ROTOTILT ICS User manual

_7225 2018-04-06
2200230
CAT 311-335 E/F
Control System - ICS
Translation of the Original Instructions _EN

2018-04-01
ICS control system for
CAT 311 - 335 E/F
Translation of
EC Declaration of incorporation of partly completed machinery
In accordance with Machinery Directive 2006/42/EC. Appendix II B
Manufacturer
Rototilt Group AB
Box 56
SE-922 21 Vindeln
SWEDEN
declare under our sole responsibility that the following product:
Product:
Qualied to compile the technical documentation in accordance with annex 7B:
Niklas Bjuhr
VP Engineering, Rototilt Group AB
Place and date: Vindeln, Sweden
Name and signature of authorized person:
a) complies with the following essential health and safety requirements:
1.1.3, 1.2, 1.7.4,
in, the European Parliament and European Council Machinery Directive 2006/42/EC of 17 May,
2006.
b) is manufactured in accordance with other applicable directives such as:
Directive 2014/30/EU of The European Parliament and Of The Council of 26 February 2014 on
the harmonisation of the laws of the Member States relating to electromagnetic compatibility
c) is manufactured in accordance with the following harmonized standards:
SS-EN ISO 12100:2010, SS-EN ISO 13849-1:2016, as well as applicable parts
of SS-EN 474-1:2006+A5:2018 and SS-EN 474-5:2006+A3:2013.
Anders Jonsson
CEO, Rototilt Group AB
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23
1
64
7
EN English
Overview
The product described in the document consists of components for the ICS control system. The overviews
show standard equipment and options.
Refer to the gures and lists below as well as on the following pages.
ICS control system
ICS control system consists of the
following components:
1. Harness, boom
Contact (SecureLock, machine
coupler)
Contact with safety plug
2. Display
Switch for tool replacement.
Cab control unit, CCU
3. Handles with controls to operate
Rototilt® functions and base machine
functions are ordered separately
4. Valve block
Electric swivel
5. Rototilt®control unit, TCU
Zero-position sensor. (ICS sensor,
ICS SecureLock)
Frequency sensor. (ICS sensor,
ICS SecureLock)
6. Connection to the base machine
control unit.
7. Locking cylinder sensor.
(ICS SecureLock)
LED lighting. (ICS SecureLock)
!
IMPORTANT - Read the Instructions for Use for the
control system, tiltrotator and base machine before
starting work. Pay particular attention to the safety
instructions.
!
IMPORTANT - Pressurising the Rototilt®hydraulic
system means that the quick coupler locking
function will be pressurised.
!
IMPORTANT - Connected safety plug ensures that
the base machine’s quick coupler is not opened
accidentally during use of the tiltrotator.
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!
PULSATING
LIGHT
FIXED
LIGHT
TCU
CCU
Sound
Light
Power
CAN-bus
Internal
Error
LED INDICATIONS
OK Error
EN English
Control unit
The control units have three LEDs:
green, orange and red. When the system
is working correctly, all LEDs light and
with no ashing.
When a malfunction occurs the relevant
LED begins ashing.
PWR (green) shows whether the unit is
powered up.
CAN (orange) shows whether communi-
cations with CAN bus are working.
SYS (red) shows whether the unit’s inter-
nal components are working correctly.
The control units are not interchangeable.
Cab control unit, CCU
The control unit receives signals from the
handles and switches.
The control unit sends signals to the
valve block shunt and tiltrotator via CAN
bus.
Rototilt® control unit, TCU
The control unit receives signals from
the cab control unit, and from sensors in
Rototilt®.
Rototilt® control unit sends signals to
valves and LED lamp.
There is a sensor in the Rototilt® control
unit that detects the tilt angle.
!
IMPORTANT - The control units have a similar
appearance but the content differs. They are not
interchangeable.
Display
Settings, calibration and activation of
certain functions are made via the display
and its keys.
There is a buzzer in the display that
sounds to attract the operator’s attention
if the quick coupler locking function is
open or in the event of a fault.
Switch, quick coupler locking
function
The quick coupler locking function switch
is interlocked. This prevents accidental
activation of the quick coupler locking
function.
!
WARNING! A problem has occurred if the buzzer
sounds without activating the quick coupler locking
function switch. The display shows information
about the current problem.
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Right
Left
B
2
A
1
Control Unit -
Excavator
C
D
EN English
Handle
The handles are equipped with switches
and rollers to control Rototilt® functions
and base machine functions.
The standard version has 2 rollers and 7
switches in each handle.
There are 5 switches for the base
machine functions.
The handle functions are congured by
an authorised installer. Functions are
programmed according to the following
standard unless otherwise stated.
Left Handle
A Rotation
1 Option 1
D Extra 2
Right Handle
B Tilt
2 Option 2
C Extra/Grapple
Also see sticker and display
!
IMPORTANT - The base machine’s factor-installed
handles have been replaced with handles adapted
for ICS.
Carefully check the changed functions, for both the
base machine and Rototilt®.
Machine control
Machine control regulates the oil ow to
the hydraulic circuit for extra equipment
on the base machine. Movement of
the rollers in the handles affects the oil
ow in the machine's main valve via the
control unit.
The system has two different functions:
Rototilt® control
When the 8-pole connector on the stick is
connected, a ow is regulated parallel to
the valves on Rototilt ® and the hydraulic
ow is adjusted to this.
The ow runs in one direction only.
Regulation of extra hydraulics
When the base machine is run without
Rototilt ®, the control can be used to
regulate the oil ow in the machine circuit
for extra hydraulics.
The ow can be regulated in both
directions.
In this mode, the extra/grapple roller
regulates MP/HP2.
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Track R/L
Joystick Functions
* Index Finger Side
Touchpoint /
Laser
Horn
Rotation /
Depth / MP
Trigger *
Grapple *
Pulse Function/ *
Shift Double Feeder
Track F/R
Hammer /
Clear Benchmark
AEC
Tilting / Slope /
Combi
Smart Boom*
Extra 2 *
Hold / *
Switch to Double Feeder
Touchpoint / Laser
Horn
Trigger
Rotation /
Depth / MP *
Grapple*
Pulse Function / *
Shift Double Feeder
Hammer /
Clear Benchmark
AEC
Smart Boom
Tilting / Slope /
Combi *
Extra 2 *
Hold / Shift to
Double Shunt
Joystick Functions
* Index Finger Side
Option 1
Option 2
EN English
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Planeringsskopa, rotation 360°
Rotation, 360° Rotation, 360°
Planeringsskopa, tilt 40°
Tilt, 40°
Tilt, 40°
Left Handle
1. Rotation, clockwise
2. Rotation, anti-clockwise
Right Handle
3. Tilt, right cylinder extension
4. Tilt, left cylinder extension
4
3
2
1
4
3
2
1
EN English
!
IMPORTANT - When using Rototilt® the base machine
pedals must not be used to further increase the oil ow, as
this can result in serious damage to Rototilt®.
Operating Rototilt®
The ICS control system permits tilt,
rotation, grapple and an extra function to
be used in parallel and to be regulated
proportionally.
ICS works in parallel with any pedals on
the base machine. When using Rototilt®
the base machine’s pedals must not be
used to regulate the oil ow.
A calibrated ICS system provides each
system with its optimal ow. The Rototilt®
can be seriously damaged if the pedals
on the base machine are used to further
increase the ow.
Carefully check the positions and
functions of the switches.
The appearance and placement of
switches may vary depending on the
base machine and handle.
The selected function opens the
equivalent valve directional on Rototilt®.
Activate the ICS control
system
The system is activated when the base
machine is in the ignition position.
Speed
The speed of all functions can be
adjusted.
The adjustment is made via Display,
Speed settings menu.
The speed can be adjusted in general
for all functions. The speed can also be
adjusted separately for each individual
function.
Operation
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2
Right
Left
B
1
2
D
EN English
Pulsating function
The ICS control system can produce a
pulsating, shaking function to spread
material out of a tilting bucket, for
example.
Press switch 1 and regulate the speed
with roller B.
Non-variable hydraulic flow, Extra 2
The ow can be locked using switch 2
(Hold) when the intended level is reached
with roller D (Extra2). Press and hold the
switch for 0.5 seconds.
The next time the switch (2) is pressed
the function releases and the ow
ceases.
!
IMPORTANT -
Carefully check the relevant functions, on the display or
the handle sticker.
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EN English
Detach the tool
Position the tool horizontally, resting on
rm ground or so that the tool cannot
slide out of the attachment when the
quick coupler locks are opened.
!
IMPORTANT - If the tool can fall or change position in
connection with the procedure, there is a risk of damaging
the tool and/or quick coupler.
!
IMPORTANT - It is only possible to open the lock when
the start menu is visible or from the troubleshooting menu.
Operating Rototilt® quick coupler
Check that the display shows the start
menu. The icon for the quick coupler
locking function is shown above the
green function key.
First press the green function key and
release it.
The buzzer in the control unit sounds.
Now move the quick coupler locking
function switch to the open position.
The switch is enabled for a period of
10 seconds.
The lock remains open as long as the
switch remains open, but pressurising
is only performed during the preset time
period, 3-12 seconds.
The preset time can be checked on the
display, Menu Settings.
The switch must be switched on and then
off again to repressurise the hydraulic
cylinder.
See the Instructions for Use for the quick
coupler.
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Indicator Rod - Open
EN English
When Rototilt® is pressurised
hydraulically the quick coupler locking
function is opened. The indication on the
quick coupler shows that the lock is open.
When the quick coupler’s locking wedge/
locking pistons are fully open, the tool
can be detached by slowly retracting the
bucket cylinder.
Return the switch to its original position
to close the lock.
Pressurising is for a preset period of
maximum 12 seconds. The default time
can be checked on the display, Menu
Settings.
The switch must be switched on and then
off again to repressurise the hydraulic
cylinder.
A warning is shown on the display if the
quick coupler is in the open position.
The base machine can be equipped with
different combinations of quick coupler
and machine coupler. The gure and
text on the display are dependent on the
combination.
Both the quick coupler and the machine
coupler are available with and without
electronic monitoring (SecureLock).
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Indicator Rod - Closed
Locking Wedge - Closed
EN English
Attach the tool
Open the quick coupler and check that
the indication shows that the attachment
is open.
Refer to the quick coupler section.
Position the quick coupler so that its
attachment is correctly aligned with the
tool’s attachment frame.
Now slowly pivot the tool by extending
the bucket cylinder.
Adjust with small stick or boom
movements if necessary.
Reset the switch for quick coupler locking
function.
The quick coupler’s locking cylinder
returns to its closed position. The
indication on the display conrms that the
switch is in the locked position.
The indicator on the quick coupler shows
that the quick coupler locking function is
in the locked position.
Inspect the quick coupler locking function
i
INFO - If the quick coupler locking function is in the
closed position when the tool is attached, the switch must
be switched on, off and on again.
Inspection of the quick coupler
locking function
Even if the indication shows that the
locking wedge has engaged in the locked
position, perform the following test to
check that the tool is securely attached:
Push the tool forwards towards the
ground; see the gure to the left.
Operate the bucket in this position, inwards
and outwards, to check that the locking
wedge has correctly locked the tool.
Rotate the quick coupler and check from
the operator position that the locking
wedge/locking pistons have engaged.
In the event of uncertainty, exit the
machine and conduct a visual check.
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1
1 2
3
EN English
Quick coupler with SecureLock
Operation in the same way as the quick
coupler without SecureLock; see above.
When the quick coupler is opened a
warning is given that the locking cylinder
has been retracted and is in the open
position.
When the quick coupler is closed, the
message indicates that the locking
cylinder is extended and is in a securely
locked position.
Inspect the quick coupler locking function
A warning text appears on the display if
the tool is not coupled correctly.
If you do not intend to couple a tool, the
warning must be acknowledged.
First press the green function key and
release it.
Now press the OK function key. The
buzzer warning signal stops.
Return to the start menu using any key.
A visual warning will be shown at
30-second intervals as long as Rototilt®
is running without a tool and remains
visible until any key is pressed again.
Quick coupler QuickChange™
Operation is the same as for the quick
coupler; see above.
When the quick coupler is opened a
warning is given that the locking pistons
have been retracted and are in the open
position
When closing the attachment, the rst pin
(1) is engaged, followed by pin (2) and
nally the locking pistons (3).
The quick coupler locking function cannot
be closed until both pins in the attach-
ment frame are correctly positioned.
The position on the quick coupler’s three
sensors are monitored continuously.
All sensors are shown in green on the
display when a tool is correctly coupled.
Inspect the quick coupler locking function.
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1. Remove Rototilt® from
Boom Harness
2. Demount Safety Plug
3. Connect Safety Plug to
Boom Harness
4. Protect empty connector.
1
2
3
4
EN English
Detach Rototilt®
Always park the tiltrotator on a stable and
at surface, without tools. Make sure that
Rototilt® cannot tip over.
Disconnect the hydraulic hoses and
harness between the Rototilt® and the
base machine. The tiltrotator is now
detached from the base machine.
If the machine coupler is open while the
harness to the tiltrotator is still connected,
a warning is shown on the display.
Safety plug
The function is used to lock the machine
coupler while the tiltrotator is mounted.
The lock prevents accidental opening of
the machine coupler.
Disconnect the Rototilt® contact.
Remove the safety plug and connect it to
the boom harness contact.
Control of the machine coupler works
normally again.
Operating extra hydraulics
Detach Rototilt®.
Now select regulation of extra hydraulics
on the display by activating double valve
block shunt.
Conrm with the OK function key.
For return to Rototilt ® control: First
connect the tiltrotator and then connect it
to the base machine.
Now select Rototilt® operation on the
display and conrm the selection with
the green function key and then the OK
function key.
Control of the oil ow in the base
machine’s extra hydraulics circuit can be
performed using a roller or switch. Both
alternatives work in parallel with any
pedals on the base machine.
Roller for the tilt function B regulates the
ow in both directions.
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Right
2B
Left Right
2B1
Left Right
21
EN English
!
IMPORTANT - The base machine’s factory-installed
handles have been replaced with handles adapted for
ICS. Carefully check the changed functions, for both the
base machine and Rototilt®.
Non-variable hydraulic flow
The ow can be locked using switch 2
when the intended level is reached with
roller B.
Press and hold the switch for 0.5
seconds.
The next time the switch (2) is pressed
the function releases and the ow
ceases.
On/Off control
Left handle, switch 1 starts and closes
full ow in one direction.
Right handle, switch 2 starts and closes
full ow in the other direction.
Operating CGC
Base machine equipped with CGC,
calibrated with tiltrotator coupled.
When calibration necessary, activate
double valve block shunt.
Activate: Simultaneously press and hold
the option 1 and option 2 switches for at
leas 3 seconds
Return to normal Rototilt® operation:
Repeat this procedure.
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C
A
B
10
D
9
11
4
8
3
7
2
6
1
5
English
EN
Configuration of ICS
i
INFO - Prole 0 is reserved for the installer and cannot
be modied by another user.
Display
ICS and ICS Direct are congured during
installation with the help of the display.
Operators can adjust settings on the
display and save them in individual
proles. The last selected prole remains
active after start-up; change if necessary.
The installer uses prole 0.
A. The top bar indicates the current menu
or numbered warnings. Also see alarm
list in the Schematics. section
B. 8 sub-menus are shown on the Start
menu:
1. Angles
2. Speed
3. Brightness
4. Language
5. Information
6. Handle
7. Troubleshooting
8. Settings
C. Icons are shown on the bottom bar. At
the left edge, the icons indicate which
function or function key activates in
the current view.
The current prole is shown in the
right corner.
D. The display has a total of 8 keys:
9. Three function keys
blue, green & red
10. Four arrow keys
Change values & navigate the menu
11. One key to conrm (OK).
Unless otherwise stated, make the
changes as follows:
Move the cursor using the arrow keys.
Conrm with OK.
Adjust the values with the arrow keys.
Conrm with OK.
Return to the previous menu using the
right function key (red).
Language
The language setting is changed via
the menu. The 7 options are; English,
Swedish, Finnish, Norwegian, German,
Danish and French.
Select the ag for the preferred language.
Conrm with OK. This change is enabled
only if the system is restarted.
i
INFO - A system restart is required to activate a change
in language.
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32
English
EN
iTIP -
A prole can apply to a tool instead of a user.
!
IMPORTANT - It is only possible to open the lock either
when the start menu is visible or from the troubleshooting
menu.
Operator settings
Profile
The bottom bar shows the active prole.
The prole can be changed either directly
when starting using the arrow keys or via
menu settings.
Mark the settings in the start menu,
conrm with OK.
1. Specied values for the prole are
changed using the arrow keys.
2. The selection is conrmed with OK.
3. Return to the start menu with the
right function key (red).
The settings that can be saved in a
prole are speed, roller direction and
position of tilt or rotation. Make the
settings under each menu and save to
the active operator prole. Proles 1-4
are available to users of the machine/
excavator.
Quick coupler
The icon for the quick coupler is shown
in the lower list on the menus Start and
Trouble shooting.
In order to open the quick coupler, the
green function key must rst be pressed
and the released.
The buzzer sounds and the lock
switch can then be regulated during a
10-second period.
Speed
Both the general speed, and the speed
of specic functions are adjusted via the
menu.
Navigate between the functions using the
vertical arrow keys.
Adjust the values of each function using
the horizontal arrow keys. Conrm the
settings with OK
General speed cannot be adjusted in
prole 0.
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EN
Handle
The functions of the rollers and switches
are described on the menu.
Information about handle conguration is
specied in three places: On the sticker,
on the display and in the Instructions for
Use for the base machine/excavator.
The roller direction can be changed:
select the function and conrm with OK.
Shift direction with x/x, middle function
button (green).
A dash above the function shows that it is
inverted. Conrm with OK.
The user can toggle the position of tilt
and rotation.
Switch the position using the left function
button (blue). A warning text will now be
displayed in the menu view.
A larger warning text is also displayed
upon each start-up of the system, and
upon each activation of the shut-off lever.
The warning must be conrmed with OK
to activate the tiltrotator’s functions.
The ability to switch positions for the
rotation and tilt functions should be used
as seldom as possible.
!
IMPORTANT - The base machine/excavator’s factory-
installed handles have been replaced with handles
adapted to the control system.
Carefully check the changed functions, for both the base
machine/excavator and alternative control.
i
INFO - Prole 0 is reserved for the installer and cannot
be modied by another user.
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EN
Angles
Information about rotation* and tilt
angles is found via the menu and special
functions can also be chosen here.
Pulse function
The shake function is active when
starting the system except in those cases
when the hydraulic thumb is activated.
Shake the bucket by pressing and
holding switch 1, left handle depressed,
and at the same time, pulling roller B with
the tilt function (default: roller B, right
handle).
Set position*
Select the set position and press OK to
save the current rotor and tilt positions in
the memory for the next time the system
is started.
Saved position*
Select saved position and press OK.
When switch 1, left handle is activated
the rotor and tilt functions move to the
saved, predened positions.
The function is only active in this view.
*Does not apply to ICS Basic.
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Parked position
Active
hydraulic
thumb
English
EN
Hydraulic thumb
If the base machine/excavator is
equipped with a hydraulic thumb on
the stick, the ICS system can prevent
simultaneous use of the tiltrotator and
hydraulic thumb.
The display shows the alternatives under
the Angles menu. If the text is grey
instead of black, the function cannot be
activated.
To activate this function, the tiltrotator’s
rotation position must be at the zero
position; a certain margin of error (<5°) is
allowed.
The angle of the tiltrotator in relation to
the base machine/excavator stick shall
be 0°. Perform a visual check to ensure
that this is the case.
Select the alternative and conrm with
OK.
As long as the hydraulic thumb is
activated, a warning text is shown on the
display.
Disabling the function must be done
manually. It does not shut down in
connection with system restarts or when
the base machine/excavator ignition is
turned on and off.
Before disabling the function, the
hydraulic thumb must be returned to the
parked position. Perform a visual check
to ensure that this is the case.
Turn off the function with OK.
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*
*Not visible for operator when RPS is installed.
English
EN
Automatic Grade Control
Option only available with activated RPS
and established communication with
excavator system.
If the automatic tilt and rotation function
is included in the installed excavation
system, it can be controlled via ICS.
Select the icon for the Angles menu and
then conrm your selection with OK.
Select Auto grade control (AGC) in the
view on the display using the arrow keys.
Conrm your choice with OK.
Activate the function by pressing and
holding the button on the handle. This
is generally located on the right handle;
check against the handle sticker.
The function is only active in this view.
Shake function/Frequency
Select Frequency and adjust the
frequency of the shake function.
Pressurising
Select Feeder time Coupler and set the
required value (3-12 sec). The saved
value regulates the time that the quick
coupler locking function is pressurised.
Calibrate angles
In order for the angle display to work
correctly, it must be calibrated with the
right bucket.
Rotate the bucket to the zero position.
Position the bucket bottom at against
the surface.
Now highlight the icon to save (diskette),
using the arrow keys.
Conrm with the OK function key.
i
INFO -
If RPS is installed, angles are calibrated by an authorised
installation engineer.
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