DYNAPAC
CC 82/92/222/232/422
WORKSHOP MANUAL
VBS-RELAY
W1033EN3
Svedala Compaction Equipment AB
Box 504, SE-371 23 Karlskrona, Sweden
Phone: +46 455 30 60 00, Fax: +46 455 30 60 30
Vibratory and Combination Rollers
CC 82/92/222/232/422
Work Shop Manual, VBS-Relay
W1033EN3
Valid for Relay P/N's: 35 88 00
37 02 33
Brake
ON
START
ON
VIBR.
ON
VBSRelay
FUSE
6.3 A
NEUTRAL
ON
VIBR.
ON/OFF
START
ON
EMERG.
OFF
We reserve the right to change specifications without notice.
Printed in Sweden.
P/N 35 88 00
37 02 33
CC 82/92/222/232/422
Trouble Shooting
W-1033-3 EN
P/N 35 88 00
37 02 33
Contents
Contents
Notes
Page
Safety Regulations ...................................................................................................... 4-5
Electrical principles VBS-relay .................................................................................... 6-7
Electrical trouble shooting .............................................................................................. 8
External trouble shooting ................................................................................................ 9
Analysis/ VBS-relay ...................................................................................................... 10
Test 1 and 2 ................................................................................................................. 11
Test 3 alternative 1 .................................................................................................. 12-13
Test 3 alternative 2 ....................................................................................................... 14
Notes
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CC 82/92/222/232/422
Trouble Shooting W-1033-3 EN
Safety Regulations
P/N 35 88 00
37 02 33
General advice
Make yourself familiar with the equipment of the machine.
Only operate the machine if your are completely familiar with the
operating and control elements as well as the functioning of the machine.
Use your safety equipment like helmet, safety shoes and hearing protection.
Make yourself familiar with your working field.
Only operate the machine for its intended purpose.
Please observe the guidelines of the machine
manufacturer and safety manual.
Before starting
Study and understand the operating instructions before starting.
Check the machine for any serious faults.
Do not operate the machine with defective instruments, warning lights or control
elements.
All safety devices must be in a secure position.
Do not carry loose objects or secure them to the machine.
Keep oily and inflammable material away from the machine.
Before entering the driver's cab, check if persons or obstacles are in the way
f or underneath the machine.
Be careful when entering the driver's cab, use the steps.
Adjust your seat before starting.
4
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W-1033-3 EN
P/N 35 88 00
37 02 33
Safety Regulations
Start
When starting, all operation levers must be in "neutral position".
Only start the machine from the drivers seat.
Check the indicating instruments after start to ensure that all functions are in order.
Do not leave the machine unattended when the engine is running.
When starting with batteryconnection cables, connect plus to plus and minus to
minus.
Disconnect the earth (negative) fist. Connect it last.
Warning
Exhaust fumes is dangerous. Ensure sufficient fresh air when starting in
closed rooms!
Electrical and hydraulic equipment
1. Personal safety must be observed when batteries are handled or tested.
2. A fully equipped medical kit, including eye-wash facilities, should be available and
protective clothing, including eye protection, should be worn.
3.
Acid splashes in the eye should be treated immediately with plenty of
clean water and neutralized with soldium bicarbonate solution.
4. Acid splashes on clothing must be treated with an alkali, such as ammonia, if
holes are to be avoided.
5.
A safety hazard exist during or after battery charging due to emission of
a highly flammable hydrogen gas. Any testing involving production of
sparks, e.g. electrical load test, must not be performed until the gas has
dispersed from the cell. A similar hazard occurs when a battery is fitted
on to a vehicle immediately after the battery has been removed form a
charging plant.
6.
Hydraulic equipment is under high pressure. Fluids (fuil, hydraulic oil)
which escape under high pressure can penetrate the skin and cause
serious injury. Therefore immediately consult a doctor in such injury
occurs.
7.
Notice the failure on the hydraulic or electrical system may give the
roller an upredictabel and dangerous function.
CC 82/92/222/232/422
Trouble Shooting W-1033-3 EN
CC 82/92/222/232/422
START -- pin 2
NEUTRAL -- pin 6
VIB.SWITCH -- pin 7
+ 12V -- pin 1
Only in PN 37 02 33
EMERGENCY SWITCH -- pin 8
pin 5
Trouble Shooting
1
2
pin 5
280 ohm
500 ohm
1 ohm
&
pin 5 -- GROUND
pin 4 -- START OUTPUT
pin 3 -- BRAKE OUTPUT
pin 9 -- VIBRATION OUTPUT
INPUT
S
T
R
1
2
&
AND-gate
Inverter
OUTPUT
Bistable element (flip-flop)
Digital logic elements
Electrical principles/ VBS-relay
P/N 35 88 00
37 02 33
W-1033-3 EN
P/N 35 88 00
37 02 33
Electrical principles/ VBS-relay
Switching action:
Description of the output signals at alternative input signals.
OFF (9)
Vib. switch pressed
AND voltage at (1)
no voltage (1)
Vib. switch
pressed
OFF (9)
ON
(9)
ON
Vib. switch
released
Input signal:Vib.switch not pressed = open or +12V
pin 7
Vib. switch pressed = 0V
(9)
VIBRATION-RELAY
no voltage (1)
Vib. switch
released
emergency pressed (8)
power on (1)
(7) = pin 7
Input signal:lever not in neutral position = open or 0V
pin 6
lever in neutral position = +12V
lever in neutral position
AND voltage at (1)
no voltage (1)
emergency pressed (8)
OFF (3)
ON
(3)
BRAKE-RELAY
power on (1)
START-RELAY
Input signal:start button not pressed = open or 0V
pin 2
start button pressed = +12V
start button released (2)
lever not in neutral position (6)
OFF (4)
ON
(4)
Start button pressed
AND voltage at (1)
AND lever in neutral position
no voltage (1)
Input signal:emergency not pressed = +12V
pin 8
emergency pressed = open or 0V
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Trouble Shooting W-1033-3 EN
Electrical Trouble shooting
P/N 35 88 00
37 02 33
Description
A VBS-relay controls start of engine, brakes and vibrations.
Input signals, potential difference
Pin
Pin
Pin
Pin
7
2
6
8
Vibration
Start
Neutral
Emergency brake
Output signals, potential differnece
Pin 9
Pin 4
Pin 3
Vibration
Start
Brake
Power supply
Pin 1
Pin 5
+12 V DC
- OV DC
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37 02 33
External Trouble shooting
Analysis of the roller socket for the relay
If any of the functions, engine starting, braking or vibrations do not work and you suspect that it depends on the VBS-relay, check first the external circuits and functions by
means of a multimeter.
Remove the VBS-relay from its socket
Measure in the socket and check the following:
1
9
2
3
Socket sleeves
6
7
1. Check that you get voltage (+V) on sleeve 1.
2. Check that you get voltage (+12V) on sleeve 8 when the brake switch is pulled.
3. Check that sleeve 5 is connected to minus.
4. Check that outputs to brakes (sleeve 3), starter (sleeve 4) and vibrations (sleeve 9)
are connected to their consumers and that they are not short cutted.
Switch the ignition off.
Now you can change the old relay with a new working one without risking that the
new one gets damaged. Switch the ignition on and check the functions.
If the roller still doesnt work. Switch the ignition off. Remove the relay from its
socket and check the following:
5. Check that you get voltage (+12V) on sleeve 2 when the ignition switch is in starter
position.
6. Check that you get voltage (+12V) on sleeve 6 when the speed control is in neutral
position.
CC 82/92/222/232/422
Trouble Shooting W-1033-3 EN
Analysis/ VBS-relay
P/N 35 88 00
37 02 33
7. Check that sleeve 7 is connected to minus when the vibration button in the speed
control, (F&R) is pushed.
If the roller doesnt work when you have checked inputs and outputs according to item
1-4 and item 5-7, then VBS-relay is broken ant the roller should work with a new working VBS-relay.
Analysis of the VBS-relay
The following tests of the replaced realy will give us important information about any
fault in the output circuits or input circuits of the relay and its internal logic functions.
1
8
2
4
Relay-pins
6
5
The pins of the relay
Input signals, voltage
Output signals, voltage
Pin
Pin
Pin
Pin
Pin 9
Pin 4
Pin 3
7
2
6
8
Vibration
Start
Neutral
Emergency brake
Vibration
Start
Brake
Power supply
Pin 1
Pin 5
10
+ 12V DC
- 0V DC
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Trouble Shooting
W-1033-3 EN
P/N 35 88 00
37 02 33
Test 1 and 2
Equipment: digital multimeter with voltage, diode and resistance measurement.
TEST 1: in this test the output circitry is checked with the realy not connected to the
roller socket for the relay.
Connected
polarity
+
-
Instrument reading for correct relay
diode measurement
resistance measurement
8
8
8
9
3
4
5
5
5
4
more than 2 V
more than 2 V
more than 2 V
0,5 - 0,7 V
0,5 - 0,7 V
0,5 - 0,7 V
0,5 - 0,7 V
0,5 - 0,7 V
0,5 - 0,7 V
0,5 - 0,7 V
more than 200 kohm
more than 200 kohm
more than 200 kohm
more than 200 kohm
more than 200 kohm
more than 200 kohm
more than 200 kohm
more than 200 kohm
more than 200 kohm
more than 200 kohm
9
3
4
8
8
8
4
3
9
1
TEST 2: in this test the input circitry is checked with the relay not connected to the roller
socket for the relay.
Connected
polarity
+
-
Instrument reading for correct relay
6
2
1
475 - 525 ohm
235 - 288 ohm
970 - 1030 ohm
5
5
7
resistance measurement
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Trouble Shooting W-1033-3 EN
11
Test 3 Alternative 1
P/N 35 88 00
37 02 33
TEST 3: in this test the internal logic functions is checked with the relay connected to
power and outputs load. The relay is not connected to the roller socket.
Power connectons to the relay:
+ V DC and 8 Amp face to pin 1.
0V DC to pin 5.
Alternative 1
The outputs should be loaded with a 12 V, 5 W to 25 W lamp connected to 0 V DC.
See figure below.
A mulitmeter for power difference measurement may be used in parallel with the load.
Figure showing the load connected for test of pin 4 in test 3, number 4. The lamp is
flashing if the internal logic function is OK.
12
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Test 3 Alternative 1
cont.
TEST 3 continues
Test tabel
The test tabel is to be followed in the chronological order for input and output signals.
INPUT SIGNALS:Voltage
TEST
NR
VIB
START
(7)=pin (2)
-------- --------open open
OUTPUT SIGNALS: Voltage
NEUTRAL
(6)
---------open
EMERVIB
GENCY
(8)
(9)
----------- ------+12 (off)
-
START
BRAKE
(4)
-----------
(3)
-------------
Power on
open
open
open
5
6
7
8
open
1) 0
open
1) 0
open
open
open
open
open
open
open
open
+12 (off) 0
0
+12 (off) +12 (light) 0
+12 (off) +12 (light) 0
+12 (off) 0
0
+12 (light) VIB
+12 (light)
+12 (light)
+12 (light)
open
open
open
open
open
open
open
open
open
open
open
+12 (on)
+12 (off) 0
open
0
+12 (off) 0
+12 (off) 0
+12 (light) EMERGENCY
0
0
+12 (light)
9
10
11
12
+12 (on) open
+12 (off) 0
open
+12 (on) +12 (off) 0
+12 (on) +12 (on) +12 (off) 0
0
0
+12 (light)
START
0
+12 (light)
+12 (light)
2
3
4
0
0
0
0
Note 1) When testing with the lamp in the first alternativ of test 3, you have to touch negative terminal with wire from pin 7 (that is the same as pressing the button for vibration engagements, 0V DC (ground)).
CC 82/92/222/232/422
Trouble Shooting W-1033-3 EN
13
Test 3 Alternative 2
P/N 35 88 00
37 02 33
Alternative 2
By means of the test box, see figure below, for VBS-relay all the input and output signals easily can be tested. The procedure is simplified.
The relay is connected to the test box relay socket.
The input signals and output signals are engaged according to the test tabel in test 3
above.
The signal lamps on the testbox will flash when the output signal is +12 V DC.
The test box for VBS-relay can be ordered from Dynpapac After Sales department.
Connect the power to the test box, 12 V DC
Put all switches of the box in "off" position according to test nr 1 in the tabel and
disconnect the power supply for initial position of the relay.
Power on.
Follow the test order. When performing test nr 6 the vibration button has to
be pressed (=0 or ground). In test 7 the vibration button has to be released (=open or
+12V DC).
Brake
ON
START
ON
VIBR.
ON
VBSRelay
FUSE
6.3 A
NEUTRAL
ON
14
VIBR.
ON/OFF
START
ON
CC 82/92/222/232/422
EMERG.
OFF
Trouble Shooting
W-1033-3 EN
