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Robot 185

Troubleshooting

Troubleshooting

General

The troubleshooting section focuses on the most common occurring faults and their repair. The section
gives an overview of the machine and by guides through the troubleshooting of the machine.

Troubleshooting method

• The Service display reports most of the electric and control system failures.
• Usually the reasons for the faults can be found in the electric or hydraulic system.
• Always check the supply voltage first.
• Always test drive the machine with a cable attached, if there are problems.
• Ensure that the control circuit and the control box are intact.

Tools

• All tools must be of the correct kind and approved for the measuring range in question.
• Normal tool selection with appropriate spanners.
• An ampere meter for measuring the current.
• A universal current meter for metering the voltage and the resistance.
• An additional supply cable that is undamaged.
• Pressure gauge with hoses and connectors.

Safety in troubleshooting

Components have a high voltage and that can cause various types of danger during measurement operations.
During service operations and troubleshooting, you must carefully concentrate on only the machine and on
the task at hand.
Always ensure that the machine is not on before starting a service operation.
Remember to secure parts that may move during operation, for example, the hydraulic system.
Only an authorized person is allowed to perform electricity service operations or hydraulic service
operations.
Only an authorized electrician is allowed to perform heavy current reparation operations.
Always check whether the component has been connected to heavy current.

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Содержание Robot 185

Страница 1: ...English Operator s Manual 2013 ROBOT 185 Please read this manual carefully before using the equipment and follow all instructions Keep this manual for later reference ...

Страница 2: ...alibrationofthecontrolsystem 29 Changing radio channels 30 Taking into use a new remote control 30 Alert signal 31 Charging the battery 31 Operating and changing attachment 32 Pressure adjustment of attachments 32 Installing attachments 32 Removal of attachments 32 Operating the machine in difficult conditions 33 High temperature 33 Low temperature 33 Water 33 Danger of fire and explosion 33 SERVI...

Страница 3: ... during operation 55 The overload relay blows 56 Alarms 56 Indicator lights 56 Troubleshooting the electric system 57 Troubleshooting the hydraulic system 57 Troubleshooting the control system 58 Troubleshooting the modules 58 SERVICE DISPLAY 59 Password for Service display 59 Features of the Service display 59 The service display error messages 59 ELECTRIC DIAGRAMS 66 400 V system and soft start ...

Страница 4: ... of the machine It is very important to follow all the operating and maintenance instructions so that the safety of the user or the people around the machine is not jeopardised and damage to buildings and to the machine is prevented The manual consists of safety instructions the structure and technical information of the machine operating instructions troubleshooting service instructions and a ser...

Страница 5: ...iginal parts AVANT Tecno Oy is not responsible for faults that have been caused by exposing the product to an accident change in structure or faulty operation AVANT Tecno Oy is also not responsible for defects that have occurred due to insufficient or inaccurate maintenance wrongly performed reparations problems caused by dirt water or particles in the hydraulic system or due to an insufficient el...

Страница 6: ...ctive visor protective shoes protective gloves respirator mask suitable for the work environment safety harness and other equipment Risk factors It is important to master the machine functions and properties Because of the demanding operations that the machine performs work safety must be taken into account all the time It is impossible to warn of all the risk factors because the machine is used i...

Страница 7: ...e machine Electrical safety Handle all electrical devices and connections with extreme caution Always connect the machine to a terminal which is equipped with leakage protection Before connecting the supply cable of the machine check that the voltage and the fuse size are correct Before usage check that the control and supply cables are intact Replace damaged cables immediately The electrical cabi...

Страница 8: ... turn off the control Always control the machine from a place which is not affected by the demolition operation Always stand on a surface that is above the machine when the machine is being used on an inclined surface The machine may slide on the surface Never stand at a place where you might get compressed between the boom and the machine frame or between the machine and a wall bar pillar etc Not...

Страница 9: ...the machine service the machine immediately and do not use it when it is damaged If the service operation does not require starting up the machine unplug the connection cable and make sure it cannot be plugged in again by mistake The condition of the machine must be checked regularly and the machine must be monitored every day This way the machine will remain in a condition that is safe for both t...

Страница 10: ... The engine power is either 15 kW or 18 5 kW It is possible to install steel tracks on the Robot 185 for working in hot conditions Width of the rubber track is 200mm Technical specifications Operating weight 2060 kg Hydraulic breaker 170 245 kg Attachment weight max 275 kg Radio control IEEE 802 15 4 radio standard ZigBeeRealtime Information Technology Performance Tracks 200 72 47 rubber tracks Sl...

Страница 11: ...11 Robot 185 Structure 795 1820 2030 1590 107 2290 2090 0 1 2 3 4 5 1 2 2 3 1 0 1 2 3 4 5 6 ...

Страница 12: ...inuous 360º rotating tower with a four joint boom The machine is controlled by remote control with or without a cable 1 Frame 9 Tracks 2 Outrigger 10 Drive motor 3 Slewing table 11 Slewing bearing 4 Rear boom 12 Slewing motors 5 Main boom 13 Tower control valve 6 Telescope boom 14 Frame control valve 7 Dipper boom 15 Residual current relay and fuse box 8 Quick coupling 16 Greasing device option ...

Страница 13: ...ucture 1 Electric motor 6 Switch 2 Service display 7 Supply cable support 3 Emergency stop 8 Tower module 4 Power On indicator light 9 400V electric cabinet 5 220V socket outlet 10 24V electric cabinet and frame module ...

Страница 14: ...8Z 30 00 21 2 SOFT START ABB PSR45 600 81 3 THERMAL RELAY 35 38A ABB TF42 38 4 PHASE CONTROL RELAY GAMMA G2PF400VS02 5 SWITCHED MODE POWER SUPPLY GAMMA G2PF400VS02 6 TERMINAL BLOCK RAIL 40 TS 35 7 5 F 7 CABLE FROM PHASE INVERTER 8 SOCKET COUPLING 1 5 16MM2 CU ENSTO KJ 18 9 CABLE TO THE MOTOR ...

Страница 15: ...re Electric cabinet low current Pos Name 1 SAFETY RELAY DUELCO NST2004F 2 TERMINAL BLOCK WITH FUSE HOLDER WAGO 282 698 3 TERMINAL BLOCK WAGO 280 646 4 I O MODULE EPEC 2020 5 CABINET HARNESS A35496 6 CABINET HARNESS A35496 ...

Страница 16: ...cture Hydraulic system the frame 1 Return filter 6 Hydraulic pump 2 Pressure sensort 7 Pressure accumulator 3 Cooler 8 Pressure relief valve 4 Filling cap 9 Frame control valve 5 Electric motot 10 Outrigger track block ...

Страница 17: ...ure Hydraulic system the tower 1 Revolving bearing 2 Revolving motor 3 Revolving release 4 Attachment selection valve option 5 Control module 6 Greasing device optio 7 Tower control valve 8 Tank block 9 Rotary connection ...

Страница 18: ...cture Control valve of the arm system 1 Tool 2 Main boom 3 Rear boom 4 Tower rotation 5 Tool tilting 6 Dipper boom 7 Telescope 1 Outriggers right 2 Tracks left 3 Tracks right 4 Outriggers left Control valve of the frame ...

Страница 19: ...19 Robot 185 Structure Control system 1 Control box 2 Switch panel 3 Control lever ...

Страница 20: ... off Aux Control of auxiliary equipment Tele Control of telescope Hold Hold on Hold off Parallel Parellel run on Parellel run off Motor Electric motor start up Electric motor shut down Potentiometres Hammer Hammer control Tool A Tool A control Tool B Tool B control Aux Adjust Auxiliary equipment control hammer ad justment Indicator lights System General fault Volt Phase missing blown fuse contacto...

Страница 21: ...utriggers down Left outriggers up Tower counter clockwise Tower clockwise Right joystick Right track forward Main boom down Rear boom down Extension out Right track backwards Rear boom up Main boom up Telescope in Right outriggers up Right outriggers down Tool up Tool down Others Read the manual carefully before using the machine ...

Страница 22: ... a few obstacles 50 m Indoor without any obstacles 50 m Indoor with a few obstacles 10 30 m Note Signal reaches above are theoretical Battery specifications Manufacturer HY LINE Battery type H2B179 2700 Li ion 3 6 V 4600 mAh Amount of batteries 1 pc Charger Inertek 04151A Charging time with the charger 180 minutes ...

Страница 23: ...o a terminal with leakage protection No one is allowed to be closer than 6 meters to the machine when the machine is started Before starting work the outriggers must be lowered so that the machine stands firmly Safety Always remember to leave a safe distance around the machine while it is being used Cut off the machine s supply voltage when not in use to prevent accidental use of the machine Bewar...

Страница 24: ...m the boom lifting points These lifting points can be used for lifting the tower When transporting the machine it must lay on tracks with the outriggers and booms raised so that they do not support the machine When transporting breaker attached place the tool inside separate tool bracket located in front of the machine The machine must be tied down with at least two ropes tapes There are four fast...

Страница 25: ...levers must be centred when turning the switch The electric motor is turned on with a soft start which limits the initial level current The Power light 5 on the remote control is green when the remote control is on If the battery is running low the Power light is red After starting up the machine movements are only allowed by pressing dead man function by pressing the rocker switch 6 upward with t...

Страница 26: ...ame time select the Boom Drive mode from the mode switch position 1 the highest On the Boom Drive mode the tracks are controlled with the rocker switch in the left joystick K1 When pressing the rocker switch down K1B both the right and the left tracks move backwards When pressing the rocker switch upwards K1A both the right and left tracks move forward If the outriggers are raised all the way up t...

Страница 27: ...hree positions to choose from Tool A Tool B and Hammer Tool A and B options are meant for tools that have two functions and work in a similar way but use different parameter values Thus different kind of tools can be used with different settings The Hammer mode is meant for the hammer and it has only one function K1B A minimum and maximum oil flow can be set for the hammer the amount can be adjust...

Страница 28: ...nction The Hold function is used for locking the boom and tool controls The Hold function is activated by turning the Hold switch to the up position whereupon the boom control function of the movement remains even if the joysticks are centered This function is deactivated by turning the Hold switch to the down position and centring the sticks The function is used for example to lock the drill hamm...

Страница 29: ...ve different levels can be set for both out of which the speed of each level can be defined separately with a parameter The parameter defines by what percentage the restricted maximum control is from the normal maximum control Adjustment and calibration of the control system The joysticks and the potentiometer can be calibrated when the remote control is in the calibration mode The calibration mod...

Страница 30: ...osition and releasing the switch After this the program will start scanning the channels and indicator lights will be lit one by one shift 1s The scanning will take for 15 seconds Once the scanning is ready it will propose the best possible channel If you want to approve the proposed channel press the acknowledge button until all six indicator lights will lit green red You must release the button ...

Страница 31: ...onds Use the alert signal to warn people in case of danger Charging the battery The batteries are charged with a charging device see picture below that is supplied with the remote control The charging device uses mains current and a regular plug The remote control is also charged when the control cable is plugged into the machine when the power is on Note Never leave the machine without supervisio...

Страница 32: ... see Determining the hydraulic pressure page 46 Installing attachments Lift the boom so that the upper hook of the quick coupling grips the upper shaft of the attachment Lift the boom so that also the lower hook grips the lower shaft of the attachment Lock the quick coupling into the right position by using the cylinder of the attachment until the piston rod is entirely inside Install the wedge ke...

Страница 33: ... until the temperature of the hydraulic oil has risen above 10 ºC When the temperature is below 0 ºC follow the instructions for cold starting In frosty weather the hydraulic oil must be heated Set the machine on outriggers and run the motors for 10 15 minutes Switch to Boom mode and use the cylinders of the boom system without loading them Rotate the tower a few times The lowest operational tempe...

Страница 34: ...our meter of the motor hydraulic pump When the motor hydraulic pump is being used the number in the operating hour meter increases The service interval is 500 hours When the interval is coming to an end the indicator light Service on the remote control will turn on and the Service display shows message Service interval exceeded maintenance required The first service of the machine is scheduled aft...

Страница 35: ...y maintenance Entire machine Cleaning Daily inspection Perform Tracks Lubrication damages cracks fastening leakage and operation Power sources Fastening Cooler Operation and cleaning Hydraulic system Leakage Slewing motor and table Operation Slewing gear wheel Lubrication 500 operating hours service Weekly service Perform Hydraulic pump Noise check Slewing motor and table Fastening and operation B...

Страница 36: ...ease gun into the nipple and squeeze 3 5 times Repeat on all nipples Remember to change broken and clogged nipples immediately Lubricating the slewing bearing Lubricate the top of the slewing ring and both nipples on both sides three times Start up the motor and turn the booms by 90 degrees Repeat the previous lubrication three times so that the entire slewing bearing unit and its teeth are well l...

Страница 37: ... machine shutdowns If there is an undamaged control cable available you can use it to check whether the control cable is faulty Otherwise Check the control cable visually for external damages Shut down the motor and remove the supply cable and ensure that it is not plugged in by mistake Remove the control cable Measure a possible break or short circuit in the control cable with an ohmmeter or with...

Страница 38: ...ns The supply connection of the machine must be dimensioned to the same current as to that of the plug and extension cord of the machine Rated voltage Minimum voltage Cross sectional area of the cable Starting current Engine power Regulation for thermal overload relay Cable maximum length V V mm A kW A m 380 361 0 6 90 18 5 41 7 169 0 380 361 0 10 90 18 5 41 7 281 7 380 361 0 16 90 18 5 41 7 450 7...

Страница 39: ... the leads are properly attached that no gaping contact can occur Reinstall the protective shell To be noted The black and brown leads may have been installed in a different order than presented in the figure The lead installed into the R1 connector 1 of a contact must also be installed to the same connector in the other connector Only a competent professional is authorised to carry out service in...

Страница 40: ... the tightness of the screws with a screwdriver Check that there is no load in the cables The protective conductor must be longer than the other cables so that it is last one to come off if the cable is torn off Measure the resistance of the protective conductor connect the ohmmeter between the ground level of the contact and the frame of the machine The resistance should be 0 Close the electric c...

Страница 41: ...anymore and oil consumption increases Hot oil can also break seals and cause oil leakage Air in the system may cause disturbances in the machine s operation usually the air exits during oil rotation If however air gets into the system during work there is a leakage in the suction pipe and it must be repaired immediately so the pump does not get damaged The pressure control must be kept at the corr...

Страница 42: ... the pressure from the pump LS adjuster Measuring the maximum pressure The maximum pressure occurs when a function is set to the extreme position Measuring Maximum pressure is measured the same way as idling pressure above When measuring the pressure of the breaker line remove the breaker hoses before measuring Movement specific maximum pressures can be found from the chart below Adjust the correc...

Страница 43: ...lastic cover back on top of the adjusting screw Checking the cylinders The cylinders must be checked when they are in the extreme position Turn off the motor and unplug the cable Make sure that it cannot be plugged in by accident Check that the piston rod 1 is undamaged and straight Check that the cylinder liner 2 is undamaged Check that there is nothing wrong with the cylinder fastening 3 Check t...

Страница 44: ...ry amount of additional castings Finish off by painting with a priming colour and then with a coating colour Checking the shaft lockings Check the lockings regularly Turn off the motor and unplug the cable and make sure that it is not plugged in again by mistake Check that the connections are fastened If the connections are loose tighten them Ensure with a rubber hammer that the shafts are centred...

Страница 45: ...e a damaged connector immediately The connectors must be lubricated before installing them Install attach the connectors by using the torque method or using the hand tightening method according to the instructions Torque method Install the connector collar between the pipe and the front part of the connector by screwing it in with your fingers Tighten with a torque wrench Installation torque Pipe ...

Страница 46: ...e nut has been tightened by the right amount when the connector has been removed This method is slower than the torque method but it rules out the need for special tools and problems related to the combination of different types of surfaces With this method you get a visual confirmation that the connector is tight FFFT taulukko Pipe metric Pipe Inches JIC SAE FFFT method mm thread TT ET 6 1 4 7 16...

Страница 47: ...out of the housing Remove the filter element from its clamps by opening the bolt with its supporting plates at the bottom Clean the parts and check the condition of the seals Replace with new ones if necessary Lubricate the seals and threads Install a new filter element to the clamp with a combination of bolt supporting plate Put the filter element with clamps attached into its housing Install the...

Страница 48: ... container must be full To be noted Check that the fluid is the same colour as when refilling If the colour is significantly different read the instructions of the hydraulic oil supplier See also the sections Draining hydraulic oil and Refilling hydraulic oil Refilling hydraulic oil The filling cork is placed under the front cover on the right hand side of the machine Clean the area surrounding th...

Страница 49: ...ter according to the instructions To be noted Hot oil may cause burns Wait until the oil has cooled down Pay attention to cleanliness and make sure that no dirt gets into the container Do not turn the motor on when the container is empty It would cause severe damages to the hydraulic pump Hydraulic oil and lubricants We recommend the following type of oil and lubricants to be used in the machine T...

Страница 50: ...e replaced when the rubber coating has worn out Front wheel Installation Unscrew the pressure accumulator adjustment wheel open from the outrigger block This can be found from left rear protection cover Lift up the front wheel part number 3 and push it to its locking position Before the front wheel can be removed the tracks need to be removed first Instructions for operation and service Check that...

Страница 51: ...the tracks as far as the oil level check screw located on the side of the drive motor is horizontally centered The correct oil level is at the hight of the check plug When installing the gear ensure that the parts are centred to the same line in relation to each other and that the fastenings of the hydraulic hoses are in the correct position Drive motor is installed to the frame and it is fastened...

Страница 52: ...to find out how much the part has worn or how oval they are When replacing bearings the seat must also be replaced Also the wearing of a shaft is measured from three points to determine how much the shaft has worn Measuring the shaft Measuring the bearing and the seat Other shafts Ø 40 mm Other shafts Ø 40 mm Wearing thresholds Diameter mm Min meas mm Max meas mm Shaft 40 h8 39 979 Shaft seat 40 h...

Страница 53: ...he pressure washer the delicate parts of the machine may be damaged Never direct the pressure washer so that water might get through the suction filter and through the seals of the container This may cause serious damage Clean the oil cooler with compressed air When cleaning it is important to spray in exactly a 90 degree angle to the cooler from at least a 40 cm distance so that the sheets are no...

Страница 54: ...ion with appropriate spanners An ampere meter for measuring the current A universal current meter for metering the voltage and the resistance An additional supply cable that is undamaged Pressure gauge with hoses and connectors Safety in troubleshooting Components have a high voltage and that can cause various types of danger during measurement operations During service operations and troubleshoot...

Страница 55: ...sidual current relay and check the fuses Open the electric cabinet and close the contactor manually Note that there is a 400V voltage in the electric cabinet If the electric motor hums one phase is probably missing from the supply voltage If the motor starts up late after pressing the button and straight with a contactor the smooth start SmoothStart is out of order The power outlet blows fuses The...

Страница 56: ...or light is lit continuously If there is a fault in the control system that prevents the safe control of all movements the light flashes on and off The light also flashes if the emergency stop circuit has not been acknowledged by pressing the acknowledgement button Ack after turning on the remote control or if the dead man function prevents the control of movements If no operating voltage is conne...

Страница 57: ...age of the device Troubleshooting the electric system The most typical fault in the electric system is that the machine has been connected to the wrong type of power source Check the fuses of the electrical network and the machine A blown fuse must always be interpreted as a symptom of a fault Find out what has caused the fuse to blow and fix the fault Check the cables and their fastenings see Ser...

Страница 58: ...gates the functioning of the CAN traffic between the tower module and the frame module If the fault density the relative number of faulty messages exceeds the accepted level a service request is given with the indicator light Service When controlling the motor hydraulic pump the number in the operating hour meter increases The service interval is set with a parameter when the interval is met the i...

Страница 59: ...hours and time elapsed from the last service Messages that appear to the main window disappear by pushing the button 3 on the display After this the messages are saved to the message log which can be viewed by pushing the button 3 on the display More detailed information about the messages on the next chapter The diagnostics window can be entered by pushing the button 5 This window enables to see ...

Страница 60: ...ted from General of parameter section Other parameters that can be adjusted are speed of cylinder rotation outrigger and tracks It is done by adjusting opening closing time of the acceleration and deceleration ramps Oil capacity flow is increased by increasing the maximum flow ...

Страница 61: ...ltage supply of the tower module Contact service Receiver not functional Error on radio receiver Check connections and replace the receiver if the problem does not disappear Receiver failure Error on radio receiver or between CAN2 bus frame module and receiver Module related messages Supply voltage low Supply voltage of the machine is too low machine functions are prevented Error possibly on power...

Страница 62: ...th po tential Contact service The tower valve related messages Short circuit in selector valve output Short circuit in attachment selector valve in its cable or module output The valve is damaged broken cable or short circuit to voltage Short circuit to external voltage in selector valve output Voltage without control in attachment selector valve in its cable or module output The valve is damaged ...

Страница 63: ...ontrol valve or cable The valve or cable is damaged Error in dipper boom parameters Wrong setting on parameters Check the parameter values Feedback without control in dipper boom feedback input Feedback without control in dipper boom feedback input Malfunction on wires or wiring Possible short circuit to voltage Contact service Short circuit in dipper boom output Short circuit in control valve cab...

Страница 64: ...Contact service Short circuit in motor starter output 2 3 The motor starter main contactor or cable is damaged Contact service Voltage without control in motor starter output 2 3 The motor starter main contactor or cable is damaged and short circuit to voltage Contact service Short circuit in dump valve output The dump valve or cable is damaged or valve is in short circuit to earth potential Main ...

Страница 65: ...le is damaged and in short circuit to voltage Hydraulic oil related messages Oil temperature sensor high alarm limit Oil temperature is too high Stop working and move the tracks slowly to cool down the oil Oil temperature sensor high warning limit Oil temperature is high Ease up the work and monitor the oil temperature Oil temperature sensor low warning limit Oil temperature is low Move the booms ...

Страница 66: ...66 Robot 185 Electric diagrams 400 V system and soft start ...

Страница 67: ...67 Robot 185 Electric diagrams Frame module and CAN bus ...

Страница 68: ...68 Robot 185 Electric diagrams Frame valves and sensors ...

Страница 69: ...69 Robot 185 Electric diagrams Tower module and rotating connector ...

Страница 70: ...70 Robot 185 Electric diagrams Tower module and valves ...

Страница 71: ...71 Robot 185 Electric diagrams Emergency stop circuit and remote control ...

Страница 72: ...ional block Control of right outriggers 2DCV1 Functional block Control of the hydraulic motor on the right track 3DCV1 Functional block Control of the hydraulic motor on the left track 4DCV1 Functional block Control of left outriggers PP1 Hydraulic pump Develops pressure and flow into the hydraulic system OT1 Hydraulic oil container Stores B1 Breather Lets air in and out of the container when the ...

Страница 73: ...A A CY1 B B CY2 RB RA RA RA RB RB LB LB LSC LA LA T 7 7 7 7 PC2 R11 G1 2 G1 2 G1 2 G1 4 G1 2 G1 2 G1 2 G1 2 G3 8 G3 4 G3 4 G3 4 T 1 4 1 4 1 4 1 4 B A B A B A 20 ltr OF2 G3 4 1 4 LA 1 4 LB 250 bar 66 lpm HYDRAULIKAAVIO 3 200 kg A35322 1 1 SFS 3393 B SFS 4011 Keski SFS 4012 27 8 2013 10 42 16 Pvm Suunn Toleroimat tomat mitat Suhde Pinnan suojaus tai käsittely Liittyy Nimitys Tuote R a koodi Materiaa...

Страница 74: ... of the back boom cylinder 4DCV2 Functional block Control of the dipper boom cylinder 5DCV2 Functional block Control of tool tilting cylinder 6DCV2 Functional block Control of the hydraulic motor that turns the booms 7DCV2 Functional block Control of the telescopic boom cylinder PCT1 Quick coupling Delivery coupling for hydraulic tool PCT2 Quick coupling Delivery coupling for hydraulic tool TCT1 Q...

Страница 75: ...r 66 ltr 66 ltr 30 ltr 30 ltr 30 ltr 15 ltr 15 ltr 30 ltr 30 ltr 30 ltr 30 ltr 30 ltr 30 ltr TX1 B M4A A 280 xx OPTION A B yy OPTION A B CYL xx JAWS PCT2 PCT1 PCT1 TCT1 A B E F C D HYDRAULIKAAVIO 3 200 kg A35322 1 1 SFS 3393 B SFS 4011 Keski SFS 4012 27 8 2013 10 42 16 Pvm Suunn Toleroimat tomat mitat Suhde Pinnan suojaus tai käsittely Liittyy Nimitys Tuote R a koodi Materiaalimäärä brt Ent piir U...

Страница 76: ...470 YLÖJÄRVI FINLAND Tel 358 3 347 8800 Fax 358 3 348 5511 e mail sales avanttecno com AVANT has a policy of continuing improvement and retains the right to change specifications without notice 2013 AVANT Tecno Oy Kaikki oikeudet pidätetään ...

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