 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 and The TCU. 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 re-establish the usual functional quality, with almost any previous knowledge. Even an
incorrectly or incompletely conducted teaching procedure can be repeated without problems as often
as necessary. At the first glance it seems to be at bit awkward to perform this adjustment work on
every machine, but this procedure enables the operation of all machines with the same operating
software. At the end of the day this considerably increases the spare parts availability.
6.1 Replacement of an electronic control unit
Since the control stores all teach values of the machine, each learning / teaching procedure must be
performed with the new control after a replacement.
Attention!
Before performing one of the following steps, the machine type must first be set (see 3.1.1)!
When changing the machine type all previously made adjustments will be lost!
Now the teach functions must be executed.
Learn function for the start currents of the propel system (see 3.2.1.1)
If necessary teach function for the start currents of the propel system (see 3.2.1.2)
6.2 Replacement of a propel pump
Now the following functions must be executed.

Learn function for the start currents of the propel pumps (see 3.2.1.1)
If necessary teach function for the start currents of the propel pump (see 3.2.1.2)
6.3 Replacement of front wheel drive proportioning valve block

Now the following functions must be executed.
Learn function for the start currents of the front wheel drive proportional valves (see 3.2.1.3)
6.4 Replacement of an auger or conveyor pump
Now set the proper maximum current, depending on which pump has been replaced.
In case of auger pump (see 3.4.2).
In case of conveyor pump (see 3.4.4).
6.5 Replacement of a tamper or vibration pump
Now set start and maximum currents for the new pump.
In case of tamper pump (see 3.3.2)
In case of vibration pump (see 3.3.4)
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6.6 Which components can be replaced without an adjustment procedure?
Display
Diesel engine
Engine controller
All switches in the dashboard and side panels.
Steering transducer (A45)
Speed potentiometer (R07)
Hydraulic on/off valves
L.C.S. hydraulic block
All hydraulic pumps beside propel pumps, auger pump, conveyor pump, tamper and vibration
pump (see 6.2 to 6.5)
Note: A final function test of the complete machine is highly recommended.
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7 Fault codes
7.1 Overview
Fault code Fault description

0000 - 0999 General faults / warnings / machine tests
1000 - 1999 Fault in propel system
2000 - 2499 Fault in steering system
2500 - 2999 Reserved
3000 - 4499 Fault in work functions (screed control, material flow control)
5000 - 5499 Fault related to the diesel engine
5500 - 5999 Fault related to the hydraulic system
7000 - 7499 Input of machine codes
7900 - 7999 Operating hours, load spectrum, etc.
1
8000 - 8999 Severe software error
1
9000 - 9999 Errors of external IO-nodes (data collector, module, LC-display, etc.)
1
Not all of these fault codes are decrypted here; please ask the after sales service for assistance!
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7.2 Description of fault reactions
Fault reaction Description of fault reaction

1 Warning
Fault code is displayed.
No audible signal!
2 Warning Horn
Audible signal!
3 Function Interference
The faulty function is replaced by an emergency function.
Audible signal!
4 Partial Error
The partial function cannot be overridden by an emergency function.
The machine is stopped if this fault occurs.
The machine can still be driven to a limited extent, but must be repaired by the service department as soon as possible.
Audible signal!
5 Engine Off Error
The partial function cannot be overridden by an emergency function.
The diesel engine is shut down.
The machine is no longer able to drive, e.g. because parts of the travel system are defective
Audible signal!
6 Fatal Error
The function of the control can no longer be guaranteed.
Control is switched off.
The diesel engine is shut down, if possible.
The fault code is displayed; the signal light in the monitoring board is permanently on.
No audible signal!
Note: Errors with error reaction 1 and 2 are only warning messages and are NOT stored in the error log!
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7.3 Detailed description of fault codes and their possible causes
All fault codes are shown in the documents: _error_list_BF800C_20xx_xx_xx.pdf, _error_list_BF800C_20xx_xx_xx.pdf
7.3.1 General
Fault Fault description Possible causes Terminal Input Fault

Code code for reaction
diagnosis
7.3.2 Relay engine shutdown

diagnosis
510 Relay engine shutdown short circuit Ub The connecting cable has short circuit to battery voltage. 3
Signal outside the valid range (see signal description)
511 Relay engine shutdown short circuit to ground The connecting cable has short circuit to ground. 3
Signal outside the valid range (see signal description) Coil defective.
512 Relay engine shutdown line break The connecting line between output of control and control 3
The required control power cannot be transmitted to the solenoid is interrupted.
control solenoid. The solenoid is defective.
7.3.3 Brake valve

diagnosis
1001 Brake valve line break The connecting line between output of control and control 5
The required control power cannot be transmitted to the solenoid is interrupted.
control solenoid. The solenoid is defective.
1002 Brake valve short circuit to ground The connecting cable has short circuit to ground. 5
Signal outside the valid range (see signal description). Coil defective.
1003 Brake valve short circuit Ub The connecting cable has short circuit to battery voltage. 5
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diagnosis
Signal outside the valid range (see signal description).
1004 Brake valve BTS over temperature The connecting cable has short circuit to ground. 5
Overheating of output driver in the controller. Coil defective.
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8 Input codes
Display and adjustment functions can generally only be accessed by entering "service code" 0001 beforehand!
8.1 Command codes
All command codes are shown in the documents: _disp_comm_list_BF800C_20xx_xx_xx.pdf, disp_comm_list_BF800P_20xx_xx_xx.pdf
8.1.1 Fault log
Without service code!
Input code Description of display function Display values

0700 Function "Show stored faults activated Fault codes are displayed one after the other
0701 Function "Show stored faults deactivated 0000
0705 Activate function "Stored faults with data Fault codes are displayed, jump to the next fault with the up or
down key,
press key left to view the number of occurrences,
press key right to view the time of the last occurrence.
0706 Deactivate function "Stored faults with data
0710 Activate function Delete stored faults Once the fault log is deleted it is returned to 0000
8.1.2 Changing the machine code

7010 Change machine type code see chapter "Change machine code"
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8.2 Display codes
All display codes are shown in the documents: _disp_comm_list_BF800C_20xx_xx_xx.pdf, disp_comm_list_BF800P_20xx_xx_xx.pdf
8.2.1 General

0555 Display of TCU software version E.g. 1.13 for software version V 0.21
3200 Display of SCU software version
4200 Display of MCU software version
0720 Display of machine type code The machine type code is displayed 78xx (see chapter 3.6)
8.2.2 Brake

1001 Display of voltage at control output valve brake V (e.g. 12.6 corresponds with 12,6V)
8.2.3 Hydraulics

5500 Display state hydraulic oil main circuit filter 0 = Hydraulic oil filter OK
1 = Hydraulic oil filter contaminated
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2 The main display ________________________________________________ 6

4 Fault log display and delete _____________________________________ 25

5 How to proceed when updating controller software __________________ 27

6 How to proceed when replacing components _______________________ 28

7 Fault codes ____________________________________________________ 30

Version Date Description of changes Resp.

Control Version Start Version End Software Part Number Comment

2.1 General display functions and operation

2.1.1 Entering input codes

2.1.2 Calling up service mode

3.1.1 Machine type

The following machine types can be adjusted:

3.2.1 Propel system

Start the engine

Start the engine

Start the engine

Switch ignition on. Dont start the engine!

Speed potentiometer with parallel output signals:

Speed potentiometer with cross output signals:

3.2.1.7 Drive against closed brake

Start the engine.

3.2.2.1 Enable / disable force heating in LOW idle

To disable heating in LOW idle:

To enable back heating in LOW idle:

3.2.2.2 Enable / disable cleaning function

Note: The function is enabled by default!

To disable the cleaning function:

To enable the cleaning function:

3.2.2.3 Store settings

Switch ignition on. Dont start the engine.

3.2.2.4 Restore settings

Switch ignition on. Dont start the engine.

3.2.2.5 Return to the default values

Switch ignition. Dont start the engine.

3.3.1 Teach L.C.S. potentiometers max. values

Start the engine.

Note: Enter command 5612 to ensure normal working mode operation!

3.3.3 Adjust tamper ramps

There are two possible settings for the control:

To adjust the starting ramp for the tamper:

To adjust the stopping ramp for the tamper:

Note: Enter command 5612 to ensure normal working mode operation!

3.3.5.1 Store settings

Switch ignition on. Dont start the engine.

3.3.5.2 Restore settings

Switch ignition on. Dont start the engine.

3.3.5.3 Return to the default values

Switch ignition on. Dont start the engine.

3.4.1 Enable/disable hoppers front flap

Switch ignition on. Dont start the engine.

3.4.2 Adjust maximum current for augers pumps

To adjust the maximum current of the left auger pump:

To adjust the maximum current of the right auger pump:

Note: Enter command 5612 to ensure normal working mode operation!

Note: The bigger is the value, the faster is the ramp.

To adjust the maximum current of the left conveyor pump:

To adjust the maximum current of the right conveyor pump:

Note: Enter command 5612 to ensure normal working mode operation!

3.4.6.1 Store settings

Switch ignition on. Dont start the engine.

3.4.6.2 Restore settings

Switch ignition on. Dont start the engine.

3.4.6.3 Return to the default values