Light Trailer Boom Technical Training. Rev

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Oswald Warren
5 years ago
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1 Light Trailer Boom Technical Training Rev

2 Training Objectives To learn and understand operation of Light Booms. To learn and understand Electric and Hydraulic Layouts. To be able to accurately diagnose Electric System. To be able to accurately diagnose Hydraulic System. 2

3 Contents Machine Layout and Upper and Lower Control Boxes (4-12) Component identification and descriptions (13-24) Trailer Hydraulic Schematics and Hydraulic Components (25-42) 3

4 Towable Models Articulating Boom: 3522A, 4527A, 5533A Telescopic Boom: 3632T 4

5 5 Articulating Ground Controls

6 6 Telescopic Boom Ground Controls

7 Service Menus (Hot/Hidden Keys) Maintenance Mode Hour Meter Display Engine RPM Weight Display Press & Hold for 5 seconds (Outrigger Extend,& both Rotate Buttons) Press & hold (Rabbit & Turtle) Buttons While engine is running, press (Start Engine) Button Press & Hold (Basket Compensate Up & Down Together) Moment Sense Display Press & hold (Outrigger Ext,Outrigger Retract & Boom Down Button)(Only works on 4642) Level Sensor Engine Hours While in Maintenance Mode press Auto Level Button Press & hold (Rabbit,Turtle, & Engine Start) together 7

8 8 Printed Circuit Card ECU

9 9 I/O Driver Board

10 10 Towable Upper Control Box (UCB)

11 Drive & Set Manual Activation Design objective: No longer use the parking brake for Drive & Set Brakes to hold on grade the machine can level on 12 Field retrofitable for machine in the field with Drive and Set 11

12 12 Drive & Set Manual Activation

13 Manual Activation Lift Handle & push back on locking lever Push down on handle until linkage locks in place 13

14 14

15 Drive and Set Upper Control Box (UCB) 15

16 Drive Set Controller Joystick Values Voltages from 5vdc - 2.5vdc 0.0vdc for both X and Y axis 16

If there is an open in the system then a reading of 126Ω on each module.

17 CANBus J3 Driver Board CAN Bus circuit has two resistors, and one is located in the upper circuit card and the other on the CPU card. CPU Board If the system is working properly 63Ω should be across the CAN Bus. If there is an open in the system then a reading of 126Ω on each module. 17 J2 On the I/O Driver Board in the Lower Control plug J5 pins 3 & 4 are the communication from platform. Output from J3 are pins 38 & 40 on the Driver Board to plug J2 pins 38 & 40 on the CPU Board.

18 Motor Controller Sevcon Motor Controller U2 Diagnostic LED Logic Side of Sevcon 18

19 Power System Power On Relay PA1-RL1 Main Power Contactor PA1-RA1 Inline Battery Fuse PA1-FS3 Inline Fuse Power on Relay PA1-FS2 19

20 20 Battery Charger

Battery Charger Indicators 24VDC/25Amps Battery Type Indicators Two red LED indicators are provided in order to display what type of battery the charger has been

21 Battery Charger Indicators 24VDC/25Amps Battery Type Indicators Two red LED indicators are provided in order to display what type of battery the charger has been programmed to charge. Battery System Percent Charged Indicators Four LED indicators are provided in order to display the progress of the charge cycle in percentage of charge. 21

22 Battery Charger Indicators Indications are as follows: 1ST RED LED Illuminated configured for Wet Cell and AGM batteries 2ND RED LED Illuminated configured for Gel Cell batteries 3RD RED LED Charging - Initial Charging Up To 30% 3RD & 4TH RED LEDS Charging - 60% Complete3RD, 4TH & 5TH RED LEDS....Charging - 90% Complete BLINKING GREEN LED....Finishing Stage (Note: Battery Type Indicator will also blink during this stage) STEADY GREEN LED......Charge Complete Float/Maintenance Mode-On for 5 minutes and off for 60 minutes. Your system provides an equalization stage every 30 days while plugged in. 22

23 Limit Switch Operation Jib Down Switches SW1 & SW4 NO & NC 23

24 Limit Switch Operation Boom Down Switches. SW2 & SW3, or NO & NC 24

25 Limit Switch Operation Outrigger Switches SW5 RR; SW6 RF; SW7 LR; SW8 LF shown in Picture. 25

26 Outrigger and Limit Switch Operation Outrigger enable valve CL1, CL2,CL3, & CL4 PA3-RL1 Negative Side of the outrigger coils is controlled by Limit Switches 26 Boom Down Relay

27 Level Sensor Calibration Level Sensor PA1-U1 27

28 Level Sensor Calibration Level Sensor PA1-U1 28

located between pedestal and basket or optional material lifting hook.

29 Load Cell and Interface U5 U4 Load Cell & Interface Process for Calibration of the Load Cell is located in Service/Parts Manual Unit is located between pedestal and basket or optional material lifting hook. Sensor interface is used for communication between Load Cell and Upper Control Box. 29

30 Hydraulic Power Unit Basket Compensation Valves C13, C14 Turret Rotation Valves C9, C10 Basket Compensation Counter Balance Valves Manual Pump System Relief Valve 3000PSI 206Bar Test Port TP1 Electric DC Motor Proportional Valve C8 30

31 Hydraulic Power Unit Turret Rotation Pressure Relief Valve Adj Turret Rotation Flow Control Valve Hydraulic Return Filter 31

32 Hydraulic Power Unit C11 Telescope Ext C12 Telescope Ret C7 Outrigger Ret Valve C6A Outrigger Check Valve C6 Outrigger Ext Valve 32

33 45/55 Articulated Security Valve Security valve is on the piston side of the Primary, Secondary, and Jib lift Cylinders. This valve is used to keep oil in the hydraulic line up to a certain pressure because of the sprung check valve. 33

34 34

35 Outrigger Extension Tank C6+C7*+C6A+C8+C1+C2+C3+C4= 1 * C7 comes back to 0 when 3 outriggers are on ground (C7 =1 :extra speed to respect the movement of 30sec) System 3000PSI If C8 is defective, there is no outriggers extension and no movement (except boom descent if not already in stowed position) 35

36 Outrigger Retraction Tank C7+C1+C2+C3+C4+C8 (half closed) =1 If C8 is defective, there is no outriggers extension and no movement (except boom descent if not already in stowed position) System 3000PSI 36

37 Turntable Rotation Speed Control Tank C8 + C9 ( or C10 for CCW rotation) =1 37

38 Telescope Extension Tank C8 + C11+ C12 for Extend ( or C8 + C12 for Retraction) = 1 C8 + C11 ( or C12 for retraction) = 1 System 3000PSI 38

39 Platform Compensation Tank C8 + C13 ( or C14 for down) = 1 System 3000PSI 39

40 Primary, Secondary, & Jib Lifting Double check valve (41) : set at 25 psi (2b) Only on 45 and 55ft Towable Booms Tank BOOM : C8 + C5 ARM : C8 + C16 JIB : C8 + C17 System 3000PSI 40

41 Primary, Secondary, & Jib Lowering Double check valve (57) : set at 25 psi (2b) for jib, Boom and Arm descent control on Both 45 and 55XA Primary/Lower Boom : C8+C5 Secondary/Upper Boom: C8+C16 Jib: C8 + C17 To drive manifold C8 is controlling the proportionality for gravity down functions TANK

42 42 Drive and Set Option

43 Drive & Set Manifold C20 = Dump Valve C21 = Brake Valve C22 = M2A Drive RWD RH Motor C23 = M2B Drive FWD RH Motor C24 = M1A Drive RWD LH Motor C25 = M1B Drive FWD RH Motor C26 = Proportional Valve 43

44 Drive and Set Option LEFT RIGHT FWD : C8+ C20+C21+C22/C24 + C26 REV : C8+ C20+C21+C23/C25 + C26 SHARP LEFT FWD : C8+ C20+C21+C23/C24 + C26 SHARP RIGHT FWD : C8+ C20+C21+C22/C25 + C26 SHARP LEFT REV : C8+ C20+C21+C22/C25+ C26 SHARP RIGHT REV : C8+ C20+C21+C23/C24 + C26 MAIN PUMP coming from TP3 AUX PUMP 44 TANK Flow restrictor (45) : overrun control

45 45 Lower Control Box Connectors

46 46

47 Key Switch & E-Stop 47

48 RD BLK Power on Sevcon Motor Controller Pin vdc for Sevcon Pin12 is 24v enable for Sevcon from ECU Pin1 24v wake for Sevcon from power on relay Pin 8 Negative signal for the line contactors. 48

49 49

50 Articulated Boom and Outrigger Switches NO switches are held closed when the jib & boom are stowed 87 NC switches are held open when the jib & boom are stowed 50

51 51 Manifold Harness 3632T

52 3632T Boom Switches & Outrigger Switches NC switch is held open when the boom is stowed NO switch is held closed when the boom is stowed. 52

53 End 53

J1 Plug Pin Identification

J1 Plug Pin Identification D D8 D D D D ART_8 J 8 D D0 R R R R TB 80 D D D D D D J Plug Pin Identification PIN # WIRE # SIGNAL FUNCTION 0 INPUT Drive Reverse INPUT Drive Forward OUTPUT Brake, Decel Valve signal 8 INPUT Steer Left