SMARTDRIVE PREMIER SYSTEM ELECTRONIC TRACTION AND HYDROSTATIC TRANSMISSIONS CONTROL

Transcription

1 SMARTDRIVE PREMIER SYSTEM ELECTRONIC TRACTION AND HYDROSTATIC TRANSMISSIONS CONTROL T E C H N I C A L C A T A L O G

2 SmartDrive Premier System Methodology : This document is intended for manufacturers of machines that incorporate Poclain Hydraulics products. It describes the technical characteristics of Poclain Hydraulics products and specifies installation conditions that will ensure optimum operation. This document includes important comments concerning safety. They are indicated in the following way: Safety comment. This document also includes essential operating instructions for the product and general information. These are indicated in the following way: Essential instructions. General information. Information on the model number.information on the model code. Weight of component without oil. Volume of oil. Units. Tightening torque. Screws. Information intended for Poclain-Hydraulics personnel. The views in this document are created using metric standards. The dimensional data is given in mm and in inches (inches are between brackets and italic) 2 15/01/2014

3 SmartDrive Premier System CONTENT CHARACTERISTICS 4 Foreword 4 Operating principles 5 System main characteristics 7 SmartDrive Off-Road System Diagram of working principles 9 SmartDrive Master System Description of functions 10 ACCESSORIES 13 SmartDrive ECU 13 Input / output characteristics 15 Communication connector 17 SmartDrive communication cable pin main connector 19 SmartDrive Master cable 21 SmartDrive Off-Road cable 22 Traction control (in-line) valve 23 Traction control (flanged) valve 25 AMP Connector 27 Speed sensor T4 28 M12 cable 30 Rotary potentiometer 31 SmartDrive Premier identification 33 SmartDrive Premier list of components 34 Accessories Characteristics INSTALLATION SmartDrive Off-Road System setting parameters, downloading, calibration, diagnostics 43 First level diagnostic 44 Appendix 46 15/01/2014 3

4 CHARACTERISTICS SmartDrive Premier System FOREWORD The SmartDrive TM Premier consists of the SmartDrive TM Off-Road System and SmartDrive TM Master System functions. SmartDrive TM Off-Road System foreword Hydrostatic transmissions have an inherent differential function. As consequence, the maximum torque which can be transmitted to drive wheels supplied by one pump is limited by the wheel with the poorest adhesion. Loss of adherence can cause loss of control or immobilization of the vehicle, premature tire wear, excess fuel consumption or damage to the ground. The SmartDrive Off-Road System from Poclain Hydraulics provides complete control of wheel speed, thus preventing such problems. SmartDrive TM Master System foreword Poclain Hydraulics has created and developed SmartDrive TM Master System, a system that simplifies and optimizes the running of hydrostatic transmissions of mobile machinery. It comprises a computer that regulates the running of hydrostatic transmission components (engine, hydraulic ground drive pump, hydraulic motors, and brakes) through sensors and actuators. The on-board software calculates the machine's ground drive speed in accordance with the driver setting and the programmed acceleration and deceleration ramps. These ramps, which are among the many parameters that enable the machine's behavior to be customized, determine the vehicle's responsiveness and aggressiveness.the combination of the flexibility of the electronics and the power of the hydraulics makes this a system which can be adapted and set up for all driving styles. It consists of the following components: Flow control valve Wheel speed sensor Turn sensor SA control pump Regulating computer Set-up / Calibration / Diagnostic by computer Hand held terminal Set-up / Calibration / Diagnostic by computer 4 15/01/2014

5 SmartDrive Premier System OPERATING PRINCIPLES SmartDrive Off-Road System operating principles The speed sensors incorporated in the hydraulic motors continuously measure the rotation speed of each powered wheel. The regulating computer compares those speeds and if necessary reduces hydraulic flow to the wheel which is slipping. (by means of a regulating valve). Unlike traditional flow dividers the system engages ifself only when wheel slip occurs. Only one pump is required for a vehicle with two or more drive wheels. SmartDrive Off-Road System standard configuration In the standard configuration of the Off-Road System the double regulating valves are located on the hydraulic motor supply lines. On a flat surface Example of a four drive wheel machine running on a flat surface in a straight line, in perfect conditions (perfect adherence, identical tire rolling circumference ): Pressures at P, P1 and P2 are equal; Flow Q = Q1 + Q2; The rotation speeds of the wheels number 1 and 2 are the same. If the wheel number 1 loses adherence : The overall circuit pressure falls to the one dictated by wheel number 1, which is slipping; Flow Q1 becomes greater than Q2; The rotation speed of wheel n 1 increases and the one of wheel number 2 falls to zero speed. If there is no traction control, this will cause the machine to stop. The SmartDrive Off-Road System controls wheel speeds by varying the flow (of wheels supply) within the double regulating valve (1). It reduces flow Q1 and increases the pressures P and P2 to provide machine traction and prevent wheel skid consequences. When all the wheels have reached the same rotation speed, the double regulating valve (1) opens completely. It will only close if a difference in wheel speed occurs again. This control system operates continuously. The regulating mechanism comes into play only in accordance with the parameters which have been set by the machine manufacturer. Accessories Characteristics When traveling down a slope The system works on the flat surface as well as up or down grades. For machines which need to operate on slopes in excess of 20%, the following configuration is recommended by Poclain Poclain HydraulicsHydraulics. Steep slope circuit: For machines which have to work on steep slopes (e.g. grape-harvesters, post emerge sprayers) the double regulating valve is installed on the return circuit of the front wheel. The system will then limit the return flow from the front motors and control the speed of the machine on the slope. Turn detection The SmartDrive Off-Road System operates also during turns. It detects the machine's turning direction (to the right, to the left or straight on) by means of a turn detector and either disable the regulation or corrects the flow to the wheels depending on the steering geometry. 15/01/2014 5

6 SmartDrive Premier System SmartDrive Master System operating principles The SD Master System ECU (Electronic Control Unit) regulates the running of the transmission elements (hydraulic pumps, engine, hydraulic motors, and brake) through sensors and actuators. It can therefore manage the whole transmission, offer various driving modes adapted to the vehicle and the driver, control the braking, and can offer multiples control points for the transmission's components. Block diagram with management of two dual displacement motors Auxiliary Setup C B C1 A C2 D It comprises: A. A regulation computer specific to the transmission control system; B. An actuator controlling the engine; C. One or two pumps with power assisted controls, fitted with a C1displacement control solenoid, a C2 (swashplate position) feedback potentiometer, a speed sensor and 500-bar pressure sensor; D. A joystick or pedal, mode selection switch, fault light, stop light, speed sensor display, etc. 6 15/01/2014

7 SmartDrive Premier System SYSTEM MAIN CHARACTERISTICS SmartDrive Off-Road System main characteristics Description Characteritics Number of wheels controlled by the system 2 to 4 Number of steering wheels or articulated machine 2 to 4 Number of wheels controlled by one valve 1 to 2 Maximum flow regulated per wheel 50 l/mn [13.2 GPM] Maximum flow without regulation per wheel 120 l/mn [31.7 GPM] Maximum turn detectors range ± VCC Supply voltage 24 VCC Hydraulic circuit maximum pressure 450 bar [6500 PSI] Type of use High pressure (heavy duty) Operation temperature 25 C à 70 C [-13 F to 158 F] Oil temperature -10 C à 100 C [14 F to 212 F] Features Traction control of each wheel by the electro-hydraulic system Digital measurement of wheel speed (possible use of CAN bus) Steering angle measurement (optional sensor) Examples of parameters Mechanical parameters specific to the machine Wheel circumference, type of the turn detection, Turn angle, wheel track, etc Parameters setting according to the application (3 levels of access authorization : user, manufacturer, expert) Regulation activation, minimum and maximum action speed, number of wheel to regulate, etc also offers the hydraulic synchronized transmission system using torque transfer,ms motors with TWINLOCK Accessories Characteristics 15/01/2014 7

8 SmartDrive Premier System SmartDrive Master System main characteristics Description Supply voltage Hydraulic circuit maximum pressure Intensity of use Operating temperature Characteritics 12 V DC 24 V DC 450 bar [6500 PSI] Medium to high pressure (medium to heavy duty) - 25 C à 70 C [- 13 F to 158 F] Functions Are specific to each application. In general the system offers: Hydrostatic transmission control: automatic displacement shift, management of engine rotation speed, power restriction, anti-stall, etc. Brake management Front/rear axle differential lock Signaling Speed regulation (cruise control) Limp mode management Examples of parameters The parameters can be set for each application either using the PHASES software or the portable hand held terminal. They may also be subject to special access authorization. They govern the: pump (displacement threshold for shifting from 1st to 2nd displacement; maximum permitted displacement for pump No. 1). engine (speed, etc.) hydraulic motor (displacement) brake valves (dynamic brake pressure at rest) sensors (emergency brake pressure detection threshold, etc.) cruise control function driving modes, (automotive, etc). 8 15/01/2014

9 SmartDrive Premier System SMARTDRIVE OFF-ROAD SYSTEM DIAGRAM OF WORKING PRINCIPLES Front right Rear right Front left Rear left Accessories Characteristics The SmartDrive Off-Road System consists of the following components: (a)one control regulating computer dedicated to the traction control system; (b)one double regulating valve providing regulation of the input flow of the two motors on the same axle; (c)1 or 2 turn detectors (potentiometer or On/Off sensor); (d)one speed sensor which must be installed on each regulated motor; (e)switch (on/off), operation warning light, speed display To obtain optimum traction control in turns POCLAIN HY- DRAULICS recommends to use a potentiometer turn detector. hydraulic motors used with the SmartDrive Off-Road System must be installed with motor equipped with speed sensor or speed sensor predisposition. (see speed sensor ). 15/01/2014 9

10 SmartDrive Premier System SMARTDRIVE MASTER SYSTEM DESCRIPTION OF FUNCTIONS Driving modes With agricultural machinery, the driver can have two operating configurations as standard: [ Road Mode ] This is an automotive type of driving, similar to an automatic transmission. The transmission ratio is established automatically by the load management of the engine, pump displacement and hydraulic motor displacement. The load on the engine is therefore related to the vehicle speed, enabling pollution and fuel consumption to be reduced. [ Field Mode ] The load on the engine is constant; the auxiliary tools consume the majority of its power. It is possible to define other modes, depending on the nature of the work to be carried out and the environment. Hence these ground drive defining parameters may be different from one [ Field Mode ] to another. The operational design specifications book for the vehicle transmission sets these parameters. Shifting between modes is done under different safety conditions managed by the SD Master ECU: for example a sprayer can only shift to [ Road Mode ] if the spray bars are folded back. For a forklift truck type application, we can distinguish other driving modes: [ Mode 1 ]: for novice forklift drivers: driving with safety features (limited max speed, lower acceleration rate, etc.) [ Mode 3 ]: for experienced forklift drivers: driving is more responsive and reactive (rapid acceleration). [Inching Mode ]: simultaneous application of the brake and accelerator pedals produces an inching effect (hydraulic clutch control that enables slow movement independent of the engine load). Machine transmission control Automatic displacement shift A SmartDrive Master System transmission varies speed continually. Depending on the acceleration or brake settings issued by the driver, hydraulic motor displacement shift is surge-free. This is accomplished by simultaneous pump displacement control and motor displacement shift control. So since everything takes place nearly automatically, the driver can concentrate on more tasks with greater added value, such as the machine's working functions, and particularly tool management. Rotation speed management of the engine The SD Master ECU can integrally manage the engine in two ways: by means of an actuator by means of a CAN Bus The ECU optimizes the rotation speed of the engine for the requested power level. Anti-stall function In [ Field Mode ], this function reduces the pump speed to prevent the engine stalling if the power required by the hydrostatic transmission exceeds the engine's available power. Limitation of ground drive power Agricultural machinery has engines which are generally oversize for the ground drive requirements for supplying the power needed for the onboard tools in [ Field Mode ]. In [ Road Mode ], there is no protection; the engine's full power is available. Limiting the integrated power in a transmission controlled by a SmartDrive Master System therefore protects the hydrostatic transmission from possible excess output, which could cause irreversible damage over time. Detection of pump fluid contamination The SmartDrive Master ECU is capable of detecting possible oil contamination by using the pump feedback control and a potentiometer that tells it the position of the pump's cam casing swashplate. This element protects against malfunctions caused by pump displacement shifts /01/2014

11 SmartDrive Premier System Brake management Service brake (dynamic) The brake pedal: activates mechanical braking, reduces the pump displacement via the SmartDrive Master ECU. The braking system is of the combined type, i.e. the mechanical braking torque combines with the hydrostatic transmission's braking torque (pump speed reduced). The SmartDrive Master System manages the pump and hydraulic motor displacement reduction by taking account of the level of mechanical braking, so that the hydrostatic transmission prevents possible wheel lock. Parking brake The parking brake is held by the spring force. To deactivate this brake, the driver activates either a switch, a lever or a foot control. These components then transmit pressure to the brake pistons, which overcome the spring force. Emergency stop If the parking brake switch is activated for an emergency stop, the mechanical parking brakes and the hydrostatic brake engage by means of a pump displacement ramp managed by the Smart Drive Master System. Front/rear axle differential lock This function is available for transmissions fitted with four hydraulic motors and a PW tandem pump. In [ Field Mode ], it isolates the hydraulic circuits of each front and rear axle using an electro-hydraulic valve. Speed regulation or "Cruise control" When using the machine for field operations, the driver may require a regulated constant ground drive speed. There are two possible arrangements: 1 - The operator depresses a push button that activates the "Cruise Control" function. At that moment, the traveling speed of the machine is taken as a reference. The ECU manipulates the pump speed setting to maintain the desired speed. The "Cruise Control" function can be overridden by depressing either the brake pedal or a button. 2 - The driver programs in the max speed to be reached in this "Cruise Control" function using the push buttons. The rest of the operating principle is the same as the 1st instance. The max programmed speed will then be attained for the joystick entire stroke (the control lever for the pump displacement). Accessories Characteristics 15/01/

12 SmartDrive Premier System Constant speed with combined auxiliary control In [ Field Mode ], the machine's ground drive speed remains constant in spite of the acceleration of the engine required to the auxiliary functions. The operator, now freed from controlling the speed, can concentrate on tasks with higher added value. Default Options Emergency stop Stop Cruise control Controls Pump pressure Pump speed Parking brake Engine load Pump displacement control Pressure Speed Motor displacement shift Acceleration / Deceleration Hydraulic braking Hydraulic motor speed Brake Example of driving position and types of information sent to SmartDrive Master Signaling The ECU manages the signaling (braking, reverse lights, warning beep, etc.) depending on the ground drive condition. Limp mode management Depending on possible faults with the transmission, various operations are possible in degraded mode, to enable minimal ground drive. These degraded modes may be defined in certain cases by agreement with the manufacturer. CAN Bus communication The ECU presents a standard 2.0A or the applied 2.0B CAN interface. When connected to the machine's CAN network, the SmartDrive Master ECU can therefore: Receive messages (engine setting, joystick, selectors, etc.) Send messages (signaling, fault indicator, error message, etc.) CAN customization requires major configuration in terms of the complexity of the architecture of the CAN for each manufacturer. Please consult your sales engineer /01/2014

13 ACCESSORIES SmartDrive Premier System SMARTDRIVE ECU Commercial name SD Off-Road box SD Master box SD Premier box Part number G F A11999S Features Material Mass Operating temperature Aluminium kg [4.07 lb] -25 C to 70 C [-13 F to 158 F] Mounting 4 x Ø 7 mm 4 x [0.28 dia.] Protection index of ECU with its connectors IP65 (weather proof) Electricity supply 12 V cc - 24 V cc Current 8 A 14A 20A Electrical protection Excess voltage, Inverter Polarity Microprocessor 16 bits Microprocessor frequency 20 MHz ECU setup with a PC or setup terminal Electromagnetic compatibility Associated software CISPR 25 : Measure of electromagnetic and radiated emissions. NF R : Susceptibility to the radiations of electric fields. ISO 7637 : Immunity to transitory overvoltages. ISO/CD : Immunity to electrostatic discharges e marking (Directive 2009/19/EC) The control software is adjusted for each application (see p.18). The software can be customized for each application. Poclain Hydraulics recommends that you consult your sales engineer. Setting parameters You can set parameters either by a hand held terminal or by an software called PHASES TM. See page 18. Accessories Characteristics 15/01/

14 SmartDrive Premier System Layout of SmartDrive Premier box Chassis fixing Quantity Class N.m [lb.ft] ± 10 % M ±1 [7.37±0.73] Electrical connections Communication connector COM-SD-CONNECTOR-PLUG Main connector KIT-CONNECTOR-MAIN-SD SmartDrive TM Master cable (1 m) CABLE-SD-MASTER SmartDrive TM Master cable (5 m) CABLE-SD-MASTER SmartDrive TM Off-Road cable (1 m) CABLE-SD-OFFROAD SmartDrive TM Off-Road cable (5 m) CABLE-SD-OFFROAD Communication cable (1m) COM-CABLE-SD-1000 Communication cable (5m) COM-CABLE-SD-5000 When wiring, check that the wire can neither be cut off, nor torn off when the machine is working or moving /01/2014

15 SmartDrive Premier System INPUT / OUTPUT CHARACTERISTICS On-Off digital inputs (x 15) The sensors read are NPN. Description Min. Max. Maximum current for pressure switch digital input (pin 5, 6, 7 on SmartDrive Master connector) - 54 ma Maximum current for other digital input - 12 ma Analog inputs (x 11) Description Min. Max. Measurement range 0 V 5 V Accuracy - 1 % Input impedance 100 k Frequency inputs (x 4) The sensors read can be NPN and PUSH/PULL. Description Min. Max. Measurement range 0 Hz 1,5 khz Maximum voltage for a low level - 1,5 V Minimum voltage for a high level 8 V - Differential frequency inputs (x 1) The sensors read can be PUSH/PULL and variable reluctance. For PUSH/PULL sensor only Freq (+) has to be connected. Description Min. Max. Measurement range 0 Hz 8,5 khz Maximum voltage for a low level for PUSH/PULL sensor - 1,5 V Minimum voltage for a high level for PUSH/PULL sensor 8 V - Minimum peak to peak voltage for variable reluctance sensor 500 mv - Accessories Characteristics Digital outputs (x 10) Description Min. Max. Maximum current - 0,5 A under 12 V 0,25 A under 24 V Output voltage Vbat - 1 V Vbat PWM outputs dedicated to pumps with SA control (x 2) Description Min. Max. Maximum current - 2,4 A under 12 V 1,2 A under 24 V Frequency PWM - 10 khz Analog PWM outputs (x 4) These outputs are protected against short circuits and overvoltages. Description Min. Max. Maximum current - 1,5 A under 12 V 0,75 A under 24 V Frequency PWM 80 Hz 100 Hz 15/01/

16 SmartDrive Premier System Digital PWM outputs (x 4) These outputs are protected against overvoltages. Description Min. Max. Maximum current 0 2 A under 12 V 1 A under 24 V H bridge outputs (x 1) Description Min. Max. Maximum current - 3 A Maximum output voltage - Vbat Frequency PWM 61 Hz 300 Hz Sensors power supply 5 V Description Min. Max. Maximum current ma Output voltage 4,90 V 5,10 V Sensors power supply 12 V Description Min. Max. Maximum current ma Output voltage if Vbat > 13,25 V 11,50 V 12,50 V Output voltage if Vbat < 13,25 V Vbat - 0,75 V 16 15/01/2014

17 SmartDrive Premier System COMMUNICATION CONNECTOR Commercial name Part number Features Componants Communication wiring COM SD LT CONNECTOR KIT Q Bayonet connector 14 pins Cable diameter: [ ] With PC For Hand Held Terminal Commercial name SD PC LT CABLE SD HHT LT CABLE Connector mounting Unscrew the connector sub-assemblies. Passthe cable through the securing elements. Strip the wires to a length of 5 mm [0.19 in]. Solder the wires on to the pins as shown in the table below. Accessories Characteristics 3. Remount the connector by screwing the securing elements to one another. PIN J1 Function Wire section mm² A NC Not connected B NC Not connected C NC Not connected D NC Not connected E CANL Low CAN signal 0.22 F CANL Low CAN signal 0.22 H NC Not connected J NC Not connected K CANH_120 Connexion for CAN bus end 120 Ù 0.22 L NC Not connected M CANH High CAN signal 0.22 N CANH High CAN signal 0.22 P GND ground 0.22 R GND ground 0.22 A 120 ohm bus termination resistor can be installed between K and E, or K and F. ECU side view 15/01/

18 SmartDrive Premier System SMARTDRIVE COMMUNICATION CABLE Commercial name COM-CABLE-SD-1000 COM-CABLE-SD-5000 Part number A20360F A20361G Function Connect a SmartDrive TM ECU communication elements to the machine wiring. Compatibility Electronic transmission management with SmartDrive TM ECU. Features Lenght of cable 1m 5m Material PVC Number of wires 14 Sections of wires 0.22mm 2 Layout or Electrical wiring Pin A B C D E F H J K L M N P R Wire White Brown Green Yellow Gray Pink Blue Red Black Violet Gray/Pink Red/Blue White/Green Brown/Green 18 15/01/2014

19 SmartDrive Premier System 56-PIN MAIN CONNECTOR Commercial name Part number MAIN SD CONNECTOR KIT P Features Connectors: 211PC562S0008 Locking cam: 211A Protective cover: 211A Pins: 211CC2S1120 (x60) Components Stoppers (when a pin is not used): 210A (x60) Protection index IP 68 Cable section 0.35 to 2 mm² [ to in²] Fitting the main connector Locking device position A. Place the black unit on the ECU. Note its position and separate its from the ECU. Accessories Characteristics Insert the purple locking device into the unit from the botton to the top and push until it clicks. B. The cable will have to be positioned on the locking device side. Fitting the connector 1. Unclip the 2 yellow supports. 2. Remove these supports. 3. Turn the unit over. 15/01/

20 SmartDrive Premier System Fitting the main connector 4. Strip the wire over 4 mm. Crimp each conductor on its lug using pliers FCI211S005. Insert each lug into the connector as shown in the electrical circuit diagram in the appendix. 5. In case of error, use extraction tool to remove the lug. 6. Insert the green plugs into the free ports of the connector. 7. Clip on the 2 yellow supports. Position the cover and lower it. 8. The cover tab (A) must be on the right of the unit tab (B). 9. Lock it by pulling on it until there is a click. 10. Secure the cable uising a cable grip. Removing the locking device 12. To remove the purple locking device, press as shown. 13. Partially pull out the locking device, press as shown. 14. Repeat point 12 on the other side, and completely remove the locking device /01/2014

21 SmartDrive Premier System SMARTDRIVE MASTER CABLE Commercial name CABLE-SD-MASTER CABLE-SD-MASTER Part number A20309A A20310B Function Connect a SmartDrive TM Master ECU or a SmartDrive TM Premier ECU (J1) to the machine wiring. Compatibility Electronic transmission management with SmartDrive TM Master ECU or SmartDrive TM Premier ECU. Features Lenght of cable 1m 5m Material PVC Number of wires 56 Sections of wires 1mm 2 Accessories Characteristics Layout or Electrical wiring The wires of the cable are numbered. Pin Wire green/yellow 15/01/

22 SmartDrive Premier System SMARTDRIVE OFF-ROAD CABLE Commercial name CABLE-SD-OFFROAD CABLE-SD-OFFROAD Part number A22473C A22475E Function Connect a SmartDrive TM Off-Road ECU or a SmartDrive TM Premier ECU (J2) to the machine wiring. Compatibility Electronic transmission management with SmartDrive TM Off-Road ECU or SmartDrive TM Premier ECU. Features Lenght of cable 1m 5m Material PVC Number of wires 56 Sections of wires 1mm 2 Layout or Electrical wiring The wires of the cable are numbered. Pin Wire green/yellow 22 15/01/2014

23 SmartDrive Premier System TRACTION CONTROL (IN-LINE) VALVE Q < 20 l/min [5.2 GPM] 20 [5.2 GPM] < Q < 50 l/min [13.2 GPM] Flow / voltage 12 V 24 V 12 V 24 V Commercial name VMA-020-T VMA-020-T VMA-050-T VMA-050-T Part number J J K H Function Proportional Flow Control Valve used to regulate a control wheel slip Compatibility Electronic transmission management Accessories Characteristics Hydraulic symbol Pressure loss P bar P [PSI] The valves must be supplied at G with a pressure of between 15 and 30 bars [217 PSI and 435 PSI]. Maximum flow, from P to A or B, for a fully open valve, is 120 l/min [31.7 GPM] per wheel with a pressure difference ( P) of 5 bars [72 PSI] (96 cst mineral oil at 25 C [77 F]). 15/01/

24 SmartDrive Premier System Layout Block position when fixing Chassis fixing Horizontal. Ref. Quantity Class N.m [lb.ft] ± 10 % (as per standard DIN 912) 1 M [36] Motor and valve drain piping must be connected directly to the tank. Hydraulic connections Port Function Connection Max pressure bar [PSI] N.m [lb.ft] ± 10 % P HP connection Bride DN 25 PN [6000] 90 [66] A-B HP connection M 27 x [6000] 200 [148] F Drain M 14 x [14] 45 [33] G LP supply M 14 x [217] P < 30 [435] 45 [33] M1-M2 Pressure measurement M 14 x P < 20 bar [290] 45 [33] Electrical connections on E1 and E2: 24 15/01/2014

25 SmartDrive Premier System TRACTION CONTROL (FLANGED) VALVE Flow / voltage Q < 20 l/min [5.2 GPM] 20 [5.2 GPM] < Q < 50 l/min [13.2 GPM] 12 V 24 V 12 V 24 V Commercial name VMA-020-F VMA-020-F VMA-050-F VMA-050-F Part number L L M K Function Proportional Flow Control Valve used to regulate a control wheel slip Compatibility Electronic transmission management Hydraulic symbol Accessories Characteristics Pressure loss P bar P [PSI] The valves must be supplied at G with a pressure of between 15 and 30 bars [217 PSI and 435 PSI]. Maximum flow, from P to A or B, for a fully open valve, is 120 l/min [31.7 GPM] per wheel with a pressure difference ( P) of 5 bars [72 PSI] (96 cst mineral oil at 25 C [77 F]). 15/01/

26 SmartDrive Premier System Layout Block position when fixing Horizontal. Make sure that the mounting face is clean with no grease. Remove the protective plate. Make sure that the O-rings are correctly positioned. Install the valve on the mounting face with the help of the lug. Chassis fixing Quantity Class N.m [lb.ft] ± 10 % (as per standard DIN 912) M [63.5] Hydraulic connections Port Function Connection Max pressure bar [PSI] N.m [lb.ft] ± 10 % P HP connection Bride DN 25 PN [6000] 90 [66] A-B HP connection M 27 x [6000] 200 [148] F Drain M 14 x [14] 45 [33] G LP supply M 14 x [217] P < 30 [435] 45 [33] M1-M2 Pressure measurement M 14 x P < 20 bar [290] 45 [33] Electrical connections on E1 and E2: Motor and valve drain piping must be connected directly to the tank /01/2014

27 SmartDrive Premier System AMP CONNECTOR Commercial name Part number Compatibility VMA CONNECTOR VALVE KIT S In-line valve Flanged valve Manufacturer's references Manufacturer AMP Contacts Body connector Connector mounting 1. Strip 5 mm [0.19 in] of insulation off the cables. Crimp the lugs ( F) onto the cables using an AMP CERTI-LOCK tool. Protect the connection with heat-shrink tubing (A), or Rislon fixed plastic tubing. Accessories Characteristics 2. Refer to your general wiring diagram, inserting each lug into its housing until it clicks into place. 15/01/

28 SmartDrive Premier System SPEED SENSOR T4 Commercial name T4 SENSOR T4 SENSOR T4 SENSOR Part number A22082C A22083D A22084E Lenght L(*) 44 [1.73] 53 [2.09] 62 [2.44] Function Detect movements : rotation speed Compatibility Electronic transmission management (*) : According to the size of the motor, consult your Poclain Hydraulics sales engineer Features Maximum range 1.15 mm [0.045 ] Supply voltage 8-30 V Current consumption 20 ma max. Output type - 1 push-pull square frequency signal - Maximum load current: 20 ma - Voltage at low state: < 1.5 V - Voltage at high state: > (power supply voltage V) Frequency range 0 to 15 khz Operating temperature - 40 C to C [- 40 F to 257 F] Protection rating IP68 Material Stainless steel Layout 28 15/01/2014

29 SmartDrive Premier System Disconnecting the accessories and speed set up In the case of motors predisposed to speed, the existing shutter needs to be removed and eliminated before installing the sensor and its attachment device. To install the sensor, see the '' guide'' brochure No L. Connection of the speed sensor Remove the plastic plug on the connector. Function Pin number Power supply 1 Earth 3 Square frequency signal 4 For the connection of connectors, please refer to the connection table and the general cabling plan contained in the installation brochure for your transmission. Cables for Speed Sensors T4 connection Sales Code Item Code ELEC-CABLE-M A07468S ELEC-CABLE-M A04999J Accessories Characteristics 15/01/

30 SmartDrive Premier System M12 CABLE Commercial name ELEC-CABLE-M ELEC-CABLE- M Part number A07468S A04999J Compatibility Speed sensors and digital sensors. Features Lenght of cable 5 m Material PUR Number of wires 4 Sections of wires 0.34 mm 2 Protection IP68 Layout Connector Mounting Securely hand tighten the cable's ring to sensor connector M12. Electrical wiring Pin Wire 1 Brown 2 White 3 Blue 4 Black 30 15/01/2014

31 SmartDrive Premier System ROTARY POTENTIOMETER Commercial name ANGULAR-SENSOR-CABLE-MP-WP Part number A13534L Function Detects movement: Engine operations, lever positions, etc. Compatibility Electronic transmission management Features Resistance 2.5 k Type Analog potentiometer Travel 54 Operating temperature - 40 C to + 85 C [-40 F to 185 F] Weight 230 g [0.5 lb] Protection IP 66 Layout 1 Accessories Characteristics Ø 11.4 [0.45 dia.] right milling 58 teeth Norme / Std ANSI/ASME B /01/

32 SmartDrive Premier System Mechanical fitting The steering sensor must be fitted onto a rigid plate at least 2 mm [0.08"] thick. If this sensor is used with a Smart Drive, Off Road or Premier transmission system, it must be linked with a rod to the steering column or pivot. On four-wheel steering machines, a second steering sensor will be necessary. Ref. Quantity Class N.m [lb.ft] ± 10 %(as per standard DIN 912) 1 M [7.37] Example of mounting: Sensor electrical signal control >0.4V 1.4V 3.6V >4.6V Difference min. 1V Difference min. 1V Left direction Straight Right direction Connections Commercial name Part No. Delphi Ref K 3 terminal connector: Terminal (x4) Connector mounting 1.Pass the wires through the connector. 2.Strip 5 mm from the wires. 3.Crimp the terminals with special tool Pull the wires towards the connector to fit the terminals into their housing Electric wiring: Position 0 For connections: See the connection table and the main wiring diagram in the installation brochure for your transmission system. Sensor wire ID A B C Function Supply Signal Ground 32 15/01/2014

33 SmartDrive Premier System SMARTDRIVE PREMIER IDENTIFICATION B SD PREMIER BOX A : Model code: e.g. SD PREMIER BOX B : Code (Part number): e.g J D : Number (Chronological number): e.g J The part number and the chronological order number must be specified to order spare parts. Only the calculator and the valves are identified by this model identification plate The dimensions of the components described in this brochure, the operation and the CEM chapter are given in the characteristics brochure. D A Accessories Characteristics 15/01/

34 SmartDrive Premier System SMARTDRIVE PREMIER LIST OF COMPONENTS SmartDrive TM Off-Road System list of components Commercial code Part number Regulating computer Boîtier SD Off-Road G Main connector Kit connecteur main SD P SmartDrive TM Off-Road cable (1 m) CABLE-SD-OFFROAD A22473C SmartDrive TM Off-Road cable (5 m) CABLE-SD-OFFROAD A22475E Communication connector Kit connecteur COM SD LT Q Communication cable (1 m) COM-CABLE-SD-1000 A20360F Communication cable (5 m) COM-CABLE-SD-5000 A20361G Pack connectors With: 4x kit connecteur capt tachy 4x kit connecteur valve VMA 1x kit connecteur main SD 2x kit connecteur capt direct. Wiring Kit connecteur SD Off-Road T Câble SD PC LT S Câble SD HHT LT T «PHASES» software Pack Phases Off-Road F Hand held terminal KIT TERMINAL ST A In-line valves Q < 20 l/min [5.2 GPM] 12V VMA-020-T J Q < 20 l/min [5.2 GPM] 24V VMA-020-T J 20 [5.2 GPM] < Q < 50 l/min [13.2 GPM] 12V VMA-050-T K 20 [5.2 GPM] < Q < 50 l/min [13.2 GPM] 24V VMA-050-T H Flanged valves Q < 20 l/min [5.2 GPM] 12V VMA-020-F L Q < 20 l/min [5.2 GPM] 24V VMA-020-F L 20 [5.2 GPM] < Q < 50 l/min [13.2 GPM] 12V VMA-050-F M 20 [5.2 GPM] < Q < 50 l/min [13.2 GPM] 24V VMA-050-F K Regulating valve connector Kit connecteur valve VMA S T4 SENSOR A22082C Speed sensor T4 SENSOR A22083D T4 SENSOR A22084E M12 cable for speed sensor ELEC-CABLE-M A07468S ELEC-CABLE-M A04999J Rotary potentiometer ANGULAR-SENSOR-CABLE-MP-MW A13534L Rotary potentiometer connector KIT CAPT VIRAGE K Digital sensor (wire) DETECTEUR TOR M18 CABLE A Digital sensor (connector) M12 cable for digital sensor (connector) DETECTEUR TOR M18 CONNECT Z ELEC-CABLE-M A04999J ELEC-CABLE-M A07468S Commercial codes and part numbers may change during the lifetime of the system. To have the latest update, please, contact /01/2014

35 SmartDrive Premier System SmartDrive TM Master System list of components ECU and its connections Model code Part number Regulating ECU BOITIER SD Master F Main connector KIT CONNECTEUR MAIN SD P x1 SmartDrive TM Master cable (1 m) CABLE-SD-MASTER A20309A SmartDrive TM Master cable (5 m) CABLE-SD-MASTER A20310B Communication connector KIT CONNECTEUR COM SD LT Q x1 Communication cable (1 m) COM-CABLE-SD-1000 A20360F Communication cable (5 m) COM-CABLE-SD-5000 A20361G SmartDrive TM Master connectors Kit connecteur SD Master T CAN wiring CABLE DE COMMUNICATION Y SD X Setting parameters Model code Part number Control software (including SD PC LT wiring) Pack PHASES Master E Wiring CABLE SD PC LT S Setup terminal TERMINAL EQ. ST A Wiring CABLE SD HHT LT T SA control pump environment Model code Part number SA control pump VOIR BROCHURE n L Accessories Characteristics Feedback connector KIT CONNECT. CAPT. CDE SA Z x3 Speed sensor connector KIT CONNECT. CAPT. TACHY C x1 Solenoid connector KIT CONNECT CDE SA X x1 Auxiliaries Model code Part number 600-bar PRESSURE SENSOR - 1/4G connector CAPT PRES 600b MH2 G 1/ M 160-bar PRESSURE SENSOR - 1/4G connector CAPT PRES 160b MH2 G 1/ E 600-bar PRESSURE SENSOR - 9/16 connector CAPT PRES 600b MH2 9/ L 160-bar PRESSURE SENSOR - M10 connector CAPT PRES 160b MH2 M H 15/01/

36 SmartDrive Premier System Control elements Model code Part number Suspended pedal ELECTRIC-VERTICAL-PEDAL A13540S Suspended pedal connector KIT CONNECT CAPT CDE SA Z Floor pedal (provided with connector) ELEC-HORIZ-PEDAL-30 -DUAL A50838J Joystick (provided with connector) JOYSTICK-35 -HANDLE-LOCK X Rotary potentiometer ANGULAR-SENSOR-CABLE-MP-WP A13534L Steering sensor connector KIT CONNECTEUR CAPTEUR DE VIRAGE K Linear potentiometer POTENTIOMETRE LINEAIRE ML T Engine environment Model code Part number 12V engine actuator ACTIONNEUR E GAS 12V W 24V engine actuator ACTIONNEUR E GAS 24V V Actuator connector KIT CONNECTEUR ACTIONNEUR G x1 Hydraulic motor environment Model code T4 SENSOR Part number A22082C Speed sensor T4 SENSOR A22083D T4 SENSOR A22084E M12 cable for speed sensor ELEC-CABLE-M A07468S x1 ELEC-CABLE-M A04999J x1 SmartDrive TM Premier System list of components Model code Part number SmartDrive TM Premier connectors KIT CONNECTEUR SD PREMIER U Commercial codes and item numbers may change during the lifetime of the system. To have the latest update, please contact. System study To simplify the integration of components into your system, our sales engineers investigate your specific needs /01/2014

37 INSTALLATION SmartDrive Premier System SmartDrive TM Off-Road System installation Machine safety recommendations INSTALLATION Before installation Be sure that the hydraulic system power source (engine) is stopped and that the battery is disconnected. Do not proceed to installation on a hot or pressurized hydraulic system (accumulators must be purged). During installation Some hydraulic components are very heavy. Secure them with a lifting device of adequate capacity when installing on the machine frame. During handling, protect all interface surfaces from shocks (piloting surfaces, studs, ports, connectors, plugs, etc.) Ensure cleanliness of piloting and thrust surfaces of components and devices on the chassis before reassembly (no paint). Never heat hydraulic fluid, as it may flame at high temperature. Some solvents are also flammable.do not smoke during installation. Machine wiring recommendations All the cables must be encased in flexible metal or plastic sheaths; All cables or sheaths must be held well in place and locked in to prevent pull-ou; Bring the sheath supports close together; The sheaths must be able to slide into the anchoring; Avoid mechanical stresses in the cables; Do not place the cables or sheaths close to moving or vibrating parts; Do not lay the sheaths along sharp angles. Protect them at each bend; Avoid laying the sheaths too close to high heat sources; Use wires with abrasion-resistant sheaths; Use cables that resist temperatures between 85 C and 105 C close to heat sources; Separate power cables from control cables; Pass the cables inside the machine, ensuring as much contact as possible with metal surfaces (steel). This will act as a shield against electromagnetic radiation. setting parameters The machine manufacturer is responsible for safety measures during the installation of our products. They must comply with applicable laws in the country or state. Place the machine on the wheel blocks. Set up a safety area. Observe all personnel safety instructions. Hot or pressurized hydraulic fluid may cause serious burns & infections to the human body. Consult a doctor in case of accident. The commissioning involves the downloading of the software and parameters defined by the manufacturer and. However, a customized parameter setting is possible. To set them, use the PHASES Off-Road software or the manual terminal. Accessories Characteristics 15/01/

38 SmartDrive Premier System For further information, see PHASES user guide no B and hand held terminal user guide no. A06618T. Setting by the PHASES Off Road software: Install the PHASES software (see the B installation guide). Connect the calculator to the PC computer with the CABLE SD PC LT wire by connecting the SUBD9 wire of the PC to the communication connector of the calculator. For more information on the PHASES software, refer to its hot-line. Setting by the manual terminal The manual terminal only allows to modify the parameters directly in the calculator. You can't save any configuration under no circumstances. Connect the calculator to the hand handing terminal computer with the CABLE SD HHT LT wire by connecting the RJ11 wire of the HHT to the calculator's communication connector. To parameter the system by the hand held terminal, see the n A06618T installation guide. Checking the installation before starting up The elements to be checked depend on the application of each vehicle. Please remember that each manufacturer is ultimately responsible for checking their machinery at the end of the line. Checking Check that all the valves regulating the wheels hydraulic supply and that the sensors (speed sensor and turn sensor) have been correctly connected to the electrical beam. Check the electrical wiring. Hydraulic circuit Check that the connection of the following components is in conformity with the hydraulic circuit diagram and with their respective installation and commissioning manuals. valves; hydraulic pump; hydraulic motors. The pressure drop in the hydraulic motor return circuits must not bring the pilot pressure in the valves below 22 bar [319 PSI]. The valve and motor drain piping must be connected directly to the tank /01/2014

39 SmartDrive Premier System SmartDrive TM Master System installation Machine safety recommendations Before installation The machine manufacturer is responsible for safety measures during the installation of our products. They must comply with applicable laws in the country or state. Be sure that the hydraulic system power source (engine) is stopped and that the battery is disconnected. Do not proceed to installation on a hot or pressurized hydraulic system (accumulators must be purged). During installation Some hydraulic components are very heavy. Secure them with a lifting device of adequate capacity when installing on the machine frame. During handling, protect all interface surfaces from shocks (piloting surfaces, studs, ports, connectors, plugs, etc.) Ensure cleanliness of piloting and thrust surfaces of components and devices on the chassis before reassembly (no paint). Never heat hydraulic fluid, as it may flame at high temperature. Some solvents are also flammable. Do not smoke during installation. Machine wiring recommendations. Place the machine on the wheel blocks. Set up a safety area. Observe all personnel safety instructions. Hot or pressurized hydraulic fluid may cause serious burns & infections to the human body. Consult a doctor in case of accident. All the cables must be encased in flexible metal or plastic sheaths; All cables or sheaths must be held well in place and locked in to prevent pull-ou; Bring the sheath supports close together; The sheaths must be able to slide into the anchoring; Avoid mechanical stresses in the cables; Do not place the cables or sheaths close to moving or vibrating parts; Do not lay the sheaths along sharp angles. Protect them at each bend; Avoid laying the sheaths too close to high heat sources; Use wires with abrasion-resistant sheaths; Use cables that resist temperatures between 85 C and 105 C [ 185 F and 221 F ] close to heat sources; Separate power cables from control cables; Pass the cables inside the machine, ensuring as much contact as possible with metal surfaces (steel). This will act as a shield against electromagnetic radiation. Accessories Characteristics Parking brake wiring recommendations If the box controls also the parking brake, you must IMPERATIVELY wire as shown opposite. Warning: The switch used must-to be able to carry the current which circulates in the solenoid brake. Is possible to use a switch which can not take the current, but that induces 2 constraints: The diagram should be carried out as shown opposite (switch placed on the pilot circuit of SmartDrive Master and Premier). The driver of the machine cannot operate directly the parking brake, he must make sure that this one is well applied before leaving the machine. 1- Exit orders parking brake. 2- Entry On/Off sensor. 3- Solenoid of parking brake (if supplied = brake). 4- Switch of parking brake. 5- Solenoid relay. 15/01/

40 SmartDrive Premier System setting parameters The commissioning involves the downloading of the software and parameters defined by the manufacturer and. However, a customized parameter setting is possible. To set them, use the PHASES Master software or the manual terminal. For further information, see PHASES user guide no C and hand held terminal user guide no. A06618T. Setting by the PHASES software: Install the PHASES software (see the C installation guide). Connect the calculator to the PC computer with the CABLE SD PC LT wire by connecting the SUBD9 wire of the PC to the communication connector of the calculator. For more information on the PHASES software, refer to its hot-line. Setting by the manual terminal The manual terminal only allows to modify the parameters directly in the calculator. You can't save any configuration under no circumstances. Connect the calculator to the hand handing terminal computer with the CABLE SD HHT LT wire by connecting the RJ11 wire of the HHT to the calculator's communication connector. To parameter the system by the hand held terminal, see the n A06618T installation guide. Checking the installation before starting up The elements to be checked depend on the application of each vehicle. Please remember that each manufacturer is ultimately responsible for checking their machinery at the end of the line. Checking of the electrical environment The PHASES software enables you to view any anomalies detected by the SD Master ECU, by delivering an error code, a brief explanation and a list of possible causes. In particular, it indicates: short-circuit type electrical anomalies on the ground, or the 5V, cabling errors: switch allocated/not allocated to a given part, input/output malfunctions. The portable HHT can also check these points without help files. The calibration can detect cable configurations (see next chapter). Hydraulic circuit Check that the connection of the following components is in conformity with the hydraulic circuit diagram and with their respective installation and commissioning manuals. valves; hydraulic pump; hydraulic motors. The pressure drop in the hydraulic motor return circuits must not bring the pilot pressure in the valves below 20 bar [290 PSI]. The valve and motor drain piping must be connected directly to the tank. Verification of hydraulic pump installation (clockwise rotation PV pump) Pump 1 C motor (*) 2 C motor Axle Port A Port R Port R Port L Port B Port L Port A Port R 40 15/01/2014

41 SmartDrive Premier System Pump 1 C motor (*) 2 C motor Axle * front left wheel of machine Electrical connexion: check the solenoid and feedback potentiometer connections to the pump against the electrical circuit diagram in the appendix of this brochure. Checking of hydraulic pressures Fit the machine temporarily with pressure gauges and check the against the table below. Block diagram with dual displacement motors Auxiliaries Accessories Characteristics Pressure gauge Pressure Informations bar [PSI] [0-58] Pump case pressure [ ] HP (high pressure) pressure supply [0-58] Motor case pressure [ ] HP (high pressure) pressure supply [0-580] Charge pressure 15/01/

42 SmartDrive Premier System Starting up the engine Place the machine on the wheel blocks. Set up a safety area. Observe all personnel safety instructions. Put the F/N/R (Forward/Neutral/Reverse) shift lever in the neutral position. Apply the parking brake. Switch on the ECU. Start the engine, and wait until the charge pressure is established. Press the emergency stop button and check that it stops the engine and cuts off power to the SD MASTER box. Start the engine again and then use the PHASES software in the input/output diagnostic module to check that the readings of the various sensors (switch, potentiometer sensors, etc.) are displayed correctly when you actuate them. Checking the wiring of the engine actuator (option) When you press on the travel pedal, the actuator must rotate: Clockwise (as seen from shaft end) for a clockwise connection; counter-clockwise (as seen from shaft end) for a counter-clockwise connection. Check that the feedback signal from the actuator potentiometer sensor is increasing with voltmeter. This checking can also be made using the HHT, from the calibration menu. The terminal gives a real-time display of the voltage and the actuator excitement sensor percentage. Calibrating all the parts This calibration can be carried out using either PHASES or the HHT. See their respective user manuals. Activating pump displacement Release the parking brake. Put the F/N/R shift lever (or switch or joystick) in the Forward Drive position. Gently depress the travel pedal; the wheels must turn slowly forward. Limit the wheel rotation speed to 10% of their maximum speed when the machine is on wheel blocks. Check the pressure levels. Checking the system s specific functions on wheel blocks The forward/reverse ground drive direction using the joystick or switch. Return to neutral Put the gear shift in neutral when in ground drive: the machine will decelerate in accordance with the programmed deceleration ramp. Reversal Reverse when in ground drive: the wheels of the machine will decelerate then accelerate in the opposite direction depending on the pedal position. Braking Test the parking brake: activating it deactivates the travel pedal. Test the emergency brake by fully depressing the brake pedal. Checking that the system works on wheels Repeat the previous tests (except tests of braking). Test the functions that are specific to your application (anti-stall, cruise control, etc) A functional check of the parking brake must be carried out each time it is used as an auxiliary brake (or emergency brake). For all vehicles capable of speeds over 25 km/hour, please contact your Poclain Hydraulics application engineer /01/2014

43 SmartDrive Premier System SMARTDRIVE OFF-ROAD SYSTEM SETTING PARAMETERS, DOWNLOADING, CALIBRATION, DIAGNOSTICS Setting parameters The computer parameters are set at the factory. If the machine characteristics or operating conditions change, the computer parameters of the SmartDrive Off-Road System will have to be modified. The system includes the setting and analysis PHASES. This tools manage 3 access levels to the parameters according to the user's skills: Service; Manufacturer; Expert. Loading data Using a PC and the PHASES software allows you to: Save the configuration; Load the configuration. The hand held terminal allows you to modify the data item per item (see the brochure n Z). Calibration The parameter software allows to calibrate the minimum, maximum and neutral positions of the potentiometer sensors installed on the machine in order to optimize the system's operation. Diagnostics Any modification of the parameters must be carried out by an engineer trained and approved by the machine manufacturer.the technical support team can assist you in defining your parameters. The SmartDrive Off-Road System contains 2 feed back sources : Level 1: The regulating computer shows that the system is functioning properly using 4 LED (red/green) on the front panel. Level 2 : The PHASES software allows the user to download the system's operation data. The collected data will permit to identify a possible malfunction. The hand held terminal allows to analyze a malfunction by a mistake code. Accessories Characteristics 15/01/

44 SmartDrive Premier System SmartDrive TM Off-Road System first level diagnostic FIRST LEVEL DIAGNOSTIC Dash-board indicator light: The system operation light is off if the system is deactivated, on if the system is active and blinks if there's a malfunction. Warning lights on the box front face: They shows the system state in real time. The green warning lights blink following the wheels rotation. Fixed orange or red warning lights show a malfunction in the system. The malfunction is identified by a mistake code. See the following codes table to identify the problem Defaults Error code No default - Rear right wheel speed 8 Rear left wheel speed 7 Front right wheel speed 6 Front left wheel speed 5 Rear right solenoid valve 12 Rear left solenoid valve 11 Front right solenoid valve 10 Front left solenoid valve 9 Turn sensor 2 14 Turn sensor V supply 4 12V supply 3 Low battery power 2 Battery overpower 1 Warning lamp /01/2014

45 SmartDrive Premier System SmartDrive TM Master System first level diagnostic Fault warning lamp on dashboard: The warning lamp flashes in the event of a fault. Otherwise, it remains unlit. Indicator lights on the box front face: These indicate the system status in real time. If the vehicle is fit with a speed sensor, the green indicator lights flash at the wheel rotation frequency, enabling a diagnostic on this motors' speed sensor. The indicator lights, orange if the vehicle is traveling or red if the vehicle is stationary, indicate a system failure. The malfunction is identified by an error code, represented in the table below Defaults Error code No default - 5V supply 4 12V supply 3 Low battery power 2 Battery overpower 1 Warning lamp 15 Accessories Characteristics 15/01/

46 SmartDrive Premier System APPENDIX SmartDrive TM Off-Road System appendix Electrical wiring Speed sensor (front left) Flow control valve Turn detector 1 Turn detector 2 On/Off Antiskid lamp Speed sensor (front right) Speed sensor (rear right) E 110 Q E 110 Q J 150 Q J 150 Q J 201 G J 202 H M 211 G Q 212 H Q 251 G G 252 H H 401 D D 402 F F 403 I I 404 K K 411 D K 412 F K 413 I D 414 K L 451 D E 452 F E 453 I E 454 K H 501 E M 502 E Q 503 J Q 504 J G 551 E H 552 E L 553 J D 554 J F 601 M F 602 L I 651 M I 652 L 44 Speed sensor (rear left) Flow control valve Please ask our technical department for the wiring of on/ off sensor /01/2014

47 SmartDrive Premier System Advice concerning the electrical wiring Mark out each wire with numbered plastic rings. Each wire must be securely held to the machine with clamps placed every 20 cm [7.87 in]. Sections are in mm² for a wire 10 meters long at operating temperature < 80 C [176 F]. Wire n Function Part Section mm² [in²] 110 Supply Battery 1 [0.0016] 150 GND Battery 1 [0.0016] 201 Signal Turn sensor [0.0008] 202 Signal Turn sensor [0.0008] 211 Supply Turn sensor [0.0008] 212 Supply Turn sensor [0.0008] 251 GND Turn sensor [0.0008] 252 GND Turn sensor [0.0008] 401 Signal Front left wheel speed sensor 0.5 [0.0008] 402 Signal Front right wheel speed sensor 0.5 [0.0008] 403 Signal Rear left wheel speed sensor 0.5 [0.0008] 404 Signal Rear right wheel speed sensor 0.5 [0.0008] 411 Supply Front left wheel speed sensor 0.5 [0.0008] 412 Supply Front right wheel speed sensor 0.5 [0.0008] 413 Supply Rear left wheel speed sensor 0.5 [0.0008] 414 Supply Rear right wheel speed sensor 0.5 [0.0008] 451 GND Front left wheel speed sensor 0.5 [0.0008] 452 GND Front right wheel speed sensor 0.5 [0.0008] 453 GND Rear left wheel speed sensor 0.5 [0.0008] 454 GND Rear right wheel speed sensor 0.5 [0.0008] 501 Signal Front left regulating solenoid valve 0.75 [0.0012] 502 Signal Front right regulating solenoid valve 0.75 [0.0012] 503 Signal Rear left regulating solenoid valve 0.75 [0.0012] 504 Signal Rear right regulating solenoid valve 0.75 [0.0012] 551 Signal Front left regulating solenoid valve 0.75 [0.0012] 552 Signal Front right regulating solenoid valve 0.75 [0.0012] 553 Signal Rear left regulating solenoid valve 0.75 [0.0012] 554 Signal Rear right regulating solenoid valve 0.75 [0.0012] 601 Signal Anti-skid pilot-lamp 0.75 [0.0012] 602 Signal On/Off switch 0.5 [0.0008] 651 GND Anti-skid pilot-lamp 0.75 [0.0012] 652 GND On/Off switch 0.5 [0.0008] Accessories Characteristics 15/01/

48 SmartDrive Premier System SmartDrive TM Master System appendix Example of electrical wiring Engine actuator Joystic Joystic / TP switch Teach-in switch / Setdec Road / Field Teachin switch / Res- Acc Cruise control Accumulator brake pressure Parking brake switch Travel pedale Engine RPM - Engine RPM + High pressure sensor 1C/ 2C Front axle Brake pressure sensor Solénoid 1 PArking brake status Solénoid 2 Feedback Cruise control status Pump 1 Speed Battery Solénoid 1 Field / Road mode Solénoid 2 Pump 2 Feedback Key switch Reverse lamp Brake lamp 1C/ 2C rear axle Please ask our technical department for the wiring of on/off sensor /01/2014

49 SmartDrive Premier System Advice concerning the electrical wiring Mark out each wire with numbered plastic rings. Each wire must be securely held to the machine with clamps placed every 20 cm [7.87 in]. Sections are in mm² for a wire 10 meters long at operating temperature < 80 C [176 F]. Key to table below: GND Analog inputs A Supply TOR inputs D Signal Frequency inputs F Power outputs P H bridge outputs H Wire Wire Section Pin n Pin n Function Type Part mm² [in²] A GND Battery (-) 1.5 [0.059] R GND Battery (-) 1.5 [0.059] V W Supply Battery (+) 1.5 [0.059] S W Supply Battery (+) 1.5 [0.059] B 201 N Supply Pump 1 Feedback Potent 0.5 [0.020] L 202 M Supply Pump 2 Feedback Potent. 0.5 [0.020] O 203 A Supply Joystick 0.5 [0.020] I D Supply 5V Travel pedal 0.5 [0.020] W 207 E Supply High Pressure Sensor 0.5 [0.020] W 208 F Supply Brake Pressure Sensor 0.5 [0.020] 251 N 209 X Supply Engine actuator Feed Back 0.5 [0.020] 252 M X Signal H Engine actuator 0.75 [0.030] 253 A N Signal A Pump 1 Feedback Potent. 0.5 [0.020] D M Signal A Pump 2 Feedback Potent. 0.5 [0.020] 257 E A Signal A Joystick 0.5 [0.020] 258 F D Signal A Travel pedal 0.5 [0.020] 259 X E Signal A High Pressure Sensor 0.5 [0.020] D F Signal A Brake Pressure Sensor 0.5 [0.020] J X Signal A Actuator Feed Back 0.5 [0.020] K M Signal F Pump 2 Speed 0.5 [0.020] C M Signal F Pump 2 Speed 0.5 [0.020] Q 251 N GND Pump 1 Feedback Potent. 0.5 [0.020] U 252 M GND Pump 2 Feedback Potent. 0.5 [0.020] M A GND Joystick 0.5 [0.020] N 256 D GND Travel pedal 0.5 [0.020] N 257 E GND High Pressure Sensor 0.5 [0.020] M 258 F GND Brake Pressure Sensor 0.5 [0.020] N 259 X GND Engine actuator Feed Back 0.5 [0.020] M X GND H Engine actuator 0.75 [0.030] X R Signal D Parking brake switch 0.5 [0.020] X B Signal D Road/Field switch 0.5 [0.020] E C Signal D Cruise control switch 0.5 [0.020] X S Signal D Brake accumulator pressure 0.75 [0.030] N P Signall D Engine speed (+) 0.5 [0.020] M Q Signa D Engine speed ( ) 0.5 [0.020] P T Signal D Cruise control speed increase 0.5 [0.020] T U Signal D Cruise control speed decrease 0.5 [0.020] A V Signal D Joystick /pedal switch 0.5 [0.020] Accessories Characteristics 15/01/

50 SmartDrive Premier System Pin A 351 R GND Parking brake switch 0.5 [0.020] 531 L 352 B GND Road/Field Switch 0.5 [0.020] 532 O 353 C GND Cruise control switch 0.5 [0.020] 533 G 354 S GND Accumulator brake pressure 0.5 [0.020] L P GND Engine speed (+) 0.5 [0.020] 536 O 356 Q GND Engine speed ( ) 0.5 [0.020] 537 G 357 T GND Cruise control speed increase 0.5 [0.020] 538 H 358 U GND Cruise control speed decrease 0.5 [0.020] 541 I 359 V GND Joystick /pedal switch 0.5 [0.020] 543 J A Signal D JoystickRev Switch Joystick 0.5 [0.020] K A GND Fwd Switch Joystick 0.5 [0.020] 545 I A Signal D Fwd Switch Joystick 0.5 [0.020] 547 J L Supply P Rear displacement shift 0.75 [0.030] 548 K O Supply P Front displacement shift 0.75 [0.030] G Supply P Parking Brake Lamp 0.75 [0.030] J Supply P Reverse Lamp 0.75 [0.030] 43 Wire n Pin Wire n Function Type Part Section mm² [in²] 201 N K Supply P Stop lights 0.75 [0.030] 202 M H Supply P Cruise Control Lamp 0.75 [0.030] 203 A I Supply P Road/Field Mode Switch 0.75 [0.030] 206 D 531 L GND Rear displacement shift 0.75 [0.030] 207 E 532 O GND Front displacement shift 0.75 [0.030] 208 F 533 G GND Parking Brake Lamp 0.75 [0.030] 209X L GND Reverse Lamp 0.75 [0.030] 351 R 536 O GND Brake Lamp 0.75 [0.030] 352 B 537 G GND Cruise Control Lamp 0.75 [0.030] 353 C 538 H GND Road/Field mode switch 0.75 [0.030] 354 S 541 I Supply P Road/Field mode lamp 0.75 [0.030] 355 P 543 J Supply P Reverse lamp 0.75 [0.030] Q 544 K Supply P Brake lamp 0.75 [0.030] T 545 I GND Road/Field Mode Switch 0.75 [0.030] 358 U 547 J GND Reverse lamp 0.75 [0.030] 359 V 548 K GND Brake lamp 0.75 [0.030] 457 A N Signal Pump 1 S1 (+) 0.75 [0.030] F M Signal Pump 1 S2 (+) 0.75 [0.030] M M Signal Pump 2 S1 (+) 0.75 [0.030] M N Signal Pump 2 S2 (+) 0.75 [0.030] H N Signal Pump 1 S1 ( ) 0.75 [0.030] G N Signal Pump 1 S2 ( ) 0.75 [0.030] M M Signal Pump 2 S1 ( ) 0.75 [0.030] N M Signal Pump 2 S2 ( ) 0.75 [0.030] 50 15/01/2014

51 SmartDrive Premier System Accessories Characteristics 15/01/

52 Thirteen subsidiaries and a worldwide network of more than 150 distributors and partners 15/01/2014 A06614P A06615Q Poclain Hydraulics reserves the right to make any modifications it deems necessary to the products described in this document without prior notification.the information contained in this document must be confirmed by Poclain Hydraulics before any order is submitted. Illustrations are not binding. The Poclain Hydraulics brand is the property of Poclain Hydraulics S.A. More information on