Publication No. R307-Z1-01E. Service Manual 01. Cargo crane Radio control device. Model TADANO LTD TADANO LTD. PRINTED IN JAPAN 0908 E

Transcription

1 Publication No. R307-Z1-01E Service Manual 01 Cargo crane Radio control device Model T 2009 TADANO LTD. PRINTED IN JAPAN 0908 E TADANO LTD.

2 Foreword This material is the one that Publication No.R307-Z1-03 was replaced from Japanese with English. This service manual has been prepared to deal with the Model T for use with TADANO cargo cranes. This manual is applicable to the following crane models. In servicing the radio controller system, also refer to the appropriate parts catalog and operation and maintenance manual to be able to take proper steps. As of October, 1990 Cargo crane Model Control Valve (Model) Accelerator Cylinder (Model) Receiver (Model) Transmitter (Model) TM-Z (6 blocks) (RMC-6T805-24) TM-Z (6 blocks) (RMC-6T806-24) TM-Z220-2 TM-Z (6 blocks) (RMC-6T802-24) (AC ) TM-Z (6 blocks) (RMC-6T802-24) TM-Z (6 blocks) (RMC-7T804-24) TM-Z300-2 TM-Z350-1 TM-Z (6 blocks) (DP-T03-A-D2B-9422A) (7 blocks) (DP-T03-C-D2B-9422A) (6 blocks) (DP-T03-A-D2B-9422A) (7 blocks) (DP-T03-C-D2B-9422A) (8 blocks) (DP-T03-D-D2B-9422A) (9 blocks) (DP-T03-E-D2B-9422A) (HSP-T02-1L-D2B-9439A) (RCS-250) * (RCS-250) (RCS-250) * (RCS-250) (6 blocks) (DP-T03-A-D2B-9422A) TM-Z (7 blocks) (DP-T03-C-D2B-9422A) (Note) In the receiver and transmitter columns, the part No marked with * conforms to the New Radio Law (effective from May, 1989 in Japan). For control valves and accelerator cylinders, TM-Z100-2 to TM-Z290-2 are of SANWA make. TM-Z300-2 to TM-Z500-2 are of NACHI make.

3 MEMO

4 Construction and Functions 2 Troubleshooting 32 Disassembly and Reassembly 43 Maintenance Standards 69 1

5 Construction and Functions 1. Principal specifications Model: Control system: Controllable operation: T Feedback, digital proportional control Boom telescoping Hoisting up and down by winch Boom elevating Right and left swing Acceleration Vehicle horn Safety functions: Power supply: Receiver: Transmitter: Radio waves: Frequency: Modulation: Signal transmission range: Emergency automatic stop function Anti-overwinding automatic stop function ID code setting function 24 VDC (vehicle power supply) 6 VDC (UM-3 battery x 4) Automatic power off feature provided Two frequencies in VHF 250MHz band Frequency modulation Approx. 30 m Approx. 20 m (New Radio Law conforming unit) 2. Construction drawing and circuit diagram (1) TM-Z300-2 to TM-Z500-2 Control valve Receiver (Note) For the New Radio Law conforming unit, two antennas are installed (onto the -marked position as shown at left). On the nameplate of new Radio Law conforming unit, A is indicated at the head of MFG No. Connector box Transmitter Telescoping Winch Elevating Swing Jack Jack Metal connector To overwinding detection switch (from PTO switch) From vehicle horn relay Nameplate of New Radio Law conforming unit Accelerator cylinder Fig. 1 2

6 Telescoping Winch Elevating Swing Jack Jack Control valve Fuse Fuse Unload valve coil ass y Unload valve Telescoping Winch Elevating Swing SV coil ass y Extend Retract Up Down Lower Raise Left Right Ext. Ret. Out In Spool Telescoping Winch Down Up Out In Spool Elevating Low. Raise Out In Spool Swing Left Right Out In Spool LVDT coil ass y Accelerator cylinder Out Spool Black Red Blue Yellow Violet White Black White White White White White White White White White White White White Yellow White Black Green Blue Green Blue Green Blue Green Blue Green Blue Fuse & relay box ass y Red Green White From vehicle horn relay To overwinding detection switch Receiver Black Red Green Green/blue White Black/blue Metal connector Black White/blue Red/black White Green/red White/green Red White/red White/black Black Violet Light blue Green/black Green Black/white Yellow Red/blue Black/red Brown Blue Gray Orange Red/green Black/green Pink Green/white Connector box Metal connector cable ass y Connector Transmitter (Note) As for the New Radio Law non-conforming unit, the receiver has an antenna. 3

7 (2) TM-Z100-2 to TM-Z290-2 Control valve Receiver (Note) For the New Radio Law conforming unit, two antennas are installed (onto the -marked position as shown at left). On the nameplate of New Radio Law conforming unit, A is indicated at the head of MFG No. Connector box Transmitter Jack Jack Telescoping Winch Elevating Swing Metal connector To overwinding detection switch (from PTO switch) From vehicle horn relay Accelerator cylinder Nameplate of New Radio Law conforming unit 4

8 Telescoping Winch Elevating Swing Jack Jack Accelerator cylinder Control valve Unload valve coil ass y Unload valve Telescoping Extend Retract Winch Down Up Elevating Lower Raise Swing Left Right Accelerator cylinder SV coil ass y Connector plug 1 Connector plug 2 Connector plug 3 Connector plug 4 Telescoping Out (+) Extend In (-) Retract Out (+) Winch Down In (-) Up Out (+) Elevating Lower In (-) Raise Out (+) Swing left In (-) Right Out (+) Accelerator cylinder LVDT coil ass y Connector box Fuse & relay box ass y Metal connector cable ass y connector Transmitter (Note) As for the New Radio Law non-conforming unit, the receiver has an antenna. Receiver 5

9 3. Construction (1) TM-Z300-2 to TM-Z500-2 Detail of Connectors SWP6-M connector Metal connector BS1 connector SWP3-F connector SWP7-M connector SWP2-F connector SWP1-M connector SWP4-F connector SWP5-M connector Control Valve Ass y No Part name RGB block ass y Telescoping valve block ass y Winch valve block ass y Elevating valve block ass y Swing valve block ass y Jack valve block ass y Jack valve block ass y Tank port plate Tie rod bolt Cap Solenoid valve ass y Nut Plain washer Spring washer Connector box 6

10 RGB Block Ass y Main relief valve (E) Relief valve (G) Reducing valve (D) A - A of Fig. 5 Relief valve (F) Back pressure regulating valve (C) B - B of Fig. 5 (Note) The hydraulic fluid to solenoid valves SA and SB is routed through P1 -> P2 -> P3 -> P4 -> P5 (P5, P5 ), and then to P6 shown in Fig. 7. No. Part name No. Part name No. Part name 1 Valve body 8 Choke 15 O-ring 2 Cap 9 Filter 16 O-ring 3 Slide valve 10 Ball 17 O-ring 4 Spring 11 Plug 18 Plug 5 Spring 12 Plug 19 Plug 6 Spring 13 Plug 20 Relief valve ass y 7 Spring 14 O-ring 21 Reducing valve ass y 7

11 Telescoping, Winch, Elevating, Swing Valve Block Ass y (Note) The check valve (3) is not provided for the telescoping and winch valves. No. Part name No. Part name No. Part name 1 Valve body 12 Bushing 23 O-ring 2 Spool 13 Guide 24 O-ring 3 Check valve 14 Spring 25 O-ring 4 Spring 15 Plate 26 O-ring 5 Piston 16 Backup ring 27 Backup ring 6 Bushing 17 Hexagon socket head bolt 28 Backup ring 7 Bolt 18 Hexagon socket head bolt 29 Plug 8 Plate 19 Hexagon socket head bolt 30 Solenoid valve ass y 9 Guide ring 20 O-ring 31 Differential transformer 10 Plate 21 O-ring 32 Shim 11 Plate 22 O-ring 8

12 Jack Valve Block Ass y No. Part name No. Part name No. Part name 1 Valve body 8 Guide 15 Hexagon socket head bolt 2 Spool 9 Ring 16 Plain washer 3 Check valve 10 Spring 17 O-ring 4 Spring 11 Plate 18 O-ring 5 Plate 12 Backup ring 19 O-ring 6 Cover 13 Hexagon socket head bolt 7 Bushing 14 Hexagon socket head bolt 9

13 Accelerator Cylinder Ass y No. Part name No. Part name No. Part name 1 Valve body 10 Plate 19 O-ring 2 Spool 11 Plate 20 Backup ring 3 Piston 12 Backup ring 21 Backup ring 4 Bushing 13 Hexagon socket head bolt 22 Plug 5 Bolt 14 Hexagon socket head bolt 23 Plug 6 Guide 15 Hexagon socket head bolt 24 Solenoid valve ass y 7 Spring 16 O-ring 25 Differential transformer 8 Plate 17 O-ring 26 Shim 9 Guide ring 18 O-ring 10

14 (2) TM-Z100-2 to TM-Z290-2 Detail of Connectors 3P connector B (SWP3-F connector) CN4(SWP3-M connector) Metal connector BS1 connector 3P connector A (SWP4-F connector) CN5(SWP4-M connector) (SWP5-F connector) CN6(SWP5-M connector) (SWP1-F connector) (SWP2-F connector) CN2(SWP1-M connector) CN3(SWP2-M connector) (SWP6-F connector) CN7(SWP6-M connector) Control Valve Ass y No Part name RGB block ass y Telescoping valve block ass y Winch valve block ass y Elevating valve block ass y Swing valve block ass y Jack valve block ass y Jack valve block ass y Bottom cover ass y Tie rod bolt Cap Nut Solenoid valve ass y Connector box 11

15 Front Cover Ass y Relief valve (G) Relief valve (F) Stop valve Back pressure regulating valve (C) Reducing valve (D) Main relief valve (E) (Note) The hydraulic fluid to solenoid valves SA and SB is routed through P -> P2 -> P3 -> P4 -> P5 -> PSA (PSB), and then to PSA and PSB shown in Fig. 12. No. Part name No. Part name No. Part name 1 Spring 10 Ball 19 O-ring 2 Seat 11 Spring 20 O-ring 3 O-ring 12 Orifice 21 Valve block ass y 4 Poppet 13 Filter 21-1 Valve body 5 Spring 14 O-ring 21-1 Valve 6 O-ring 15 Spring 21-3 Spool 7 Plug 16 Plug 22 Solenoid valve ass y 8 Spring 17 Ball 23 Bolt 9 Cap 18 Plug 12

16 Telescoping, Winch, Elevating, Swing Valve Block Ass y (Note) The check valve (19) is not provided for the telescoping valve. No. Part name No. Part name No. Part name 1 Bushing 14 Bolt 27 Differential transformer 2 Piston 15 Oil seal 28 Bolt 3 O-ring 16 Link 29 Spring washer 4 O-ring 17 Bolt 30 Shim 5 Sub spool 18 Cap 31 Shim 6 Flange 19 Check valve 32 Valve body ass y 7 O-ring 20 Spring 32-1 Valve body 8 Scraper 21 Ball 32-2 Spool 9 Spring seat 22 Ball 33 O-ring 10 Spring 23 Solenoid valve ass y 34 O-ring 11 Spacer 24 Solenoid 35 O-ring 12 Plate 25 Screw 36 Tube 13 Adaptor 26 O-ring 13

17 Jack Valve Block Ass y No. Part name No. Part name No. Part name 1 Valve body 6 Plate 11 Bushing 2 Spool 7 Adaptor 12 Oil seal 3 Cover 8 Plate 13 O-ring 4 Spring 9 Check valve 14 Bolt 5 Guide 10 Spring 15 Bolt 14

18 Accelerator Cylinder Ass y No. Part name No. Part name No. Part name 1 Valve body 11 O-ring 21 Flange 2 Rod 12 O-ring 22 Screw 3 Piston 13 O-ring 23 Solenoid valve ass y 4 Spring 14 O-ring 24 Solenoid ass y 5 Spring 15 Scraper 25 Screw 6 Seal cover 16 Differential transformer 26 Band 7 C-ring 17 Shim 27 Nameplate 8 Ball 18 Shim 28 Rivet 9 Ball 19 Bolt 29 Plug 10 O-ring 20 Spring washer 15

19 4. General The radio controller uses two VHF band FM frequencies. The operations of the crane are controlled by feedback type digital proportional control method by which the positions of the spools in the control valves or accelerator cylinder are determined and moved accordingly. The command voltages from the operation select switches (telescoping, winch, elevating, and swing), the command voltage from the potentiometer coupled with the speed control lever, and the voltage delivered through the A/D converter from the feedback differential transformer are all converted into digital signals before they are sent to the microcomputer of the receiver. When any of the operation select switches and the speed control lever are operated on the transmitter, the generated command signals cause the computer to send the corresponding drive pulses through the solenoid drive circuit to the appropriate solenoid valves. By controlling the regulated hydraulic pressures supplied to the solenoid valves, the corresponding control cylinders are moved accordingly. The stroke of each control cylinder is detected by the differential transformer, and the computer continues to send the drive pulses until the control cylinder reaches the target position that corresponds to the displacement of the speed control lever. When the target value is reached, the computer stops sending the drive pulses, and places the control cylinder in a position. After the control cylinder has been placed in the position, it may depart from the target position due to leaks from the valve etc. In such a case, the computer outputs a corrective drive pulses to re-drive the control cylinder to correct its position. Since each control cylinder is directly connected to the spool of the control valve, the movement of the actuator can be controlled as desired by changing the flow of the hydraulic fluid. The radio controller makes additional controls to ensure proper crane operation against changes in voltage or fluid temperature, etc. A combination of receiver and transmitter in the radio controller has a unique ID code set for the combination, and it is not operated by another radio controller. Since either of two FM frequencies can be used, even if the crane stop is caused by the same frequency transmitted from other unit, the control of the crane can be made active again by switching the frequency. Transmitter ID code (Pin header) Power supply circuit Power supply switch Operation select switch (telescoping, winch, elevating, swing) Speed control lever (Potentiometer) Horn switch A/D converter Buffer RF (Transmission circuit) Control Valve Differential transformer OSC (Transmitter) Solenoid valve Control cylinder Spool Receiver RF (Reception circuit) ID code (Pin header) Bus transceiver A/D converter Buffer Latch Selector Self diagnosis circuit Differential transformer interface Tr driver (Solenoid valve drive circuit) Address decoder Latch Buffer (6) OSC (Transmitter) (Note) As for New Radio Law non-conforming unit, the receiver has an antenna. 16

20 5. Functions The radio controller system, as shown in the construction drawing, consists of a control valve, receiver, transmitter, and accelerator cylinder. The functions of the individual components are described below. (1) Control valve block (i) TM-Z300-2 to TM-Z500-2 [1] Main relief valve (E) Limits the maximum pressure of the hydraulic system. [2] Unload valve (SVI) When the radio controller is normal, the valve switches to the on-load state (power ON state) so that the crane can be operated. When a serious error occurs, the valve stays in the un-load state (power OFF state) so that the crane is stopped automatically. [3] Back pressure regulating valve (C) Let the upstream and downstream pressures of this valve be P1 and P2. During the period the pump is in rotation, even if any of the spools is in the neutral position, the P1 retains the pressure set by this valve to reserve the minimum hydraulic pressure required for operating the control cylinder as shown below. Pressure setting for back pressure regulating valve (C) Pressure setting for reducing valve (D) [4] Reducing valve (D) Maintains the hydraulic pressure to be supplied to the control cylinder to a predetermined pressure by releasing excess pressures. [5] Relief valve (F) This valve is an overload relief valve which releases the high pressures generated in the circuit. [6] Relief valve (G) This valve is a relief valve which directs the hydraulic fluid toward the reducing valve when the filter is clogged. [7] Solenoid valve (SA, SB) These solenoid valves drive the control cylinders in response to signals from the receiver. An example of solenoid valve operation is described below, assuming that power is supplied to an SB valve (no power to the SA valve paired with it) (refer to Fig. 17). The push rod of the SB valve is pressed down by the magnetic force generated in the solenoid coil. As a result, the force is transmitted from the push rod to steel ball A, steel ball B and steel ball C in that order, and steel ball A is pressed against seat a in the sleeve to close the passage, whereas steel ball C leaves seat b in the sleeve to open the passage. Accordingly, the hydraulic fluid from port P is routed to the chamber at the left of the piston in the control cylinder as shown in the figure. As for the SA valve, on the other hand, the upward force of the hydraulic fluid from port P raises steel ball C and force is then transmitted to steel ball B and steel ball A. Consequently, steel ball A leaves seat a in the sleeve thereby opening the passage, whereas steel ball C is pressed against seat b in the sleeve to close the passage. As a result, the hydraulic fluid in the chamber at the right of the piston is led to port T as shown, and the control cylinder piston moves to the right. 17

21 Sleeve Control cylinder Piston [8] Control cylinder Driven by the hydraulic fluid from the solenoid valves (SA, SB), and moves the spool in the directional control valve incorporated in the control cylinder. [9] Differential transformer With an induction detector operating on the principle of electromagnetic induction, the differential transformer detects the displacement of the spool and feeds it back to the receiver. As shown in Fig. 19, the primary coil is supplied with a certain level of AC voltage E0 (square wave). When the moving core (integrated with the spool) is in the neutral position, voltage E (= E1 E2) output to the secondary coil is zero. [Although this is true with a general differential transformer, the voltage that is actually output in this radio controller after passing through the IC (differential transformer interface) in the receiver is at several volts even with the moving core in the neutral position.] When the moving core is moved from the neutral position, voltage E (= E1 E2) is output to the secondary coil. The differential transformer has a shim for adjustment of the output voltage. Shim Specifications Secondary coil Stroke Exciting voltage Square wave Moving core Primary coil 18

22 Output voltage Primary coil Yellow White Stroke Blue Black Green IN side end Neutral position OUT side end Secondary coil (Note) The IN side end corresponds to the position of the moving core in Fig. 18 when it is moved to the right stroke end, whereas the OUT side end corresponds to the position of the moving core when it is moved to the left stroke end. (ii) TM-Z100-2 to TM-Z290-2 [1] Main relief valve (E) Limits the highest pressure of the pump circuit. [2] Unload valve (SV1) When the remote controller is normal, the valve switches to the on-load state (power ON state) so that the crane can be operated. When a serious error occurs, the valve stays in the unload state (power OFF state) so that the crane is stopped automatically. [3] Stop valve When the unload solenoid valve SV1 is short-circuited or open-circuited, the valve switches to the unload state so that the crane cannot be operated. In such a case, tighten the plug (refer to Fig. 11) to make on-load state mechanically where the crane can be operated manually. [4] Back pressure regulating valve (C) Let the upstream and downstream pressures of this valve be P1 and P2. During the period the pump is in rotation, even if any of the spools leaves in the neutral position, the P1 retains the pressure set by this valve to reserve the minimum hydraulic pressure required for operating the control cylinder as shown in the figure below. Pressure setting for back pressure regulating valve (C) Pressure setting for reducing valve (D) 19

23 [5] Reducing valve (D) Maintains the hydraulic pressure to be supplied to the control cylinder to a predetermined pressure by releasing excess pressures. [6] Relief valve (F) This valve is an overload relief valve which releases the high pressures generated in the circuit. [7] Relief valve (G) This valve is a relief valve which directs the hydraulic fluid toward the reducing valve when the filter is clogged. [8] Solenoid valve (SA, SB) These solenoid valves drive the control cylinders in response to signals from the receiver. An example of solenoid valve operation is described below, assuming that power is supplied to an SA valve (no power to the SB valve paired with it) (refer to Fig. 21). The push rod of the SA valve is pressed down by the magnetic force generated in the solenoid coil. Then, the steel ball (upper) closes the passage at seat 'a', pushes the poppet, and opens the seat 'b'. As a result, the hydraulic fluid from port PSA presses down the steel ball (lower) and is routed through seat 'c' to the chamber at the left of the piston in the control cylinder as shown. As for the SB valve, the hydraulic fluid from port PSB and spring force move the poppet upward to close seat 'b' and move the steel ball (upper) upward to open seat 'a'. As a result, the hydraulic fluid in the chamber at the right of the piston is led to port T as shown, and the control cylinder (piston) moves to the right. Poppet Power not supplied Power supplied Control cylinder Piston 20

24 [9] Control cylinder Driven by the hydraulic fluid from the solenoid valves (SA, SB), and moves the spool in the directional control valve incorporated in the control cylinder. [10] Differential transformer With an induction detector operating on the principle of electromagnetic induction, the differential transformer detects the displacement of the spool and feeds it back to the receiver. As shown in Fig. 23, the primary coil is supplied with a certain level of AC voltage E 0 (square wave). When the moving core (integrated with the spool) is in the neutral position, voltage E (= E1 E2) output to the secondary coil is zero. [Although this is true with a general differential transformer, the voltage that is actually output in this radio controller after passing through the IC (differential transformer interface) in the receiver is at several volts even with the moving core in the neutral position.] When the moving core is moved from the neutral position, voltage E (= E1 E2) is output to the secondary coil. The differential transformer has a shim for adjustment of the output voltage. Shim Secondary coil Specifications Stroke Exciting voltage Square wave v Primary coil Moving core Output voltage Primary coil Yellow White Stroke Blue Black Green IN side end Neutral position OUT side end Secondary coil (Note) The IN side end corresponds to the position of the moving core in Fig. 22 when it is moved to the right stroke end, whereas the OUT side end corresponds to the position of the moving core when it is moved to the left stroke end. 21

25 (2) Accelerator cylinder The accelerator cylinder is connected to the control valve through a piping. The hydraulic fluid flows from the control valve via the reducing valve and is directed to the solenoid valves (SA5, SB5) to drive the accelerator cylinder, which in turn controls the engine speed. Displacement of the piston of the accelerator cylinder, like that of the control valve, is detected by a differential transformer. The displacement information is fed back to the receiver. As shown in Fig. 24, the accelerator cylinder is designed to start operating only after the control valve has moved full stroke (6 mm). Differential transformer specifications Stroke Exciting voltage Square wave Output voltage Accelerator cylinder stroke (mm) Stroke Valve stroke (mm) Neutral position (IN side end) OUT side end 22

26 (3) Transmitter When the operation select switches and the speed control lever are operated, the transmitter sends the command signals associated with the respective crane operations to the receiver. The transmitter consists of the operation select switches, speed control lever (with a potentiometer), power switch, horn switch, power indicator lamp (LED), batteries (1.5 V x 4), antenna, and a board integrating the CPU, ROM, RAM, pin headers for ID code, etc. The functions of the individual components are described below. (New Radio Law non-conforming unit) (New Radio Law conforming unit) [1] Power switch When the power switch is turned ON, the self-diagnosis checks (operation select switch OFF check and speed control lever neutral value (IDL value) check) are initiated. If there is no error, the power indicator lamp (LED) described in Paragraph (2) flashes to indicate the frequency in use (frequency A or B) before it steadily lights up. If there is an error, the power indicator lamp does not light up (the transmitter does not function). Check that the operation select switches are not in the activated position and the speed control lever is not pulled. (Also when the battery voltage is extremely low, the power indicator lamp does not light up.) To switch the frequency from A to B, turn the power switch OFF and then ON again in 3 to 10 seconds. 23

27 Power switch Power indicator lamp ON OFF Frequency A Approx. 3 to 10 sec Frequency B Caution lf the power switch is switched from OFF to ON too quickly or slowly (more than 10 seconds), the frequencies will not be switched. If the operation is restarted after an operation using frequency B (10 or more seconds after the first operation is finished by turning OFF the transmitter's power supply), the transmitter will operate at frequency B. Caution Be sure to turn ON the power switch of receiver before turning ON the power supply of the transmitter. (The signal (radio wave) to be used for making the unload valve SV1 (control valve) in the on-load state (power supplied) is transmitted for only a few seconds after the power switch has been turned ON. Therefore, it is necessary that the power supply of the receiver is turned ON first to make the receiver ready for receiving the command signal from the transmitter. (Once the signal switching the unload valve to the on-load state is received, it is retained thereafter.) [2] Power indicator lamp (LED (red)) The power indicator lamp flashes or steadily lights to indicate the ON or OFF state of the power supply, the frequency in use, and the time to replace the batteries (run-down batteries). The time to replace the batteries is indicated in Fig. 28. Power switch Low battery voltage indication ON OFF Power switch Approx. 0.5 sec ON OFF Low battery voltage indication Caution With Fig. 17, (i) corresponds to a low battery voltage state which occurs intermediately during operation, and (ii) corresponds to the low battery voltage state which already exists when the power switch is turned ON. [3] Horn switch Pressing the horn switch causes the horn of the vehicle to sound. [4] Operation select switch Telescoping Pressing this switch shown in Fig.26 upward causes the boom to extend, and pressing it downward causes the boom to retract. The radio controller has a fast idle control feature which, when an operation select switch (telescoping, winch, elevating or swing) is pressed, automatically increases the engine speed by approx. 200 rpm even if the speed control lever is not pulled. 24

28 Caution If any of the operation select switches (telescoping, winch, elevating, and swing) is kept pressed for more than five minutes, the power supply of the transmitter will be automatically turned OFF. To continue the operation, turn ON the power supply again. In addition, the radio controller is provided with an automatic power-off feature. If none of the operation switches is pressed for more than 10 minutes, the power supply of the transmitter will be automatically turned OFF. To use an operation select switch, press the power switch again to turn ON the power supply. [5] Operation select switch Winch Pressing this switch shown in Fig. 26 upward causes the winch to wind the wire rope, and pressing it downward causes the winch to unwind the wire rope. [6] Operation select switch Elevating Press this switch shown in Fig. 26 upward raises the boom, and pressing in downward lowers the boom. [7] Operation select switch Swing Pressing this switch shown in Fig. 26 upward causes the boom to swing left, or pressing it downward causes the boom to swing right. [8] Speed control lever The speed control lever has a potentiometer which detects the amount of movement of the lever. The engine speed is controlled according to the detected amount of the lever movement. (The analog data from the potentiometer is converted into digital signal before transmission.) The speed control lever cannot control (increase/decrease) the engine speed unless it is used simultaneously with an operation select switch. When an operation select switch is placed in the neutral position (released) with the speed control lever pulled, the engine speed is brought back to the idling speed. Play Play Control valve spool operation range (idling range) Acceleration cylinder operation range [9] Pin header (for setting an ID code) The pin header for setting a specific ID code is located on the board in the transmitter. It registers a multiplex transmission data code. The ID code is expressed by hexadecimal notation using alphanumeric characters from 0 through F. Hexadecimal notation: 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, A, B, C, D, E, F <Example> Digit Digit Digit Digit (Hexadecimal notation) (Decimal number) 25

29 An ID code is created by using 16 pin headers. To register C as the ID code, the pin headers are set as shown in Fig. 31. Pin header Pin on board Pin header Printed characters on board Pin header inserted position H indicates the upper two-digit section of four-digit number, and L indicates the lower two-digit section. Numbers 0 to 7 indicate a position in the upper or lower section. Pin header Caution Insert the pin header in parallel to the pin, and in the direction indicated by the arrow, as shown in Fig. 32. Pin 26

30 The relationship between hexadecimal number and pin header insertion position is as shown in Fig. 33. Printed character on board or Printed character on board or [10] Batteries [11] Battery case [12] Antenna 27

31 (4) Receiver In response to a command signal from the transmitter, the receiver sends the corresponding signal to the control valve or accelerator cylinder. In addition, the receiver receives the feedback signals from the control valve and the differential transformer of the accelerator cylinder, and the overwind signal from the two-blocking detection switch. When the power supply for the receiver is turned OFF or when both the receiver power supply and transmitter power supply are turned ON, the unload valve (control valve) is switched to the on-load state, allowing manual operation. The receiver accommodates a power switch, power indicator lamp (LED), operation (telescoping, winch, elevating, swing, acceleration) indicator lamps (LED), BNC connector (for connection of antenna), metal connectors and a board which integrates the CPU, ROM, RAM, pin header for ID code, fuses, etc. The functions of the individual components are described below. (Note) This figure shows New Radio Law conforming unit. [1] Power switch When this switch is turned ON, the self-diagnosis check is started. If there is no error, all the indication lamps (LED) are switched from ON to OFF, ON, and OFF in that order, then the receiver becomes in the state where power-on signal from the transmitter is waited (refer to Fig. 24-1). As for the New Radio Law conforming unit, when the power switch is turned ON, all the indicator lamps (LED) are switched from ON to OFF, ON, and OFF in that order and the LED 0 to 5 turns ON and OFF repeatedly once a second, and then the receiver becomes in the state where power-on signal from the transmitter is waited (refer to Fig. 24-2). If there is any error, the indicator lamps (LED) and the crane operate differently according to the error. (For details, refer to the Troubleshooting section.) <Self-diagnosis check items (for initial diagnosis immediately after turning ON the power supply)> - Computer, memory and their peripheral circuits checked - Power voltage (+24 V) checked - A/D converter and its peripheral circuits checked - Solenoid valves (SA, SB), solenoid for unload valve (SV1), and horn relay coil short/open circuit checked - Primary and secondary windings of differential transformer checked for open circuit, and secondary winding checked for abnormal output - Differential transformer neutral position value checked <LED indication pattern after turning ON the power switch (New Radio Law non-conforming unit)> Receiver power switch ON Transmitter power switch ON ON OFF When there is any error, all-off ( -marked) state is not indicated, but error indication appears. (Approx. 0.3 sec) (Approx. 0.5 sec) 28

32 <LED indication pattern after turning ON the power switch (New Radio Law conforming unit)> Receiver power switch ON Repeats the -marked section Transmitter power switch ON ON OFF (Approx. 0.3 sec) (Approx. 0.5 sec) (Approx. 1 sec) When there is any error, all-off ( -marked) state is not indicated, but error indication appears. The radio controller runs self-diagnosis check even during the crane operation to detect error. <Self-diagnosis check items (for diagnosis during operation)> - Power voltage (+ 24 V) checked - A/D converter and its peripheral circuit checked - Primary and secondary windings of differential transformer checked for open circuit, and secondary winding checked for abnormal output - Differential transformer neutral position value checked - Control cylinder (spool) checked for return to the neutral position (after an operation) [2] Power indicator lamp (LED0 (red)) Steadily lights up or flashes to indicate the receiver power switch ON/OFF state, and to display the probable occurrence section of error detected by self-diagnosis check by combining with the operation indicator lamps (LED 1 to 5). (For details, refer to the Troubleshooting section.) When the receiver detects an error by the self-diagnosis check, the receiver accomplishes (i) indication of error section by LED and (ii) deactivation (deenergizing) of the hydraulic circuit (by placing the unload valve (SV1) in the unloading position) or operation stop of appropriate solenoid valves (SA, SB). Each of the above cases is described below. (i) Indication of error section by LED The LED indication pattern is classified depending on the severity: major error or minor error. Major error : The power LED (LED0) flashes. (However, if WDT (CPU monitor circuit) error occurs, it lights up.) Minor error : The power LED (LED0) lights up or goes out. For some errors, probable error section is indicated by changing the lighting pattern, or the valve relating to the error is shown by flashing the corresponding LED. (ii) Deactivation of hydraulic circuit or operation stop of appropriate valve only The hydraulic circuit is controlled depending on the severity: major error or minor error. Major error : The unload valve (SV1) is unloaded. - Errors causing LED0 to flash or - All the valves or differential transformer are abnormal. Minor error : The appropriate valve (SA, SB) only is deactivated. In the event of a major error, manual control of the crane is also impossible. To move the crane by the manual control under such a condition, turn OFF the receiver power switch to place the unload valve in the on-load state. When the problem is caused by the failure of the solenoid for unload valve (SV1), the valve is not made in the on-load state even by the above operation. For TM-Z100-2 to TM-Z290-2, use the stop valve to mechanically place it in the on-load state (for the operation method, refer to the section of stop valve on page 19), and operate the crane manually. In the event of a minor error, the valve corresponding to the flashing LED does not operate, but the unload valve stays in the on-load state, allowing manual operation of the crane. When a two-blocking state occurs, no error code is indicated, but the boom extending and hoisting up motions are all disabled. (The both operations can be performed under manual control.) 29

33 [3] Telescoping indicator lamp (LED1 (red)) Steadily lights up or flashes to indicate the drive pulse of telescoping valves (SA1, SB1), and to display probable error section (for details, refer to the Troubleshooting section) by combining with other indicator lamps (LED0 to LED5). <Indication of valve drive pulse> When the valve is driven by signals from the transmitter, the LED is lit for the time period equivalent to the drive pulse width. In other words, while the directional control valve spool is moving, the LED is lit. When the directional control valve spool reaches the position set by the speed control lever of receiver, the valve is retained at the position, thus the drive pulse is no longer output. As a result, the LED goes out. In Fig. 25 below, the relationship between pulses output to SA and SB with SA driven and drive pulse indication is illustrated. Lit Unlit Control start Target value reached Corrective operation (in the event of a deviation from the target value) that may occur with the lapse of time Caution When the directional control valve spool is moved full stroke, SB1 is turned OFF and LED1 lights up upon reach of the stroke end. [4] Winch indicator lamp (LED2 (red)) Lights up or flashes to indicate the drive pulse of winch valves (SA2, SB2) and to display probable error section by combination with other indicator lamps (LED0 to LED5). [5] Elevating indicator lamp (LED3 (red)) Lights up or flashes to indicate the drive pulse of elevating valve (SA3, SB3) and to display probable error section by combination with other indicator lamps (LED0 to LED5). [6] Swing indicator lamp (LED4 (red)) Lights up or flashes to indicate the drive pulse of swing valves (SA4, SB4) and to display probable error section by combination with other indicator lamps (LED0 to LED5). [7] Accelerator indicator lamp (LED5 (red)) Lights up or flashes to indicate the drive pulse of accelerator valves (SA5, SB5) and to display probable error section by combination with other indicator lamps (LED0 to LED4). 30

34 [8] Pin header (for setting ID code) The pin headers used for setting a unique ID code are installed on the board in the receiver, and sets a data code for multiplex data transmission. (For details, refer to the Pin header section in (3) Transmitter.) Pin header Fuse [9] Fuse (2A) Protects the electronic circuit against a short circuit. (For the location of the fuse, refer to Fig.37.) [10] BNC connector Connect the cable from the antenna. [11] Metal connector Connect the cable from the control valve. 31

35 Troubleshooting The receiver of the radio controller system has programmed diagnosis functions (self-diagnosis functions) for the system components except the transmitter, whereas the transmitter incorporates diagnosis functions for the transmitter itself. The receiver and transmitter also have capabilities to indicate errors. When an error occurs in the radio controller system, refer to and follow the troubleshooting chart shown below to locate the error section. Before determining a symptom, conduct the check at least two times. Remember that the hydraulic circuit state, transmitter power switch positions and receiver power switch positions are related with one another as shown in the following table. Receiver power switch position Transmitter power switch position Hydraulic circuit state (position of unload valve (SV1)) OFF ON or OFF On-load ON OFF Unloaded ON On-load (Note) 1. When the receiver makes a serious error judgment with both the receiver power switch and transmitter power switch ON, the hydraulic circuit becomes the unloaded state. 2. In the table above, when the hydraulic circuit is in the on-load state, manual operation is allowed. Troubleshooting Charts Radio controller system is out of order. When receiver power supply is turned ON During operation, transmitter and receiver power ON When transmitter power supply is turned ON 32

36 Was power ON operation normal? Any of LEDs fails to light. All LEDs fail to light. 1. Shows the case where any of 6 LEDs (LED0 to LED5) do not light up. - Then, were all LEDs OFF? - Then, did LED0 to LED5 light up sequentially? (New Radio Law conforming unit) Replace receiver ass y. Refer to the receiver LED table. Check whether or not: - The metal connector from the control valve is connected. - The batteries are properly connected. - All the fuses are good. - The ground cable is properly connected. - The PTO switch is ON. Did receiver power supply LED0 illuminate when receiver power supply is turned ON? Did LEDs on transmitter illuminate? Check whether or not: - The antenna is connected to the receiver. - The transmitter antenna is set in position. - The antenna cable is broken Check whether or not: - The transmitter to receiver distance is not more than 30 m (20 m for New Radio Law conforming part). - There is an obstacle like a metal net between the transmitter and receiver. Was the operation select switch left pressed or the speed control lever left pulled? The transmitter determines this state as error. Release the switch or lever and start the operation again. Install the batteries correctly. - Are transmitter batteries in position? - Are battery positive and negative poles in correct directions? Check whether or not: - The ID codes are in agreement. Replace the batteries. 33

37 The associated solenoid valve is held in open position (because of dust, etc.) The associated solenoid valve is held in open position (because of dust, etc.) 1. After operation of transmitter Does each valve (including accelerator) operate normally? Are transmitter s operation select switches and speed control lever potentiometers normal? - If any of operation select switches are in failure, replace the upper case ass y. - If the speed control lever potentiometer is in failure, replace the lever case ass y. All valves do not operate. Some valves do not operate. The associated solenoid valve is held in open position (because of dust, etc.) Does each valve operate smoothly? Do all valves operate smoothly? - Replace the receiver ass y. - The associated solenoid valve is held in open position (because of dust, etc.) Does the same phenomenon occur near the antenna? Poor radio transmission conditions around transmitter and receiver. Change frequencies or wait for a while until conditions improve. No error Replace transmitter ass y or receiver ass y. For information on how to change frequencies, refer to the Construction and Functions section. 34

38 TM-Z300-2 to TM-Z500-2 Is manual control possible? - The unload solenoid valve (SV1) is held in open position (because of dust etc.) - The main relief valve (E) is held in open position (because of dust, etc.) Is pressure of back pressure regulating valve (C) normal? kg/cm 2 0 The back pressure regulating valve (C) is held in open position (because of dust, etc.) Test port: PG port Is pressure of reducing valve (D) normal? kg/cm 2 0 Test port: PI port The spool of reducing valve (D) is malfunctioning, or the circuit protection relief valve (F) is held in open position (because of dust, etc.) The choke located behind the reducing valve (D) is clogged with dust etc. 35

39 TM-Z100-2 to TM-Z290-2 Is manual control possible? - The unload solenoid valve (SV1) is held in open position (because of dust etc.) - The main relief valve (E) is held in open position (because of dust, etc.) Is pressure of back pressure regulating valve (C) normal? 20±2 kg/cm 2 The back pressure regulating valve (C) is held in open position (because of dust, etc.) Is pressure of reducing valve (D) normal? kg/cm 2 0 The spool of reducing valve (D) is malfunctioning, or the circuit protection relief valve (F) is held in open position (because of dust, etc.) Test port: PG port Test port: R port (Refer to the Maintenance Standard section.) (Note) The pressure at the R port can raise to kg/cm 2 0 pressure setting for the relief valve (F) because there may be leakage from the spool of reducing valve. Check again from the beginning. 36

40 Is transmitter power indicator LED ON? - If an operation select switch is kept pressed continuously for more than five minutes, the transmitter judges it as an error and the transmitter's power supply is automatically turned OFF (the LED of the transmitter will go out). To resume operation, press the power switch of the transmitter again. - If none of the operation select switch is pressed for 10 minutes, the power supply of the transmitter is turned OFF automatically by the automatic power OFF function for energy saving (the LED of the transmitter will go out). To resume operation, press the power switch again. Is receiver LED indication normal? Refer to the receiver LED table. Are only the boom telescoping and hoisting-up operations impossible? The two-blocking detection switch is in the ON state. Perform the hoisting-down operation to clear the two-blocking state. The operation stops intermittently? Check whether or not: - The transmitter to receiver distance is more than 30 m (20 m for New Radio Law conforming unit). - There is an obstacle like a metal net between the transmitter and receiver. - The receiver antenna is set in position. - The antenna is not properly connected to the receiver. The radio wave condition around the radio controller may be poor. Change frequencies or wait for a while until conditions improve. Eliminate these problems and carry out the operation again. If the conditions are not improved, replace the transmitter ass y or receiver ass y. 37

41 Is receiver power switch ON? Turn ON the receiver power switch. 38

42 Receiver LED indication, error and remedy LED indication code : Lit : Continuously flashing (n): n = 1, 2, 3, 4, 5, (Each repeats flashing 1 to 5 times.) <Example> The indication pattern (3) of the telescoping indicator LED appears. Unload valve (SV1) symbol : Onload position : Unload position Note When pattern (n) (= (1) to (5)) is indicated by flashing, the solenoid valves (SA, SB) in the associated (error) section do not operate. LED0 to LED5 all light up immediately after the receiver power switch is turned ON. At this time, check whether each of LEDs is burnt out. No. LED indication Unload valve (SV1) Probable error section 1 - WDT error - (1) CPU, memory, and their peripheral circuits (2) Errors in program processing due to noise 2 - A/D converter error - (1) A/D converter, multiplexer, etc. 3 - Sum check error - (1) CPU, memory, and their peripheral circuits 4 - Other errors - (1) CPU, memory, and their peripheral circuits 5-24 V error - (1) Abnormal drop or abnormal rise of battery voltage (2) Short-circuit, loose contact, etc. due to incorrectly connected battery wiring 6 - Unload valve solenoid error - (1) Unload valve solenoid open-circuited (2) Wiring for unload valve solenoid open-circuited, in loose contact (3) Unload valve solenoid driving transistor (IC) out of order (on receiver) Remedy Replace the receiver ass y. Replace the receiver ass y. Replace the receiver ass y. Replace the receiver ass y. Make sure that voltage supplied to the receiver is between 18 and 32 V. Check for open circuit by tester. Repair or replace if necessary. Solenoid resistance: 35 to 43 Ω (NACHI make) 33 to 41 Ω (SANWA make) Replace the receiver ass y. 39

43 No. LED indication Unload valve (SV1) Indication pattern (3) of the LED corresponding to the error section appears. Indication pattern (1) of the LED corresponding to the error section appears. Probable error section - Solenoid valve, horn relay coil short circuit error - (1) There is a short circuit to ground in unload valve, horn relay coil, and a side and b side wiring of solenoids (SA, SB) for individual valves (wirings from the valves to the receiver). (2) Wiring, connector for the parts in (1) above short-circuited (3) Common wire (+24 V) for SA and SB solenoid short-circuited (4) Individual solenoid driving transistors (IC) out of order (on receiver) - Control cylinder return-to-neutral error - (1) Control cylinder concerned does not operate smoothly because of dust, or is locked at a position out of the neutral position. - Solenoid a side open circuit error - (1) a side wiring for solenoid (SA) of valve concerned (the wiring from the valve to the receiver) open-circuited (2) Wiring, connector for the solenoid in (1) above open-circuited, in loose contact, or incorrectly connected (3) Drive transistor (IC) for the solenoid in (1) above out of order (on receiver) Remedy Check for short circuit by tester. Repair or replace if necessary. (In the event of a short circuit, the measurements appear as if all the parts were short-circuited. Split the circuits into sections corresponding to the parts by disconnecting the connectors during measurements.) Solenoid resistance (NACHI make): 34 to 42 Ω Solenoid resistance (SANWA make): - For unload valve: 33 to 41 Ω - For each valve: 34 to 42 Ω Horn relay coil (NACHI make, SANWA make): 990 to 1210 Ω Replace the receiver ass y. Manually operate the control cylinder to check its condition. If it does not operate smoothly because of dust or is locked, replace (or repair) the valve concerned. When the valve is unavoidably used without replacement or repair (however, it is recommended to replace or repair it as soon as possible), turn on the receiver power supply again, then if a neutral position error does not occur, reuse the valve and check the operating state. (If a neutral position error occurs, replace or repair the corresponding valve.) Check for open circuit by tester. Repair or replace if necessary. [Solenoid resistance: 34 to 42 Ω] Replace the receiver ass y. 40

44 No LED indication Indication pattern (2) of the LED corresponding to the error section appears. or (Transmitter power supply ON) Indication pattern (3) of the LED corresponding to the error section appears. or Unload valve Probable error section (SV1) - Solenoid b side open circuit error - (1) b side wiring for solenoid (SB) of valve concerned (the wiring from the valve to the receiver) open-circuited (2) Wiring, connector for the solenoid in (1) above open-circuited, in loose contact, or incorrectly connected (3) Drive transistor (IC) for the solenoid in (1) above out of order (on receiver) (4) If all LEDs flash, the common wiring for SA or SB solenoid (+24 V) open-circuited, or in loose contact or connected incorrectly at connectors. - Differential transformer neutral position error - (1) The control cylinder concerned is not in the neutral position. (2) The differential transformer circuit concerned in receiver is out of order (3) If all LEDs flash, the receiver is out of order. Remedy Check for open circuit by tester. Repair or replace if necessary. (Solenoid resistance: 34 to 42 Ω) Replace the receiver ass y. Check for open circuit by tester. Repair or replace if necessary. (Solenoid resistance: 34 to 42 Ω) Manually operate the control cylinder to check whether or not the LED concerned turns OFF. (If the LED disappears, adjust the shim.) If the LED remains on, connect the satisfactory differential transformer to connector SWP2 or SWP5 (NACHI make) or SWP2 or SWP6 (SANWA make) to check whether or not the LED goes out. (If the LED goes out, replace the differential transformer with the satisfactory one.) Replace the receiver ass'y if the above remedy does not solve the problem. Replace the receiver ass y. 12 (Transmitter power supply ON) or (Transmitter power supply ON) Indication pattern (4) of the LED corresponding to the error section appears. or - Differential transformer output error - (1) The differential transformer circuit concerned in receiver is out of order. (2) If all the LEDs flash, the receiver is out of order. Check whether or not the error condition is cleared when the receiver ass'y is replaced. If the condition is cleared, replace the receiver ass'y with a satisfactory one. Replace the receiver ass y. (Transmitter power supply ON) 41