ROTOTILT ICS Direct User manual

2018-04-22
_7225
Control System - ICS Direct
2200401
Wheel Control
Translation of the Original Instructions _EN

© Rototilt Group AB 2018-04-27
ICS Direct Wheel
English
Declaration of conformity for the incorporation of a partly-completed machine.
In accordance with Machinery Directive 2006/42/EC. Appendix II B.
Rototilt Group Systems AB
Box 56
SE-922 21 Vindeln
SWEDEN
declare under our sole responsibility that the following product:
a) is manufactured in accordance with and meets all applicable provisions in EC Directive
2006/42/EC,
b) is manufactured in accordance with the following standards:
ISO 5010:2007 Earth-moving machinery—Rubber-tyred machines—Steering requirements,
EN 474-1:2006+A5:2018 Earth-moving machinery – Safety – General requirements and
EN 474-5:2006+A3:2013 Earth-moving machinery – Safety – Requirements for hydraulic
excavators.
The party-completed machine also meets the requirements in EC Directive 2014/30/EC in respect of
electromagnetic compatibility.
The partly-completed machine may not be put into operation before the completed machinery in which it is
to be incorporated is in accordance with the provisions in 2006/42/EC.
An avoidance maneuver test in accordance with 10.4 in ISO 5010:2007 must be carried out for the
alternate steering function. The test determines the authorized speed with the alternate steering active, to
a maximum of 20 km/h.
We conrm that the relevant technical documentation has been compiled in accordance with Appendix 7B.
The authorized individual to compile the technical documentation is:
Niklas Bjuhr
VP Engineering
Upon reasoned request from national authorities, we undertake to provide relevant information in respect
of the partly-completed machine. This provision is made by the requested information being sent in writ-
ing by post to the national authority within a reasonable timeframe following the request, unless otherwise
agreed.
Place and date: Vindeln, Sweden 2018-04-27
Name and signature of authorized person:
Anders Jonsson
CEO
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© Rototilt Group AB 2018-04-27
1 2
3
4 5
EN English
Overview
Control system of the ICS
Direct type
A base machine/excavator equipped with
ICS Direct wheel control has the following
components installed:
1. Indicator lamp
Decal - wheel control
2. Handles with controls to operate the
base machine/excavator, ordered
separately
3. Display - included in the control
system ICS,
ordered separately
4. Valve block - Wheel control
5. Control unit
Buzzer
!
IMPORTANT - Read through the instructions for the
control system, tiltrotator and base machine/excavator use
before starting work. Pay particular attention to the safety
instructions.
!
IMPORTANT -
If you suspect alternative control if malfunctioning, always
use the base machine/excavator's controls.
The product described in the document consists of components for the ICS Direct wheel control system.
The overviews show standard equipment and options.
Refer to the illustrations and lists below and on the following pages.
ICS Direct is design to facilitate the movement of the base machine/excavator when working. ICS Direct
wheel control is manoeuvred using switches and or rollers in the handles. In most cases this permits the
operator to work in a more ergonomic position.
Restriction
The system can and may not be used to
drive the base machine/excavator at a
higher than approved speed.
The speed restriction must be tested
during evasive action testing in
accordance with ISO 5010:2007, 10.4.
The test determines the approved speed
for alternative steering.
The highest permitted speed may never
exceed 20 km/h.
The base machine/excavator’s controls
for operation always have master priority
over alternative steering.
Steering wheel movement must under all
circumstances shut-off alternative control.
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© Rototilt Group AB 2018-04-27
Alternative
steering
inactive
ICS Direct
activated
ICS Direct
installed
EN English
Control unit
The control unit has two diodes and is
connected to a buzzer.
The buzzer sounds in the event of a
system error and twice during start-up.
When the system works correctly, the
green diode lights with a xed light and
the buzzer is silent.
When a system malfunction occurs the
LEDs light and the buzzer sounds in
various combinations.
See Trouble shooting ICS Direct
The control unit can be connected to a
PC for reprogramming, calibration and
detailed trouble shooting.
Lamp and decal
A lamp and decal are installed on the
right-hand console. The decal shows
alternative control is installed on the base
machine/excavator.
When ICS Direct is activated the lamp
lights.
When the operation inhibitor is activated
the lamp ashes to warn that the system
is switched off.
Valve block, wheel control
The valve block is connected in parallel
to the base machine/excavator's orbitrol
control of the hydraulic ow.
The operator controls the operation and
steering of the base machine/excavator
via the rollers and switches tted in the
handles.
Alternative operation is only active when
the base machine/excavator’s:
• control inhibitor is deactivated
• drive mode switch is set to work mode
• and any additional drive mode switch
is set to low speed mode
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© Rototilt Group AB 2018-04-27
S3
R3
T5
Left Handle
Right Handle
EN English
!
IMPORTANT - The base machine/excavator’s factory
mounted handles have been replaced with handles
adapted for ICS Direct.
Carefully check the changed functions, for both the base
machine/excavator and alternative control.
Display
The symbol on the display comes on
when alternative operation is activated.
Handles
The handles are equipped with switches
and rollers to control the functions on
the base machine/excavator and for
alternative control.
The rollers in the handles must have
proportional control.
The handle functions are congured by
an authorised installer.
One of several possible examples of
connection to the alternative control is
described below.
Left Handle
S3 Activate alternative control
R3 Steering
Right = Turn right
Left = Turn left
Right Handle
T5 Drive
Up = Drive forward
Middle = Neutral
Down = Drive backwards
Information about functions
Information concerning the handles'
current conguration is available in three
places: On the decal, on the display and
in the instructions for the base machine/
excavator.
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© Rototilt Group AB 2018-04-27
Inactivate
5
Activate
Sound
1
3
4
Shut off
Lever
Light
Warning Flashing light
Sound 3 sec.
6
Drive Mode
Switch
Travel Limit
2
EN English
Operation
Activate alternative control
1. The operation inhibitor must be
deactivated, (usually occurs in the
horizontal position).
2. Turn the drive mode switch to work
mode. If there is a drive mode switch
for the speed, this should be turned
to low speed mode.
3. Activate alternative control with the
connected switch in the handle.
4. The control system's indicator lamp
lights to indicate that alternative
control is activated.
The alternative control symbol on the
display is shown.
The base machine/excavator’s controls
for operation always have master priority
over alternative steering.
Deactivate
ICS Direct is deactivated as follows:
5. Switch off alternative control with the
switch in the handle.
The control system's indicator lamp
goes out to indicate that alternative
control is deactivated.
The symbol is not shown on the
display.
or
6. Use the base machine/excavator’s
control for steering (wheel).
Alternative steering always has a
lower priority than the base machine/
excavator’s control. The control
system's indicator lamp ashes and
the buzzer sounds for 3 seconds to
warn that the system is switched off.
or
7. Turn the drive mode switch to
transport mode.
Warning signals as above.
!
IMPORTANT - If you suspect alternative control if
malfunctioning, always use the base machine/excavator's
controls.
i
INFO - If the voltage to the base machine/excavator fails,
the drive mode switch must be turned to work and
transport mode, as a function control.
!
WARNING!
Alternative steering must not be possible to use at a
higher than permitted and tested speed. Max. 20 km/h.
!
WARNING!
Steering wheel movement must under all circumstances
shut-off alternative control.
Operation
When alternative control is activated the
base machine/excavator is operated as
follows:
Drive (forwards and backwards) with
the right-hand handle. Steering (left and
right) with the left-hand handle.
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© Rototilt Group AB 2018-04-27
Inactivate
3
Activate
Sound
2
Shut off
Lever
Light
20
1
EN English
Malfunctioning
When an error code is generated from a
function, all functions are blocked.
Once the error code has been identied
in the trouble shooting table, the buzzer
can be temporarily switched off.
The buzzer stops if the activation switch
is pressed and held for 3 seconds.
Restarting activates the buzzer again.
Alternative connection
ICS Direct Wheel control can also be
connected to a frequency sensor in the
base machine/excavator’s transmission.
Once contact has been established
between the control system and the
frequency sensor, the system can be
activated.
Activate alternative control
1. Deactivate the operation inhibitor and
drive at a low speed, max 20 km/h.
2. Activate alternative control with the
connected switch in the handle.
Deactivate
3. ICD Direct is deactivate with the
connected switch in the handle.
4. Use the base machine/excavator’s
control for steering (wheel).
Alternative steering always has a
lower priority than the base machine/
excavator’s control. The control
system's indicator lamp ashes and
the buzzer sounds for 3 seconds to
warn that the system is switched off.
Safety latch
The speed must not exceed the permitted
limit, that is why alternative steering is
shut-off when the speed limit is exceeded.
The control system's indicator lamp ashes
and the buzzer sounds for 3 seconds to
warn that the system is switched off.
If the speed is lowered immediately the
system continues to be active.
Connection to the frequency sensor is
used on base machines/excavators not
tted with a drive mode switch.
i
INFO - If the voltage to the base machine/excavator
fails, the base machine/excavator must rst be driven at a
low speed so that the system can be reactivated.
!
IMPORTANT - The speed must not exceed the
permitted limit, that is why alternative steering is
shut-off when the speed limit is exceeded.
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© Rototilt Group AB 2018-03-26
trouble:1 English
EN
EN -
Troubleshooting ICS Direct
Fundamental signal
combinations
The control unit has two diodes and a buzzer, which indicate how the control system is working.
The components light and sound at different intervals and combinations.
The components are controlled by the signals that pass between the control unit and the other parts of the
control system.
Correct function - When the green LED
lights with a xed light the control system
works correctly.
System inactive - When the green and
red LEDs light with a xed light the drive
mode switch is not activated.
Calibration - When the green and red
LEDs ash quickly and the buzzer sounds
the rollers are not calibrated correctly.
Input signal - When the green and red
LEDs ash slowly and the buzzer sounds
the input signal does not work correctly.
Output signal - When the green LED
ashes and the Red LED lights with a
xed light and the buzzer sounds the
output signal does not work correctly.
Detailed troubleshooting
Calibration
Red LED Green LED Buzzer Possible cause Action
Flashes
quickly.
1 ash Sounds
at the
same
rate as
the red
LED.
Roller left not calibrated. The
control system clears the roller’s
calibration and stops output
signals.
Cable breakage, connector play
or roller fault.
• Calibrate the roller by pulling it to each
end position for at least 3 seconds.
• Change the roller and perform the
calibration as set out above.
• Contact the service workshop.
Flashes
quickly.
2 ashes Sounds
at the
same
rate as
the red
LED.
Roller right not calibrated. The
control system clears the roller’s
calibration and stops output
signals.
Cable breakage, connector play
or roller fault.
Red LED Green LED Buzzer Possible cause Action
Extin-
guished
Fixed light Silent System works. None
Correct function
Red LED Green LED Buzzer Possible cause Action
Fixed light Fixed light Silent System inactive. Activate the system
System inactive.
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© Rototilt Group AB 2018-03-26
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EN
EN -
Input signal
Red LED Green LED Buzzer Possible cause Action
Flashes
slowly.
1 ash Sounds
at the
same
rate as
the green
LED.
The supply to roller left broken,
caused by an open or short
circuit on the harness.
• Check the harness to the joystick in
terms of crush damage or open circuit.
• Restart the system.
• Contact the service workshop.
Flashes
slowly.
2 ashes Sounds
at the
same
rate as
the green
LED.
Roller left activated during start-
up of the control system. The
rollers’ output signal and the
output signal to the proportional
valve is blocked by the system.
• Return the roller to its zero position.
• Check that none of the rollers are
mechanically blocked.
• Check the condition of the rollers.
• Restart the system.
• Contact the service workshop.
Flashes
slowly.
3 ashes Sounds
at the
same
rate as
the green
LED.
The supply to roller right
broken, caused by an open or
short circuit on the harness.
• Check the harness to the joystick in
terms of crush damage or open circuit.
• Restart the system.
• Contact the service workshop.
Flashes
slowly.
4 ashes Sounds
at the
same
rate as
the green
LED.
Roller right activated during
start-up of the control system.
The rollers’ output signal
and the output signal to the
proportional valve is blocked by
the system.
• Return the roller to its zero position.
• Check that none of the rollers are
mechanically blocked.
• Check the condition of the rollers.
• Restart the system.
• Contact the service workshop.
Flashes
slowly.
5 ashes Sounds
at the
same
rate as
the green
LED.
Deviations in signal state on full
deection of roller left.
Error from the roller’s output
signals discovered by the
system after 0.2 seconds.
In the event of deviations,
the system blocks the roller’s
output signal and the output
signal to the proportional valve.
• Check the condition of the harness and
rollers.
• The fault lasts less than two
seconds:Return the roller to its zero
position.
• The fault lasts longer than two seconds:
Return the roller to its zero position.
Restart the control system.
Contact the service workshop.
Flashes
slowly.
6 ashes Sounds
at the
same
rate as
the green
LED.
Deviations in signal state on full
deection of roller right.
Error from the roller’s output
signals discovered by the
system after 0.2 seconds.
In the event of deviations,
the system blocks the roller’s
output signal and the output
signal to the proportional valve.
• Check the condition of the harness and
rollers.
• The fault lasts less than two
seconds:Return the roller to its zero
position.
• The fault lasts longer than two seconds:
Return the roller to its zero position.
Restart the control system.Contact the
service workshop.
Flashes
slowly.
7 ashes Sounds
at the
same
rate as
the green
LED.
Left roller activated during start-
up of the system.
• Return the roller to its zero position.
• Contact the service workshop.
Flashes
slowly.
8 ashes Sounds
at the
same
rate as
the green
LED.
Input signal fault from the
pressure sensor.
• Check the harness in terms of crush
damage or open circuit.
• Check the sensor
• Contact the service workshop.
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© Rototilt Group AB 2018-03-26
trouble:3 English
EN
EN -
Output signal
Red LED Green LED Buzzer Possible cause Action
Fixed light 1 ash Sounds
at the
same
rate as
the green
LED.
Functional fault on output
signal wire 1.
Output signal blocked.
• Check the harness in terms of crush
damage or open circuit.
• Check the condition of the valve.
• Return the roller to the zero position.
• Contact the service workshop.
To reset the fault indication, restart the
system by disconnecting the voltage on the
base machine.
Fixed light 2 ashes Sounds
at the
same
rate as
the green
LED.
Functional fault on output
signal wire 2.
Output signal blocked.
• Check the harness in terms of crush
damage or open circuit.
• Check the condition of the valve.
• Return the roller to the zero position.
• Contact the service workshop.
To reset the fault indication, restart the
system by disconnecting the voltage on the
base machine.
Fixed light 3 ashes Sounds
at the
same
rate as
the green
LED.
Functional fault on output
signal wire 3.
Output signal blocked.
• Check the harness in terms of crush
damage or open circuit.
• Check the condition of the valve.
• Return the roller to the zero position.
• Contact the service workshop.
To reset the fault indication, restart the
system by disconnecting the voltage on the
base machine.
Fixed light 4 ashes Sounds
at the
same
rate as
the green
LED.
Functional fault on output
signal wire 4.
Output signal blocked.
• Check the harness in terms of crush
damage or open circuit.
• Check the condition of the valve.
• Return the roller to the zero position.
• Contact the service workshop.
To reset the fault indication, restart the
system by disconnecting the voltage on the
base machine.
Fixed light 5 ashes Sounds
at the
same
rate as
the green
LED.
Start-up check that indicates
whether one of the valves is
not connected to the control
system.
• Check the harness in terms of crush
damage or open circuit.
• Check the condition of the valves.
• Restart the control system.
• Contact the service workshop.
To reset the fault indication, restart the
system by disconnecting the voltage on the
base machine.
Fixed light 6 ashes Sounds
at the
same
rate as
the green
LED.
Functional fault on output signal
wire Auxiliary.
Output signal blocked.
• Check the harness in terms of crush
damage or open circuit.
• Check the condition of the valves.
• Restart the control system.
• Contact the service workshop.
To reset the fault indication, restart the
system by disconnecting the voltage on the
base machine.
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© Rototilt Group AB 2018-04-27
schema:1
Schematics and Overwievs for hydraulic as well as electrical systems, in the following pages are meant to
serve mainly as a guide for Troubleshooting.
!
WARNING!
More extensive adjustments and repairs must be done by
an authorized service workshop.
Schematics
Valve Block, Wheel Control
1. Port T1
2. Port T
3. Port P IN
4. Port LSO
5. Port A
6. Port B
7. Connector 3
8. Connector 4
9. Connector 2
10. Pressure Sensor, PT
11. Port EF
12. Port LSP
13. Pressure Relief
9
12
5
7
8
10
11
1
2
3
4
6
13
English
EN
EN -
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© Rototilt Group AB 2018-04-27
schema:2
Open Center
ICS Direct Wheel Control can be adapted
with two alternative options for Valve
Block. Both Valve Blocks are connected
to the same functions for the system.
Illustration below shows the Open Center
Version.
Valveblock, Wheel Control - Open Center
English
EN
EN -
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© Rototilt Group AB 2018-04-27
schema:3
Statisk / Dynamisk Inkoppling
ICS Direct Wheel Control can be adapted
with two alternative options for Valve
Block. Both Valve Blocks are connected
to the same functions for the system.
Illustration below shows the the Static /
Dynamic Version.
Valveblock, Wheel Control - Static / Dynamic
English
EN
EN -
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© Rototilt Group AB 2018-04-27
schema:4
LSO
LSP
EF
TT
PP IN
A BR L
ADAPTER
HOSE
3
⁄
8
”
HOSE ¼”
BYPASS
PLUG
Hydraulic connections, Open Center
English
EN
EN -
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© Rototilt Group AB 2018-04-27
schema:5
LSO
LSP
LS
CF
EF
TT
P
P
P IN
A BR L
ADAPTER
HOSE
3
⁄
8
”
HOSE ¼”
BYPASS
EF
LS
Hydraulic connections, Static / Dynamic
English
EN
EN -
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© Rototilt Group AB 2018-04-27
schema:6
Harness ICS Direct
Harness ICS Direct General version
i
INFO - Schematic refers to the general version of ICS
Direct. Adapted versions of the system may differ.
English
EN
EN -
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© Rototilt Group AB 2018-04-27
schema:7
Harness, Pressure Sensor
English
EN
EN -
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