Hinowa LightLift 15.70 3S Technical Course Booklet Download

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8.2.2

PUMPS AND UNDERCARRIAGE PART HYDRAULIC DIAGRAM

TO THE

AERIAL PART

VALVEBLOCK

Summary of Contents for LightLift 15.70 3S

Page 1: ...1 TECHNICAL COURSE BOOKLET LightLift 15 70 3S PERFORMANCE TTLL1570021702 ...

Page 2: ...CONTROL 22 4 2 OUTRIGGERS MOVEMENTS 23 4 2 1 AUTOMATIC STABILIZATION 24 4 2 2 OUTRIGGERS AUTO RETRACTION 25 4 2 3 SINGLE OUTRIGGER MOVEMENTS 27 5 AERIAL PART MOVEMENTS 28 5 1 ENGINE CARTER CONTACT PREVENTION SYSTEM 30 6 PEDAL OPTIONAL 31 7 EMERGENCY OPERATIONS 32 7 1 EMERGENCY DEVICES AND TOOLS LOCATION 32 7 2 AERIAL PART EMERGENCY OPERATIONS 34 7 2 1 GRAVITY EMERGENCY DESCENT 35 7 2 2 OPERATIONS ...

Page 3: ...2 DRIVE GEAR MOTORS 57 8 4 3 TRACKS WIDENING 59 8 5 AERIAL PART HYDRAULIC SYSTEM 60 8 5 1 FIRST AND SECOND BOOMS 61 8 5 2 THIRD BOOM 62 8 5 3 TELESCOPE 62 8 5 4 JIB 62 8 5 5 BASKET LEVELING 62 8 5 6 BASKET ROTATION 62 8 5 7 TURRET ROTATION 63 8 5 8 EMERGENCY GRAVITY DESCENT SYSTEM 63 9 ELECTRICAL SYSTEM 64 9 1 ELECTRONIC BOARDS INTRODUCTION AND LOCATION 64 9 2 SOFTWARE 65 9 3 CAN BUS SYSTEM 65 9 4...

Page 4: ...10 1 9 3 TIME 89 10 1 9 4 PASSWORD 89 10 1 9 5 DATE 89 10 1 9 6 LOAD SENSOR 90 10 1 9 7 INCLINATION SENSOR 90 10 1 9 8 EXTRA 90 10 1 9 8 1 FIRMWARE 90 10 1 9 8 2 CARDS 90 10 1 9 8 3 MODEM 91 10 1 9 8 4 GPS 91 10 1 9 8 5 OPTIONAL PAGE1 91 10 1 9 8 5 1 PEDAL 91 10 1 9 8 5 2 BEEPER 92 10 1 9 8 5 3 SECOND SPEED 92 10 1 9 8 5 4 ELECTRIC MOTOR 92 10 1 9 8 5 5 LAMPS 92 10 1 9 8 5 6 CHK INC 92 10 1 9 8 6 ...

Page 5: ...01 11 3 LITHIUM MACHINE WITH 36V LITHIUM BATTERY SYSTEM 103 APPENDIX 1 TILT SENSOR CALIBRATION 109 APPENDIX 2 LOAD CELL BOARD ECM3 CALIBRATION 110 APPENDIX 3 REMOTE CONTROL JOYSTICK CALIBRATION 111 APPENDIX 4 REMOTE CONTROL STOP BUTTON BY PASS 112 APPENDIX 5 PHOTOCELLS SETTING AND CALIBRATION 113 APPENDIX 6 MASTER BOARD ECM1 REPLACEMENT AND SETTING 114 APPENDIX 7 ACOUSTIC RECALL DEVICES 117 APPEND...

Page 6: ...al part of the LightLift name identify the machine maximum working height in meters while the last two digits indicate the maximum outreach in decimetres The aerial platform is equipped with an hydraulic system and an electrical system that interact to ensure safe operating in any situation The present manual describes those two systems and how they interact 1 1 PARTS DENOMINATION The base sides o...

Page 7: ...t in the basket anyway there are others options illustrated and described later TELESCOPE FIRST BOOM THIRD BOOM CYLINDER SECOND BOOM JIB CYLINDER BASKET THIRD BOOM FIRST AND SECOND BOOMS CYLINDER TURRET SLEW RING JIB ...

Page 8: ...TION To identify the machine a serial number plate is affixed on to the frame of the machine The following illustrations showing its location The machine serial number is also printed on the frame SERIAL NUMBER PLATE LOCATION ...

Page 9: ...ine machine operating weight without operator 1940 Kg Diesel machine operating weight without operator 1960 Kg Lithium machine operating weight without operator 1992 Kg Gasoline Diesel machine Max drive speed with double speed 0 7 1 4 2 6 Km h Lithium machine Max drive speed with double speed 0 4 0 8 1 6 Km h Angle of attack 20 36 Max admitted translation inclination in translation direction with ...

Page 10: ...Kw 10HP at 3600rpm Max rated engine speed 3600 rpm Max torque 25 Nm at 2000rpm No of cylinders 1 Displacement 462 cm Tank capacity 5 litres GASOLINE ENGINE TECHNICAL DATA Brand model HONDA iGX 390 Fuel cooling Gasoline Air Power SAEJ1349 8 7 kw 11 7HP at 3600rpm Max rated engine speed 3600 rpm Max torque 26 4 Nm at 2500rpm No of cylinders 1 Displacement 389 cm Tank capacity 5 3 litres LITHIUM PACK...

Page 11: ...E IS SHOWN HERE BELOW WITH THE 2 PERSONS BASKET DIMENSIONS REPORTED IN THIS DRAWING ARE NOMINAL THE REAL VALUE OF EACH DIMENSION CAN BE INFLUENCED BY COMPONETS MANUFACTURE TOLLERANCES AND ELASTIC DEFORMATIONS DUE TO THE FORCES EFFECTS ...

Page 12: ...12 ...

Page 13: ...13 2 4 LL15 70 WORKING AREA 230 KG UNRESTRICTED CAPACITY ...

Page 14: ...he following icon indicating to press and release the remote control emergency stop button to initialize the machine After stop button will be pressed and released the machine is ready to be used and main display indications will be visualized IN case of nec To switch ON the electric motor the machine need to be plugged to the local electric network with a proper cable shorter than 10m and with a ...

Page 15: ...n 3 it s always possible to verify their condition To start the engine on display position 3 has to be shown the first icon here above After that machine has been used it must be switched OFF by the main key on ground control box When outriggers are not touching the ground and both engine and electric motor are switched OFF but main key is still ON remote control emits an intermittent acoustic sig...

Page 16: ...s work with dedicated 12 Volt lines not used by the other machine sensors or devices In case of emergencies it s possible to by pass the remote control stop button following the procedure indicated at APPENDIX 10 3 3 REMOTE CONTROL FUNCTIONS The remote control is essential for the machine it displays all the information on the platform status and any error message in case of incorrect use of the c...

Page 17: ...n of ENGINE PREHEATING ENGINE START STOP and ELECTRIC MOTOR START STOP ENGINE WARM UP ONLY FOR GASOLINE MACHINE OR GRAVITY EMERGENCY DESCENT LEFT TRACK 1 2 ARMS JIB TURRET ROTATION RIGHT TRACK THIRD BOOM BASKET ROTATION TELESCOPE ELECTRIC MOTOR START STOP ENGINE START STOP UNDERCARRIAGE CLOSING AUTO STABILIZATION ENGINE SPEED SELECTOR SINGLE OUTRIGGER MOVEMENT SELECTOR SERVICE MENU SELECTOR DISPLA...

Page 18: ...sage aside The operator has to act on the two external remote control red joysticks to move the tracks With the jib closed it s possible to drive the tracks standing on the ground or standing on the basket To drive the tracks with jib opened the basket must be taken off its support and operator will keep remote control in his hand NOTE With Skyguard installed to unload the basket it has to be disc...

Page 19: ...he jib or to drive the tracks with jib already opened In those cases the error message UNLOAD THE BASKET will be displayed To reach the total length of 3400 mm the basket must be unloaded and its support must be lifted acting on its pin as indicated below UNLOAD THE BASKET ICON ...

Page 20: ... operator standing into the basket has to press the pedal while moving the tracks For safety reason as soon as the basket is lifted from the load cell sensor the aerial part movements are disabled and display shows LOAD MIN icon NOTE If pedal option is active and the remote control is on its basket support the operator standing into the basket has to press the pedal while moving the tracks LOAD MI...

Page 21: ...ipped with second speed that is an optional it will be possible to select the faster speed HARE ENGINE a TURTLE b NORMAL c HARE When there s no movement in progress none of the joysticks acted engine keeps minimum rpm On the machine equipped with second speed thanks to AUTO2SPEED system in case of the torque required to the tracks sensibly increases for instance driving on a slope the machine will...

Page 22: ...e control buzzer activated c Tracks movement stopped display icon NOTE To get out from a stability risk condition when tracks movements are stopped it s necessary to press button 8 on remote control as indicated by the above icon tracks movements will be allowed in turtle speed for 10 seconds while the counter down will be activate on the display Operator will have to drive machine back into safe ...

Page 23: ...e settled this chapter details how to do it To allow outriggers movements machine must be closed and aligned this condition is indicated by the relevant icon displayed on position n 6 Machine is closed and aligned when booms including jib are completely lowered cylinder closed and turret is aligned as indicated by the two arrows see picture aside that the operator has to keep as visual reference C...

Page 24: ... 4 2 1 AUTOMATIC STABILIZATION To be able to automatically stabilize the machine it must be closed and aligned to automatically stabilize the machine it has to be press remote control button n 7 AUTO STABILIZATION and keep it pressed until that display shows OK AUTO STABILIZATION procedure sets all the outriggers at the ground and automatically levels the machine on both axles X and Y while the pr...

Page 25: ...gers auto retraction while two or three outriggers are touching the ground the engine automatically runs at minimum rpm to ensure smooth movements NOTE If pedal option is active the MACHINE STABILIZED icon appears after pedal have been pressed to enable the aerial part movements 4 2 2 OUTRIGGERS AUTO RETRACTION To be able to automatically retract the outriggers the machine must be closed and align...

Page 26: ...oke that side hydraulic oil pressure rises to the maximum value and it is detected by the pressure switch When both sides oil pressures are at maximum values machine starts to feed only one side outriggers at a time in order to have more power available This helps when especially with electric motor outriggers need more power to be moved as when hydraulic oil is very cold OUTRIGGERS AUTOMATIC RETR...

Page 27: ...er n 1 the menu is recursive so that to select another outrigger button n 2 has to be pressed again Pressing button n 2 five times display will come back to the main page Once the desired outrigger is selected to move it it s enough to use button n 1 and button n 7 as indicated by the arrows displayed When an outrigger is touching the ground its led will be flashing to indicating it to the operato...

Page 28: ...the remote control display shows the MACHINE STABILIZED icon on position n 5 Being that basket weight is about 50 Kg the load input read by the display need to be less that about 280 Kg On the remote control basket support there s a magnet that interacting with remote control detects when the remote control is properly placed on it When the machine is stabilised and the remote control in place the...

Page 29: ...e ground INCL FAIL means that the machine is not levelled within the inclination clearance LOAD FAIL means that basket is overloaded more than 230Kg into the basket so more than about 280 Kg charged on the load sensor In this case of the basket is overloaded display will visualize also the OVERLOAD icon BASKET FAIL means that the remote control is not properly placed on its basket support PEDAL OP...

Page 30: ...om part would touch the engine carter lithium pack In order to avoid that contact LL15 70 is equipped with a contact prevention system that in certain conditions avoid turret rotation or first boom lowering informing the operator accordingly by the display If the first boom is not lifted enough machine could not be rotated over a certain angle on both sides when machine is almost completely rotate...

Page 31: ...nts controlled the basket this function grant further control avoiding unintentional movements This option can be enabled or disabled on all of the machines even for those countries where it s not required To enable this further control the pedal must be installed in the basket When activated the pedal must be pressed and kept pressed before to operate the machine from the basket otherwise the mov...

Page 32: ...ther emergency procedure in order to displace the machine By this chapter are detailed the emergency procedures instructions and the list of the relevant potential cases where they could be required NOTE Remember ground personnel must be present all the time the platform is operating 7 1 EMERGENCY DEVICES AND TOOLS LOCATION In order to fulfil the emergency procedures the machine is equipped with a...

Page 33: ...e left side of the electric components compartment installed on the machine rear side of the machine Hand pump lever is under the aerial part valveblock bonnet BY PASS KEY SWITCH HAND PUMP LEVER AERIAL PART VALVEBLOCK GROUND LEFT SIDE VALVEBLOCK GROUND RIGHT SIDE VALVEBLOCK HAND PUMP HYDRAULIC MANIFOLD ALUMINUM BLOCK CONTROL POSITION SELECTOR ...

Page 34: ...re all the emergency devices and tool must be put back on original position condition 7 2 AERIAL PART EMERGENCY OPERATIONS The main purpose of an emergency descent is to safely take to the ground the operator staying into the basket Some emergency descent can be carried out from the basket some other from the ground MAIN KEY AND BY PASS KEY GROUND CONTROL BOX KEY BASKET LEVELING SPARE KEY N 2 X MA...

Page 35: ... PROCEDURE Keep pressed button n 4 of the remote control and at the same time use the joystick relevant to the boom to low By this emergency descent being using the gravity it s possible to do only the movements indicated here below with blue circles so third boom lowering 1st and 2nd booms lowering and jib lowering i e closing 2nd cylinder 1st cylinder or jib cylinder It s not possible to lift th...

Page 36: ...respected except for the remote control position To use the ground control position it s necessary to ignite engine or electric motor and to keep turned rightward the control position selector while acting on the aerial part valveblock levers NOTE If the ground control box is closed it must be opened with its key NOTE Operating from the ground control box engine carter lithium pack contact prevent...

Page 37: ... It s required to rotate the turret to align the machine after the gravity emergency descent CONDITIONS REQUIRED Engine and or electric motor properly working Electrical system properly functioning The aerial part safety device by pass can be carried out by using the safeties by pass key switch that is under the slot on the left side of the electric components compartment installed on the machine ...

Page 38: ... operations than the ones specified by the present procedure in particular are forbidden operations such as telescope opening booms lifting outriggers movements while machine is not closed and aligned or with person in the basket in general any operation that may compromise the machine stability To carry out emergency descent from the ground with hand pump the here below steps have to strictly fol...

Page 39: ...ssed act on the movements levers following the sticker indications on the rear side of the cover Emergency lowering must be done following the safer movements sequence NOTE In case the ground control box is closed open it with the proper key NOTE Operating with hand pump of course there s no electronic control activated including the engine carter contact prevention system MOVEMENTS LEVERS PROPORT...

Page 40: ...ties by pass enables only tracks movements for safety reason it does not enable the outriggers movements EMERGENCY POTENTIAL SITUATIONS Breakage of an outrigger microswitch CONDITIONS REQUIRED Engine and or electric motor properly working Electrical system properly functioning The ground safety device by pass can be carried out by using the safeties by pass key switch on the electric components co...

Page 41: ...lift machine on the outriggers it s absolutely forbidden to make different operations than the ones specified by the present procedure in particular are forbidden all of the outriggers movements while machine is not closed and aligned or with person in the basket in general any operation that may compromise the machine stability To move an outrigger by the hand pump the here below steps have to be...

Page 42: ...cated the deviator valve unscrew its cork and completely unscrew the red cap screw as indicated by the following picture in order to feed the right side ground part HAND PUMP DEVIATOR HAND PUMP LEVER AERIAL PART GROUND RIGHT PART DEVIATOR ...

Page 43: ...completely pressed act on the right side relevant levers as indicated by the sticker to move the outriggers n 3 and n 4 g In order to move the left side outriggers shift the deviator on the manual pump into the position for ground left side leftward as indicated by the hand pump sticker and place the hand pump lever HAND PUMP DEVIATOR HAND PUMP LEVER RIGHT SIDE GROUND PROPORTIONAL VALVE BUTTON AND...

Page 44: ...the emergency operation is finished it must be unscrewed the deviator valve activator to restore the original condition 7 4 ENGINE EMERGENCY START PROCEDURE The following procedure shows how to separate engine from the platform system It could be useful in the followings cases To verify if the engine is out of order To handle manually the machine s hydraulics by the proportional valves and or devi...

Page 45: ...45 7 4 1 GASOLINE HONDA iGX390 EMERGENCY START ...

Page 46: ...46 7 4 2 DIESEL HATZ 1B40 EMERGENCY START ...

Page 47: ... inside the bonnet contains the ground valveblocks the hydraulic manifold the deviator valve the double pump valve the blowoff manifold the second speed manifold and the hand pump The most of the hydraulic components here above indicated are shown at the chapter 7 1 the ones missing are shown here below TRACKS WIDENING MANIFOLD HYDRAULIC MANIFOLD WITH DEVIATOR VALVE DOUBLE PUMP VALVE AND SECOND SP...

Page 48: ... Hydraulic manifold aluminium block contains deviator valve double pump valve and second speed valve DOUBLE PUMP VALVE DEVIATOR VALVE SECOND SPEED VALVE DOUBLE PUMP VALVE DEVIATOR VALVE SECOND SPEED VALVE ...

Page 49: ...49 8 2 HYDRAULIC DIAGRAM 8 2 1 HYDRAULIC DIAGRAM INDEX ...

Page 50: ...50 8 2 2 PUMPS AND UNDERCARRIAGE PART HYDRAULIC DIAGRAM TO THE AERIAL PART VALVEBLOCK ...

Page 51: ...51 8 2 3 AERIAL PART HYDRAULIC DIAGRAM FROM THE DEVIATOR VALVE ...

Page 52: ...d with only one pumps unit with n 2 pumps 3 15 cc rev connected to the three phases electric motor plus the hand pump All of the pumps units outlines are conveyed through the hydraulic manifold into two lines A and B Six one way valves avoid oil under pressure to flow back to the tank through an unused pump unit The position of the pumps arrivals to the hydraulic manifold is described here below E...

Page 53: ...e ground but remote control is not placed on its support NOTE On lithium machine deviator coil is always energized when machine is ON and not stabilized or not respecting all the conditions to allow aerial part movements doesn t matter if engine electric motor are running or not B line sends oil under pressure to the double pump valve that is physically included into the hydraulic manifold and tha...

Page 54: ...three valveblocks two for ground part and one for aerial part the outgoing oil is collected by the blowoff manifold to the tank filter TO THE RIGHT VALVE BLOCK TO THE AERIAL PART VALVEBLOCK TO THE LEFT VALVEBLOCK TO THE SECOND SPEED ACTIVATION TO THE BLOWOFF MANIFOL D TO THE SECOND SPEED ACTIVATION TO THE RIGHT VALVE BLOCK TO THE AERIAL PART VALVEBLOCK TO THE LEFT VALVEBLOCK TO THE BLOWOFF MANIFOL...

Page 55: ...ntrolled by two hydraulic valveblocks right side and left side both equipped with one maximum pressure valve one proportional valve and an ON OFF valve for each ground part movement ON OFF VALVES PROPORTIONAL VALVE MAX PRESSURE VALVE LEFT SIDE VALVE BLOCKK RIGHT SIDE VALVE BLOCK ON OFF VALVES PROPORTIONAL VALVE MAX PRESSURE VALVE ...

Page 56: ...eblock controls the two left side outriggers n 1 and n 2 the left track drive gear motor and the tracks widening cylinders Right side ground valveblock controls the two right side outriggers n 3 and n 4 and the right track drive gear motor 8 4 1 OUTRIGGERS Outrigger cylinders are controlled by the cylinder valves block that is screwed on the cylinder when machine is setup on outriggers oil is kept...

Page 57: ...iable capacity so that they can perform two different hydraulic speeds in order to change tracks speeds further that rpm regulation The second speed block contains the coil in charge to activate the second speed selecting HARE from remote control button the control module will energize that coil When that coil is energized oil is sent to both drive gear motors to move their plate so that their cha...

Page 58: ...speed valve reducing the gear rate and the tracks speed Auto2speed allows to manage automatically the available power providing on demand a higher torque with a slower speed or an faster speed with a lower torque Second speed activation oil coming from second speed valve coil is sent to both drive gear motors through the second speed manifold that is installed on the undercarriage base SMALLER CHA...

Page 59: ...rolled together in parallel by the same valveblock element on the left side valveblock Track widening system oil is sent to both cylinders through the track widening manifold that is installed on hydraulic components compartment SECOND SPEED SIGNALS HOSES 3 AND 4 DRAINAGE LINES HOSES 1 AND 2 ...

Page 60: ...ter 5 The aerial part is controlled by an hydraulic valveblocks equipped with one maximum pressure valve one proportional valve and an ON OFF valve for each aerial part movement ON OFF VALVES PROPORTIONAL VALVE MAX PRESSURE VALVE AERIAL PART VALVEBLOCK ON OFF VALVES PROPORTIONAL VALVE MAX PRESSURE VALVE ...

Page 61: ... the turret rotation motor the cylinder for moving 1st and 2nd booms the cylinder for moving the 3rd boom the telescope cylinder the jib cylinder the basket rotation actuator and the basket levelling circuit On each cylinder and actuator is installed a couple of calibrated valves one each direction when a movement is in progress on one direction the opposite valve is piloted to open letting oil fl...

Page 62: ...ircuit is composed by two cylinders one on the basket and one on the third boom connection rod basket is automatically kept levelled while third boom is moving because of the basket cylinder is moved by connection rod cylinder In particular while third boom is opening the connection rod cylinder will be closing so that its oil will be send to the basket cylinder achieving the automatic basket leve...

Page 63: ... emergency descent they are controlled by the control module when the remote control button gravity emergency descent is pressed When they are fed they open a calibrated passage and under the gravity effect weight they will allow oil to get out from the bottom of the cylinder flowing back to the tank through the ON OFF valves so that booms will slow down The coil valve for gravity emergency descen...

Page 64: ...ds described here below that interact each other and with machine sensors and actuators The main board called master board or ECM1 controls the main machine functions including the movements is located on the right side of the electric components compartment on the machine rear side ECM1 is just behind the modem The modem carries out the communication with Hinowa server further details are describ...

Page 65: ...dem could contain the machine main software for instance if it was sent by R A H M the remote assistance available via internet and it could update the master board with it in case of need more details about it are described in the appendix 6 The machine main software is composed by two separated parts one is belonging to the safety and the other one is belonging the settings not involving the saf...

Page 66: ...etailed in Lithium technical training The ECM1 has 5 different lines 10 wires for CAB BUS communication CAN BUS 0 Diagnostic plug modem CAN BUS 1 Cylinder position sensors ECM3 remote control CAN BUS 2 Free ECM4 for bigger machines models CAN BUS 3 Inclination Sensor CAN BUS 4 Lithium system 9 4 SENSORS COMMUNICATING THROUGH CAN BUS Together with those boards some machine sensors interact through ...

Page 67: ...ic purposes has also a dedicated CAN BUS line The diagnostic plug jumper has a 120 Ohm resistance so that it must be fitted to work with the machine Also diagnostic device cable need to fit the 120 Ohm resistance to be able to interface e with the machine Further details about the CAN BUS system connections are indicated on the wiring diagrams DIAGNOSTIC DEVICE CABLE ADDITTIONAL RESISTENCE 120 Ohm...

Page 68: ...signals are compared and transduced by ECM3 that communicates the load measured through CAN BUS to the ECM1 The load cell sensor must be calibrated on the machine with its own ECM1 and ECM3 only the 0 calibration is necessary and it must be done with the basket unloaded from its support 2 Turret rotation proximity it s sensor that working with the slew ring eyelet detect when the machine is almost...

Page 69: ... rear side interacting with the reflector installed on the bottom of jib when they receive back the reflector signal it means that machine is closed and aligned They are directly connected to the ECM1 working in parallel as a double line sensor One photocell is normally opened NO the other is normally closed NC so their regulation is different The followings picture shows the lights conditions whi...

Page 70: ...rmally opened NO Each line is directly connected to the ECM1 6 Pressure sensors they are two pressure sensors installed on each hydraulic line that give the signal to the ECM1 when a high pressure value is reached for example when both outriggers are lifted at the end of the stroke They are normally opened NO released when the pressure is lower than that value They are directly connected to the EC...

Page 71: ...the ECM1 through CAN BUS Thanks to that sensor coupled with the magnet installed on the basket support remote control feels its proper position on basket support this is the reason why it need to be properly installed and fixed to avoid that machine movements make it losing the position 9 Emergency stop button on the remote control it s a switch inside the remote control that through ECM3 is conne...

Page 72: ...on the upper part of jib detecting if the jib is completely closed or not It is normally closed NC and is released when the jib is closed It is connected to the ECM3 with a double line 12 Tracks widening sensor switches they are two sensors used for the AUTOMATIC SPEED CONTROL function They are installed on the two tracks widening cylinders and detect the position of tracks completely widened or n...

Page 73: ... case of one of these components need to be replaced the calibration must be carried out as indicated by the APPENDIX 1 9 7 LOAD CELL SYSTEM The load cell system has two components load cell board ECM3 and the load cell sensor The load cell sensor is located under the basket and it has four extensimeters so that send a double signal for both the lines to the ECM3 ECM3 is located into the jib arm b...

Page 74: ...he electric network activate the circuit breaker start the motor by pressing the electric motor start button on the remote control or at the ground control box so that its contactor is closed Electric motor runs always at minimum speed 1500 rpm it is equipped with two capacitors in order to limit the absorption during the motor starting POWER SUPLLY PLUG CIRCUIT BREAKER BOX ELECTRIC MOTOR CIRCUIT ...

Page 75: ...the transformer described by the following chapter while machine is plugged to the electric network 9 10 BATTERY CHARGE SYSTEM The battery charge is carried out by the electronic transformer located under the base bonnet aside the electric motor The output tension from the electronic transformer is fixed at 13 4 Volt DC and it does not depend on the electric network tension or frequency The output...

Page 76: ...des an interactive display that should be always check in particular situations such as movements avoided or breakdowns as it gives operational and breakdown indication The following chapter details the remote control diagnose functions and settings 10 1 1 DISPLAY ICONS The display indicates machine conditions and eventual errors occurred in order to help operator and to have a quick diagnose here...

Page 77: ...d by gravity emergency descent 12V battery voltage low 12V battery down or 3rd boom cables sensor anomaly Wrong remote control connection on the basket at the ground Remote connection in progress Skyguard bar pressed option Safeties by pass activated Automatic periodical service reminder Double line sensor error check error menu Undercarriage part movements safeties by pass activated Main key off ...

Page 78: ...vices giving an input signal to the ECM1 it s so possible to check eventual changes of status The device status visualized depends on the signal received by the ECM1 so that it depends on the device itself but also on the connections The picture aside shows for instance the status of the first device of INPUT menu Pressing button n 1 PREV brings back to the previous device of the list pressing but...

Page 79: ...und the switch is released line A is open and line B is closed UP UP Outrigger n 3 lifted the switch is pressed line A is closed and line B is open ST4GND AB DOWN DOWN Outrigger n 4 on the ground the switch is released line A is open and line B is closed UP UP Outrigger n 4 lifted the switch is pressed line A is closed and line B is open BYPASAE AB OFF OFF The aerial part safeties are deactivated ...

Page 80: ...cell A contact is open and photocell B contact is closed OFF OFF Photocells are not aligned with the reflector machine is not closed and aligned Photocell A contact is closed and photocell B contact is open ST12 CLOSED ON Pressure switch of outriggers n 1 and n 2 closes the contact the outriggers are at end run and the max pressure valve is opened OFF Pressure switch contact of outriggers n 1 and ...

Page 81: ...leased MOTOR TEMP Only for Diesel machine ON The engine reached the max functioning temperature emergency condition OFF The engine maintains the correct functioning temperature normal working condition MOTOR PRES Only for Diesel machine ON The engine oil pressure is inadequate emergency condition OFF The engine oil pressure is OK normal working condition START M EL ON The ground button for electri...

Page 82: ...ft track is fully widened Widening cylinder of left track contact is closed OFF Left track is not fully widened Widening cylinder of left track contact is open TRACK OPEN B ON Right track is fully widened Widening cylinder of right track contact is closed OFF Right track is not fully widened Widening cylinder of right track contact is open INCLIN X 0 05 Indicates the inclination of the machine on ...

Page 83: ...ine 2220 Indicates the Diesel engine rpm TEMPERAT 37 62 Indicates the temperature of the ECM1 in C SUPPLY V 12 15 Indicates the batteries voltage or the output voltage from the battery charger ONLY LITHIUM INPUT SOC 89 Indicates the charge level of the battery pack 100 is the maximum 0 is the minimum V LITHIUM 40 Indicates the total voltage of the lithium pack When the cells are not under charge o...

Page 84: ...r charge or under discharge it tends to the nominal value that is around 3 3 Volt 12 Indicates the number of the lowest cell BMS A CHG 25 Indicates the maximum current Amp that BMS requires to the battery charger with lithium pack not fully charge T MAX CELL 23 Indicates the highest temperature C detected among the cells 2 Indicates the number of the temperature sensor with the highest temperature...

Page 85: ...mOhm of the cells 1 Indicates the number of the cell with the lowest resistance HOURS INV 27 It counts the working hours with engine running RPM INV 0 Indicates the engine rpm read by the engine rpm sensor At a certain rpm setting the rpm read depends also on the electric load 10 1 3 LANGUAGE Through this page it is possible to select the visualization language among ITALIAN GERMAN ENGLISH FRENCH ...

Page 86: ...lways possible to come back to the SERVICE menu main display pressing button n 9 When a device reference is marked with a NO that means there s an error and that device has one line signal not coherent with the other PAGE 1 PAGE 2 ST1 GND Outrigger n 1 on the ground switch ST2 GND Outrigger n 2 on the ground switch ST3 GND Outrigger n 3 on the ground switch ST4 GND Outrigger n 4 on the ground swit...

Page 87: ...um error in progress More information about those data are detailed on the Lithium Training 10 1 5 RAMPS This menu is used by Hinowa 10 1 6 CURRENTS This menu is used by Hinowa MICRJIB Jib opening switch INCL Machine inclination sensors LOAD Basket load cell sensor CODE Do not consider REMOTE Remote control CIL3 3RD boom cylinder position sensor INCL Machine inclination sensors 48XS B Load cell bo...

Page 88: ...rest position to 127 joystick fully pressed up or down Moving the selected joystick it s so possible to check its proportionality and its end of the stroke about 127 steps both forward and backward 10 1 9 SETUP SETUP menu gives the access to other settings and under menus The here aside picture shows the SETUP menu display from SETUP menu pressing button from n 1 to n 8 it s possible to enter into...

Page 89: ...s the time in meridian 0 10 1 9 4 PASSWORD Some setting requires a password some passwords are relevant to more than one setting some other passwords are dedicated to only one setting By PASSWORD page it s possible to insert the password required pressing the keyboard buttons password are composed by 4 numbers if password is accepted display will visualize an OK 10 1 9 5 DATE By this page is visua...

Page 90: ...he in the APPENDIX 1 10 1 9 8 EXTRA EXTRA menu gives the access to other settings and under menus The here aside picture shows the EXTRA menu display from EXTRA menu pressing button from n 1 to n 6 it s possible to enter into further pages Pressing button n 9 ESC brings back to the SETUP menu 10 1 9 8 1 FIRMWARE Check the dedicated procedure 10 1 9 8 2 CARDS Check the dedicated procedure INCLINATI...

Page 91: ...1 9 8 5 OPTIONAL PAGE1 PAGE 1 OPTIONAL menu gives the access to other settings The here aside picture shows the OPTIONAL menu first page display from which pressing button from n 1 to n 6 it s possible to enter some settings Pressing button n 8 it s possible to enter into a second page of settings shown below Pressing button n 9 ESC brings back to the EXTRA menu 10 1 9 8 5 1 PEDAL By this page it ...

Page 92: ...utton n 2 OFF second speed will be deactivated 10 1 9 8 5 4 ELECTRIC MOTOR By this page it s possible to set the electric motor power setting after having inserted the relevant password 3522 pressing button n 1 2 2 KW machine will be set for 2 2 Kw electric motor pressing button n 2 1 2KW it will be set for 1 2 Kw electric motor The main difference between the two settings is in the auto stabiliza...

Page 93: ...page it s possible to set the RC SPEED function when it is activated it avoids to operate tracks maximum speed when operator is not into the basket After having inserted the relevant password 4771 pressing button n 1 ON second speed will be activated pressing button n 2 OFF it will be deactivated 10 1 9 8 6 3 RC MOVE By this page it s possible to set the RC MOVE function when it is activated it bi...

Page 94: ... lithium machine by this page it s possible to set the maximum charging current after having inserted the relevant password 1138 pressing button n 1 it will be settled 25 Amp pressing button n 2 it will be settled 18 Amp This setting considering the transformation rate has to respect the maximum current available on local electric plug 10 1 9 8 7 2 INV SET For a lithium machine by this page it s p...

Page 95: ...idden to use the remote control connected on the ground while someone is in the basket except for emergency reasons At the ground cable is connected the CONNECTOR JUMPER necessary to close the STOP lines on basket connector If the remote control is connected to the basket connector but the control position selector switch is wrongly turned left to select the remote control ground position the disp...

Page 96: ...s properly fulfilled than machine will be ready to be used From this position at the ground it s possible to move both the aerial part and the ground part While using aerial part with remote control connected on the ground the control module will avoid moving if there s more than 50 Kg in the basket Only for emergency reasons it s possible pressing and keeping pressed remote control button n 8 to ...

Page 97: ... MAX MAX 1 2 BOOMS DOWN MIN DOUBLE PUMP MED DOUBLE PUMP MED SECOND PUMP 1 2 BOOMS DOWN MIN MED MED 3 BOOM UP MIN MED MED 3 BOOM DOWN MIN MIN MIN 1 2 AND 3 BOOMS TOGETHER WITH AT LEAST ONE UP MIN MAX MAX 1 2 AND 3 BOOMS TOGETHER NONE UP MIN MED MED TELESCOPE OUT MIN DOUBLE PUMP MAX DOUBLE PUMP MAX SECOND PUMP TELESCOPE IN MIN MAX MAX SLEW ROTATION MIN MED MED JIB MIN MIN MIN BASKET ROTATION MIN MIN...

Page 98: ...ms both for gasoline and for diesel machines Engine relays board is the same for gasoline or diesel machines but some relay has different functions Engine relays board is located on the right side of the electric components compartment on the machine rear side just below the modem Engine bridge boxes are also located into the electric components compartment ENGINE RELAYS BOARD ENGINE BRIDGE BOXES ...

Page 99: ... 4 N m at 2500 rpm Fuel consumption at continuous net power 3 5 L h at 3600 rpm Compression ratio 8 2 1 Lubricating system butterfly valve type Oil capacity 1 1 l Starting system Recoil and starter motor Stopping system Ignition primary circuit open Carburetor Floating valve type Air cleaner Dual element type Governor STR self turning regulator governor The ECM1 is interfaced with an electronic un...

Page 100: ...itions occur SW1 SW2 RPM OFF OFF MIN ON OFF MED OFF ON MAX The configuration of the rpm is calibrated through a special program directly in Hinowa If the carburetor is replaced a new parameterization of the electronic unit of the motor is required SERIAL NUMBER LOCATION The serial number is stamped on the cylinder barrel Refer to this when ordering parts or making technical inquiries SERIAL NUMBER...

Page 101: ...l pressure oil temperature 100C 2 5 bars at 3000 rpm Lubricating oil capacity with oil sump 3 2 l Max lubricating oil consumption after running in 1 of fuel consumption at full load Direction of rotation power take off end Anti clockwise Valve clearance 10 30C 0 10 mm Weight incl fuel tank air cleaner exhaust silencer recoil starter and electric starter Approx 55 Kg TYPE PLATE ENGINE SERIAL NUMBER...

Page 102: ... sensor and according to the movement selected by the operator controls a solenoid that regulates the rpm The configuration of the rpm is calibrated through the engine revolution schedule In case of replacement rpm regulation actuator has to be installed in order to have the acceleration lever excursion completely included within the excursion of the actuator piston this condition has to be achiev...

Page 103: ...YSTEM CHARGE INFORMATION The level of charge of the lithium pack is shown by the icon on the right lower corner of the display or more in detail by the input SOC State Of Charge When Lithium pack State of Charge SOC is lower than 21 remote control beeper is activated to inform the operator that machine need to be charged When SOC is lower than 11 inverter feeds electric motor with an half of the s...

Page 104: ...tted on the lithium pack otherwise the one close to the magneto thermic switch DC DC TRANSFORMER A part for Lithium system that works at 36 nominal Volt the rest of the machine electronic boards and components still work at 12 5 Volt so Lithium system includes a DC DC transformer that convert the 36 Volt into 12 Volt Machine is equipped with 12 Volt battery necessary to switch ON Lithium system EL...

Page 105: ...ED TRACKS WIDENING 1500 2100 2100 1 2 BOOMS DOWN 750 1500 DOUBLE PUMP 1500 DOUBLE PUMP 1 2 BOOMS DOWN 750 1500 1500 3 BOOM UP 750 1800 1800 3 BOOM DOWN 750 1500 1500 1 2 AND 3 BOOMS TOGETHER WITH AT LEAST ONE UP 1500 1800 1800 1 2 AND 3 BOOMS TOGETHER NONE UP 1050 1500 1500 TELESCOPE OUT 1500 1800 DOUBLE PUMP 1800 DOUBLE PUMP TELESCOPE IN 1500 1800 1800 SLEW ROTATION 750 1500 1500 JIB 750 1050 105...

Page 106: ... is plugged to the electric network battery charger activated While heaters are working on the display will appear the icon batteries cold and machine could be moved only in lower speed turtle In hot environmental temperature the fans system automatically cool down the cells they are automatically activated by the BMS when cells temperature raises over 37 C they are automatically switched off when...

Page 107: ...107 LITHIUM SYSTEM COMPONENTS LOCATION UPPER LAYER LOWER LAYER BATTERY CHARGER INVERTER SUPPLEMENTARY INSULATOR FRONTAL FAN DC DC TRANSFORMER MAIN FUSE INTERNAL CONTACTOR CELLS PACK BMS ...

Page 108: ...108 CELLS PACK WITHOUT COVER ...

Page 109: ...ometers reset must be done while machine is perfectly levelled in both axles both motors need to be switched OFF no vibrations and the basket need to be empty Here follows the calibration procedure 1 Turn ON the main key and wait for display switching ON 2 Press button n 6 SERVICE and then press button n 7 SETUP 3 Press button n 5 PASSWORD The display will ask for the password 4 Inserting password...

Page 110: ... into saving the value 0 done without the basket here follows the calibration procedure 1 Turn ON the main key and stay out from the basket with remote control on hands 2 Press button n 6 SERVICE and then press button n 7 SETUP 3 Press button n 5 PASSWORD The display will ask for the password 4 Inserting password 6138 the display will confirm with OK 5 Press button n 9 EXIT and then button n 7 LOA...

Page 111: ...ction JOYSTICK DIRECTION AERIAL MOVEMENT 1 FORWARD LEFT TRACK FORWARD BACKWARD LEFT TRACK BACKWARD 2 FORWARD 1ST AND 2ND BOOMS UP BACKWARD 1ST AND 2ND BOOMS DOWN 3 FORWARD 3RD BOOM UP BACKWARD 3RD BOOM DOWN 4 FORWARD TELESCOPE IN BACKWARD TELESCOPE OUT 5 FORWARD BASKET ANTICLOCKWISE ROTATION BACKWARD BASKET CLOCKWISE ROTATION 6 FORWARD JIB UP BACKWARD JIB DOWN 7 FORWARD TURRET ANTICLOCKWISE ROTATI...

Page 112: ...achine stabilized while remote control is connected to its basket connector with stop button pressed in case of an emergency it s possible to by pass it keeping turned rightward the control position selector and switching ON one motor by its ignitions button While control position selector is kept pressed it s possible to move the aerial part acting on the aerial part valveblock levers as soon as ...

Page 113: ...abilized closed and aligned Machine perfectly aligned condition must be achieved looking at the following conditions Same distance on both sides between the second boom and the outriggers 1 and 3 lifted completely up ROTAT A and ROTAT B on INPUT menu reading 180 1 Alignment yellow arrows perfectly aligned Those conditions must be all verified at the same time With machine perfectly closed and alig...

Page 114: ...ARD ECM1 REPLACEMENT AND SETTING Machine software contains the software for all the TTC Hinowa machine models produced till that moment so that when a new master board ECM1 in installed on a machine the machine model need to be selected NEW MASTER BOARD When a new master board never used is fitted on the machine the remote control need to be connected to its ground cable and the control position s...

Page 115: ...DE FAIL it means that the machine model selected is not correct even if that alarm does not appear on the display the machine model selected need to be check Here below the example shows on the image A the case of machine model selected is wrong and on image B the case of machine model selected is the right one for a LL15 70 3 In case of the engine model selected is not correct with button n 7 MOT...

Page 116: ...cted to its connectors as well as when the contacts on the load cell board ECM3 have been changed machine will check if the machine model selected on the master board corresponds to the machine model where it is fitted on If the machine model selected on the master board does not correspond to the machine model the correct machine model must be selected by the VERSION menu as indicated at chapter ...

Page 117: ... the back side it is on the left of the electric motor The table here below details the functioning of remote control beeper and warning buzzer REMOTE CONTROL BEEPER WARNING BUZZER optional CONDITION EVENTUAL FURTHER CONDITION ON OFF Emergency stop pressed ON OFF Alarm LOAD MAX ON OFF Alarm LOAD MIN ON OFF No outrigger at the ground ON ON Photocell signal OFF Aerial part inclination limit ON OFF N...

Page 118: ...king some aerial part movement all of the aerial part movements will be immediately stopped In case of machine was carrying on certain aerial part movements not for all the movements it will also carry out the same movement on the opposite side for instance if the operator press the Skyguard bar while he was opening the telescope the machine will automatically close the telescope for a certain tim...

Page 119: ... the valve coil is indeed possible to determinate errors such as short circuits or connections missing For some kind of anomalies affecting one aerial part valve coil including gravity emergency descent valves second pump valve etc all the machine aerial part movements could be blocked for safeties reasons Resetting the machine by the main key key OFF key ON from the software release 2 0 if the an...

Page 120: ...t will be displayed the CODE MENU that is a list of DEVICE with potentially anomalous signal NOTE By CODE MENU not all the DEVICEs signed with an ERROR and ACTIVE YES have to be considered as an anomaly only in case of the icon FAIL INPUT OUTPUT is displayed there s an anomaly in progress DEVICE 4 ERROR 15 VALUE 0x100 COUNT 16 ACTIVE NO 1 PREC 2 NEXT 3 ESC EXAMPLE OF CODE MENU FOR DEVICE INDICATIO...

Page 121: ...ve coil 38 1 2 booms lowering valve coil 39 3 boom lowering valve coil 40 Telescope extraction valve coil 41 Telescope retraction valve coil 42 Jib opening valve coil 43 Jib closing valve coil 44 Basket levelling up valve coil 45 Basket levelling down valve coil 46 Turntable right rotation valve coil 47 Turntable left rotation valve coil 48 Basket right rotation valve coil 49 Basket left rotation ...

Page 122: ...ror 9 Timeout error 12 Reading error 14 Selection error 15 Occupied 16 Default value not valid EXAMPLES Here follow some examples of what could be displayed on CODE menu EXAMPLE OF A CODE MENU INDICATION WITH NO ERROR IN PROGRESS STOWED MACHINE WITH NO ERROR DEVICE CODE ERROR CODE ACTIVE 11 12 NO 12 9 YES 64 2 YES 65 9 NO 66 9 NO 67 4 YES 73 2 NO 89 12 YES 133 1 YES 145 2 YES 154 8 NO 155 8 NO 166...

Page 123: ...ith ERROR 7 Safety deactivation COIL CONNECTION ERROR EXAMPLE DEVICE CODE ERROR CODE ACTIVE 12 9 YES 36 7 YES 1 2 booms lifting valve coil 37 5 YES 3 boom lifting valve coil 38 7 YES 1 2 booms lowering valve coil 39 7 YES 3 boom lowering valve coil 40 7 YES Telescope extraction valve coil 41 7 YES Telescope retraction valve coil 42 7 YES Jib opening valve coil 43 7 YES Jib closing valve coil 44 7 ...

Page 124: ... part movements will be re activated except for the third boom lowering that will be re activated only after its coil anomaly is restored COIL CONNECTION ERROR AFTER KEY RESET EXAMPLE DEVICE CODE ERROR CODE ACTIVE 12 9 YES 37 2 YES 3 boom lifting valve coil 64 2 YES 65 9 NO 66 9 NO 67 4 YES 73 2 NO 89 12 YES 133 1 YES 145 2 YES 154 8 NO 155 8 NO ...

Page 125: ... opposite side YES Problem depends on something from the hydraulic manifold to the valveblock Manifold could be tested reversing its outlines hoses NO Problem depends on something from the valveblock outline to the drive gear motor or on drive gear motor itself YES Check red joystick functioning by the JOYSTICK menu Verify that tracks controls lever or button on the valveblocks are not activated T...

Page 126: ... ground inclination is not over the machine limits eventually check on INPUT MENU voices INCLIN X and INCLIN Y and if they are not correct recalibrate the inclinometers Try manual stabilize by remote control outriggers moved one at a time on all the outriggers to be sure ON OFF valves are all fed If only one side outriggers left ones or right ones are moving verify if it depends on deviator valve ...

Page 127: ...e remote control is not properly positioned in its basket support or the sensor inside remote control is not working properly PEDAL optional if NO indicates that pedal has to be pressed to allow the aerial part movements AUTOST if NO indicates that automatic stabilization procedure has not been properly completed till the OK on the display With software RamHino it could be find also an eventual in...

Page 128: ...ntrol verify on the connector wires n 5 low and n 6 high continuity verify 2 4 2 6 Volt between wires n 5 low and n 7 and between wires n 6 high and n 7 Did you find any anomaly YES Check green connector on master board and CAN BUS line between remote control and master board Check control position selector position NO Try to connect the remote control at the ground with the optional cable operati...

Page 129: ...be high enough if battery has lost its capacity it could cause SEN 3 FAIL especially after engine ignition Does SEN 3 FAIL appear only after an engine ignition and disappears when machine switched OFF ON YES Charge or replace the lead battery NO Verify connector wires of the third boom cylinder sensor 3 12V BATTERY TROUBLESHOOTING NOT FOR LITHIUM MACHINES Before to proceed with troubleshooting it ...

Page 130: ...k the engine generator output or the battery level directly that s should be over 13 Volt even if at minimum rpm the voltage could be lower 4 ELECTRIC MOTOR TROUBLESHOOTING NOT FOR LITHIUM MACHINES A Electric motor doesn t work fine Make sure that the magneto thermic switch is ON and proportional valves not pressed If electric motor stalls check electric motor condenser Check that electric network...

Page 131: ...ank is empty Check fuel arrival to the engine and if fuel pump is working properly B Engine switches OFF Check if tank is empty Isolate engine from machine following the relevant procedure if engine does not start it s an engine matter and it should be asked to the engine constructor service C Rpm regulation not working fine Check rpm regulation actuator in case it could be verified feeding it wit...

Page 132: ...lifted the switch is pressed and A line is opened ST2 GND B ON Outrigger n 2 on the ground the switch is released and B line is open OFF Outrigger n 2 lifted the switch is pressed and B line is closed ST3 GND A ON Outrigger n 3 on the ground the switch is released and A line is closed OFF Outrigger n 3 lifted the switch is pressed and A line is opened ST3 GND B ON Outrigger n 3 on the ground the s...

Page 133: ...y pass is closed BYPASCB A OFF The ground part safeties are deactivated through the safeties by pass key switch emergency condition line A of the ground part safeties by pass is closed ON The ground part safeties are activated normal working condition line A of the ground part safeties by pass is opened BYPASCB B OFF The ground part safeties are deactivated through the safeties by pass key switch ...

Page 134: ...ntrol is pressed B line is open OFF The stop button on remote control is released B line is closed FOTO A ON Photocell A receives the signal from the reflector Aerial part closed and aligned OFF Photocell A does not receive the signal from the reflector Aerial part opened FOTO B ON Photocell B does not receive the signal from the reflector Aerial part closed and aligned OFF Photocell B receives th...

Page 135: ...re probe is open GENERATOR ON Engine is running OFF Engine is not running EMRG COMM ON The control position selector for aerial part operation from the ground is activated emergency condition OFF The control position selector for aerial part operation is released normal working condition START M TE ON The ground button for engine start is pressed OFF The ground button for engine start is released ...

Page 136: ...open PEDAL B ON The pedal is pressed the pedal electric line B is open Option OFF The pedal is released the pedal electric line B is closed R C BASKET ON The remote control is in the support in basket OFF The remote control is not in the support in basket TRACK OPEN A ON Tracks are fully widened Widening cylinders switches A are pressed contact is closed OFF Tracks are not fully widened Widening c...

Page 137: ...g of the 3rd boom cylinder in tenths of a millimetre PROXIMITY ON Indicates that booms are almost completely rotated on the engine carter OFF Indicates that booms are not almost completely rotated MICR BR 1 2 ON Indicates that 1st boom is opened enough to rotate above the engine carter OFF Indicates that 1st boom is not opened enough to rotate above the engine carter ANTISCH ON Indicates that Skyg...

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Hinowa LightLift 15.70 3S, Technical Course Booklet

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