16.Terex BCS

TEREX ELECTRIC MAINTENANCE TRAININGBOARD CONTROL SYSTEM

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TEREX BOARD CONTROL SYSTEM

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.

BCS

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TEREX BOARD CONTROL SYSTEMBCS

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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 Pump Drive G/Box oil temperatureWater temperature Fuel levelHydraulic Temperature Grease PressureBattery Voltage Slew PressuresEngine RPM Engine Oil temperatureAmbient 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.

Start Up Screen

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TEREX BOARD CONTROL SYSTEMStart Up Screen

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Current faults will also be displayed on the BCS screen, as well as other relevant information, eg. “Travel Brake Applied”

Fault Screen

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TEREX BOARD CONTROL SYSTEMFault Screen

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By pressing the “HELP’ button, recommended courses of action will be displayed, after arrowing up or down to the selected fault.

Fault Screen

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Fault Screen

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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 changeService = hours to go until next serviceEngine = engine operating valuesHydraulics = hydraulic operating valuesDevice = contamination's recorded against hydraulic pumps, motors and pump drive gearboxesOperating hours = engines, travel swing and loadSet time / date = change date and time setting Error list = fault storageContrast = adjust display screen contrastService O&K = access additional sub menus, code required.

EngineIn 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 Menu

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TEREX BOARD CONTROL SYSTEMService Menu

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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.


Service Menu : Hours

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Service Menu

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NOTES: Service Menu

Service. The display shows the number of operating hours to the next service.


Service Menu

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Service Menu

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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.


Service Menu

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Service Menu

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NOTES: Service Menu

Hydraulics. This sub menu displays important values for the hydraulic system. Also the hydraulic oil, swing and ambient temperatures.


Service Menu

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300 300

42820 225

1920

35

25

300 300

42820 225

1920

35

25

25

600 600

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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.


Service Menu

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NOTES: Service Menu

Operating Hours. The screen displays following operating hours/load ratings:

Total hours operated = engine running

Hours operated under = engine running times at load rated load

Hours operated at work = hours run by the hydraulics at work, swing or travel

Engine utilization (%) = hours operated under load divided by total hours operated

Hydraulic utilization (%) = hours operated at work divided by total hours operated.

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


Service Menu

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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 / DOWNAlter value with UP / DOWN


Service Menu

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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 occurredEnd = 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.


Service Menu

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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 Menu

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Service Menu

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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 Menu

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CMS Screen

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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 listChange 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

Terex Service Menu

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TEREX BOARD CONTROL SYSTEMTerex Service Menu

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Confirm Service.

Terex Service Menu

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Confirm Oil Change.

Terex Service Menu

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Change Operating Hours. Use this screen to change component operating, eg, after changing out an engine.

Terex Service Menu

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

Terex Service Menu

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

Terex Service Menu

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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 GermanSpeaker = Yes / No audible warning sounded on occurrence of faultDTS Functionality = Yes /No telemetry fittedPrinter No = printer type used to download information (Seiko, Epson or data shuttle)System Of Unit = metric or imperialConfirm Oil Change / Service = Yes / No reset oil change and service intervalSuppress 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

Terex Service Menu

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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 sensorName = 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.

Sensors : Analog

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TEREX BOARD CONTROL SYSTEMSensors : Analog

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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.

Sensors : Analog

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TEREX BOARD CONTROL SYSTEMSensors : Analog

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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 switchName = abbreviated name of switch and current status indicator (open / closed)Error = 0 if no fault is present or 1 if a fault is present.

DER Cards

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TEREX BOARD CONTROL SYSTEMSensors : Digital

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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.

Sensors : Digital

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TEREX BOARD CONTROL SYSTEMSensors : Digital

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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 speedNominal Speed = pump regulation speed normally 12% lower than high idle speed settingHigh Idle Speed = engine speed at the time the load switch closes.Water Temperature = current engine coolant temperatureGLR Current = governor load limit regulation current (PMS current) 250 - 850 mALoad DSL = current status of load switch for working equipment functionsDriving DSF = current status of load switch for travel functionLifting Force DSS = for special attachments e.g. hammer, grab etc..Clam DSH = current status of clam function Lower FSA = engine auto rev reduction activated.

Process data PMS

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TEREX BOARD CONTROL SYSTEMProcess data PMS

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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.

CMS Screen

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CMS Screen

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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,

CMS Screen

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CMS Screen

Documents

16.Terex BCS