light trailer boom technical training · load cell & interface process for calibration of the...

Light Trailer Boom Technical Training

Rev 04-15 1

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.

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

Towable Models

Articulating Boom: 3522A, 4527A, 5533A Telescopic Boom: 3632T

4

Articulating Ground Controls

5

Telescopic Boom Ground Controls

6

Maintenance Mode Press & Hold for 5 seconds (Outrigger Extend,& both Rotate Buttons)

Hour Meter Display Press & hold (Rabbit & “Turtle) Buttons

Engine RPM While engine is running, press (Start Engine) Button

Weight Display 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 While in Maintenance Mode press Auto Level Button

Engine Hours Press & hold (Rabbit,Turtle, & Engine Start) together

Service Menus (Hot/Hidden Keys)

7

Printed Circuit Card ECU

8

I/O Driver Board

9

Towable Upper Control Box (UCB)

10

Drive & Set Manual Activation

11

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

12

Drive & Set Manual Activation

13

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

Manual Activation

Drive and Set Upper Control Box (UCB)

15

Drive Set Controller

Joystick Values Voltages from 5vdc - 2.5vdc – 0.0vdc for both X and Y axis

16

CANBus

CAN Bus circuit has two resistors, and one is located in the upper circuit card and the other on the CPU card. 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. 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.

17

Driver Board

CPU Board

J3

J2

Diagnostic LED

Sevcon Motor Controller U2

Logic Side of Sevcon

Motor Controller

18

Main Power Contactor PA1-RA1

Power On Relay PA1-RL1

Inline Battery Fuse PA1-FS3

Power System

19

Inline Fuse Power on Relay PA1-FS2

Battery Charger

20

Battery Charger Indicators

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.

24VDC/25Amps

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Battery Charger Indicators

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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.

Jib Down Switches SW1 & SW4

NO & NC

Limit Switch Operation

23


24

Boom Down Switches. SW2 & SW3, or NO & NC


25

Outrigger Switches SW5 RR; SW6 RF;

SW7 LR; SW8 LF shown in Picture.

Outrigger enable valve CL1, CL2,CL3,

& CL4

Outrigger and Limit Switch Operation

Negative Side of the outrigger coils is controlled by Limit Switches

PA3-RL1

26 Boom Down Relay

Level Sensor Calibration

Level Sensor PA1-U1

27

Level Sensor Calibration

28

Level Sensor PA1-U1

Load Cell and Interface

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.

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U5 U4

Electric DC Motor Proportional Valve C8

System Relief Valve 3000PSI 206Bar

Manual Pump

Test Port TP1

Basket Compensation Valves C13, C14

Basket Compensation Counter Balance Valves

Turret Rotation Valves C9, C10

Hydraulic Power Unit

30

Turret Rotation Flow Control Valve

Turret Rotation Pressure Relief Valve

Adj

Hydraulic Return Filter


31

C11 Telescope Ext

C12 Telescope Ret

C6A Outrigger Check Valve C6 Outrigger Ext Valve

C7 Outrigger Ret Valve


32

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.

45/55 Articulated Security Valve

33

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)

If C8 is defective , there is no outriggers extension and no movement (except boom descent if not already in stowed position)

Tank

System Relief @ 3000PSI

Outrigger Extension

35

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)

Tank


Outrigger Retraction

36

C8 + C9 ( or C10 for CCW rotation) =1

Speed Control

Tank

Turntable Rotation

37

C8 + C11 ( or C12 for retraction) = 1 C8 + C11+ C12 for Extend ( or C8 + C12 for Retraction) = 1

Tank


Telescope Extension

38

C8 + C13 ( or C14 for down) = 1

Tank


Platform Compensation

39

BOOM : C8 + C5 ARM : C8 + C16 JIB : C8 + C17

Double check valve (41) : set at 25 psi (2b) Only on 45 and 55ft Towable Booms

Tank


40

Primary, Secondary, & Jib Lifting

TANK

Primary/Lower Boom : C8+C5 Secondary/Upper Boom: C8+C16

Jib: C8 + C17 C8 is controlling the proportionality for gravity down functions

Double check valve (57) : set at 25 psi (2b) for jib, Boom and Arm descent control on Both 45 and 55XA

To drive manifold

Primary, Secondary, & Jib Lowering

Drive and Set Option

42

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

Drive & Set Manifold

43

MAIN PUMP coming from TP3

AUX PUMP

TANK

FWD : C8+ C20+C21+C22/C24 + C26 REV : C8+ C20+C21+C23/C25 + C26

Flow restrictor (45) : overrun control

LEFT RIGHT

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

Drive and Set Option

44

Lower Control Box Connectors

45

47

Key Switch & E-Stop

48

Pin5 0-4.5vdc 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.

Power on Sevcon Motor Controller

BLK RD

Articulated Boom and Outrigger Switches

50

87

NC switches are held open when the jib & boom are stowed

NO switches are held closed when the jib &

boom are stowed

Manifold Harness 3632T

51

52

NC switch is held open when the boom is stowed

NO switch is held closed when the boom is stowed.

3632T Boom Switches & Outrigger Switches

End

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light trailer boom technical training · load cell & interface process for calibration of the...

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