light trailer boom technical training · load cell & interface process for calibration of the...
TRANSCRIPT
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Light Trailer Boom Technical Training
Rev 04-15 1
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Training Objectives To learn and understand operation of Light Booms.
To learn and understand Electric and Hydraulic Layouts. To be able to accurately diagnose Electric System. To be able to accurately diagnose Hydraulic System.
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Contents
Machine Layout and Upper and Lower Control Boxes (4-12)
Component identification and descriptions (13-24)
Trailer Hydraulic Schematics and Hydraulic Components (25-42)
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Towable Models
Articulating Boom: 3522A, 4527A, 5533A Telescopic Boom: 3632T
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Articulating Ground Controls
5
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Telescopic Boom Ground Controls
6
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Maintenance Mode Press & Hold for 5 seconds (Outrigger Extend,& both Rotate Buttons)
Hour Meter Display Press & hold (Rabbit & “Turtle) Buttons
Engine RPM While engine is running, press (Start Engine) Button
Weight Display Press & Hold (Basket Compensate Up & Down Together)
Moment Sense Display Press & hold (Outrigger Ext,Outrigger Retract & Boom Down Button)(Only works on 4642)
Level Sensor While in Maintenance Mode press Auto Level Button
Engine Hours Press & hold (Rabbit,Turtle, & Engine Start) together
Service Menus (Hot/Hidden Keys)
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Printed Circuit Card ECU
8
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I/O Driver Board
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Towable Upper Control Box (UCB)
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Drive & Set Manual Activation
11
Design objective: No longer use the parking brake for Drive & Set Brakes to hold on grade the machine can level on 12° Field retrofitable for machine in the field with Drive and Set
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Drive & Set Manual Activation
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Lift Handle & push back on locking lever Push down on handle until linkage locks in place
Manual Activation
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Drive and Set Upper Control Box (UCB)
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Drive Set Controller
Joystick Values Voltages from 5vdc - 2.5vdc – 0.0vdc for both X and Y axis
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CANBus
CAN Bus circuit has two resistors, and one is located in the upper circuit card and the other on the CPU card. If the system is working properly 63Ω should be across the CAN Bus. If there is an open in the system then a reading of 126Ω on each module. On the I/O Driver Board in the Lower Control plug J5 pins 3 & 4 are the communication from platform. Output from J3 are pins 38 & 40 on the Driver Board to plug J2 pins 38 & 40 on the CPU Board.
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Driver Board
CPU Board
J3
J2
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Diagnostic LED
Sevcon Motor Controller U2
Logic Side of Sevcon
Motor Controller
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Main Power Contactor PA1-RA1
Power On Relay PA1-RL1
Inline Battery Fuse PA1-FS3
Power System
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Inline Fuse Power on Relay PA1-FS2
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Battery Charger
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Battery Charger Indicators
Battery Type Indicators Two red LED indicators are provided in order to display what type of battery the charger has been programmed to charge. Battery System Percent Charged Indicators Four LED indicators are provided in order to display the progress of the charge cycle in percentage of charge.
24VDC/25Amps
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Battery Charger Indicators
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Indications are as follows:
1ST RED LED . . . . . . . . . . .Illuminated configured for Wet Cell and AGM batteries
2ND RED LED . . . . . . . . . . . . .Illuminated configured for Gel Cell batteries
3RD RED LED . . . . . . . . . . . . .Charging - Initial Charging Up To 30%
3RD & 4TH RED LEDS . . . . . . .Charging - 60%
Complete3RD, 4TH & 5TH RED LEDS . . . .Charging - 90% Complete BLINKING GREEN LED . . . .Finishing Stage (Note: Battery Type Indicator will also blink during this stage)
STEADY GREEN LED . . . . . .Charge Complete –Float/Maintenance Mode-On for 5 minutes and off for 60 minutes. Your system provides an equalization stage every 30 days while plugged in.
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Jib Down Switches SW1 & SW4
NO & NC
Limit Switch Operation
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Limit Switch Operation
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Boom Down Switches. SW2 & SW3, or NO & NC
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Limit Switch Operation
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Outrigger Switches SW5 RR; SW6 RF;
SW7 LR; SW8 LF shown in Picture.
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Outrigger enable valve CL1, CL2,CL3,
& CL4
Outrigger and Limit Switch Operation
Negative Side of the outrigger coils is controlled by Limit Switches
PA3-RL1
26 Boom Down Relay
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Level Sensor Calibration
Level Sensor PA1-U1
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Level Sensor Calibration
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Level Sensor PA1-U1
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Load Cell and Interface
Load Cell & Interface Process for Calibration of the Load Cell is located in Service/Parts Manual Unit is located between pedestal and basket or optional material lifting hook. Sensor interface is used for communication between Load Cell and Upper Control Box.
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U5 U4
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Electric DC Motor Proportional Valve C8
System Relief Valve 3000PSI 206Bar
Manual Pump
Test Port TP1
Basket Compensation Valves C13, C14
Basket Compensation Counter Balance Valves
Turret Rotation Valves C9, C10
Hydraulic Power Unit
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Turret Rotation Flow Control Valve
Turret Rotation Pressure Relief Valve
Adj
Hydraulic Return Filter
Hydraulic Power Unit
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C11 Telescope Ext
C12 Telescope Ret
C6A Outrigger Check Valve C6 Outrigger Ext Valve
C7 Outrigger Ret Valve
Hydraulic Power Unit
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Security valve is on the piston side of the Primary, Secondary, and Jib lift
Cylinders. This valve is used to keep oil in the hydraulic line up to a certain
pressure because of the sprung check valve.
45/55 Articulated Security Valve
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C6+C7*+C6A+C8+C1+C2+C3+C4= 1
* C7 comes back to 0 when 3 outriggers are on ground
(C7 =1 :extra speed to respect the movement of 30sec)
If C8 is defective , there is no outriggers extension and no movement (except boom descent if not already in stowed position)
Tank
System Relief @ 3000PSI
Outrigger Extension
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C7+C1+C2+C3+C4+C8 (half closed) =1
If C8 is defective , there is no outriggers extension and no movement (except boom descent if not already in stowed position)
Tank
System Relief @ 3000PSI
Outrigger Retraction
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C8 + C9 ( or C10 for CCW rotation) =1
Speed Control
Tank
Turntable Rotation
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C8 + C11 ( or C12 for retraction) = 1 C8 + C11+ C12 for Extend ( or C8 + C12 for Retraction) = 1
Tank
System Relief @ 3000PSI
Telescope Extension
38
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C8 + C13 ( or C14 for down) = 1
Tank
System Relief @ 3000PSI
Platform Compensation
39
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BOOM : C8 + C5 ARM : C8 + C16 JIB : C8 + C17
Double check valve (41) : set at 25 psi (2b) Only on 45 and 55ft Towable Booms
Tank
System Relief @ 3000PSI
40
Primary, Secondary, & Jib Lifting
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TANK
Primary/Lower Boom : C8+C5 Secondary/Upper Boom: C8+C16
Jib: C8 + C17 C8 is controlling the proportionality for gravity down functions
Double check valve (57) : set at 25 psi (2b) for jib, Boom and Arm descent control on Both 45 and 55XA
To drive manifold
Primary, Secondary, & Jib Lowering
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Drive and Set Option
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C20 = Dump Valve C21 = Brake Valve C22 = M2A Drive RWD RH Motor C23 = M2B Drive FWD RH Motor C24 = M1A Drive RWD LH Motor C25 = M1B Drive FWD RH Motor C26 = Proportional Valve
Drive & Set Manifold
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MAIN PUMP coming from TP3
AUX PUMP
TANK
FWD : C8+ C20+C21+C22/C24 + C26 REV : C8+ C20+C21+C23/C25 + C26
Flow restrictor (45) : overrun control
LEFT RIGHT
SHARP LEFT FWD : C8+ C20+C21+C23/C24 + C26 SHARP RIGHT FWD : C8+ C20+C21+C22/C25 + C26 SHARP LEFT REV : C8+ C20+C21+C22/C25+ C26
SHARP RIGHT REV : C8+ C20+C21+C23/C24 + C26
Drive and Set Option
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Lower Control Box Connectors
45
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46
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Key Switch & E-Stop
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Pin5 0-4.5vdc for Sevcon Pin12 is 24v enable for Sevcon from ECU Pin1 24v wake for Sevcon from power on relay Pin 8 Negative signal for the line contactors.
Power on Sevcon Motor Controller
BLK RD
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Articulated Boom and Outrigger Switches
50
87
NC switches are held open when the jib & boom are stowed
NO switches are held closed when the jib &
boom are stowed
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Manifold Harness 3632T
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NC switch is held open when the boom is stowed
NO switch is held closed when the boom is stowed.
3632T Boom Switches & Outrigger Switches
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End
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