Schwing CPC3 User manual

SCC Fault Isolation Manual 6/03/2020
Page 1of 11 Rev. 01 9/20/2021
Schwing CPC3 Fault Isolation Manual
General Information
This manual will give a brief overview of each component of the system as well as basic steps to troubleshooting. This manual will not list truck specific components or wiring as those change for every vehicle type.
CPC3 is a drop-in replacement of the previous CPC systems. CPC3 system is an upgraded system for C32, CPC and CPC2, as well as all the variations and revisions of each one. Due to this, CPC3 may vary depending on what the original system was and how it
was changed over the years and what options were originally installed.
If you have a problem with this system, please email/call Schwing Service Techs, who will email the Electrical Engineering Team with what the problem was and the fix for it. This allows us to evaluate what caused the issue and update our procedures as well
as this troubleshooting guide.
This manual is not 100% and is only meant to give general steps on how to troubleshoot the system. As more issues arise and data is given to the Electrical Engineers, we will continually update this document to provide as many options as possible.
System Overview:
Functions:
•All C32, CPC and CPC2 functions that the unit had previously.
•Shows PTO, Pump and Boom Hours
•Easy Troubleshooting screens
•Maintenance Switch –Gives constant power to the Dump Valves
•Easy Teach mode operation
98455320
Schematic CPC3
98458772
Full Panel Assembly
98391422
PLC
98465074
PDM
98395784
2.8” Display
98455321
Rear Keypad
98463187
Local/Remote Switch Assembly
98457837
Panel Harness
98457028
I/O-E Harness
98465743
Scanreco Transmitter
98461655
Scanreco Receiver
98465556
Oil Temp Harness
98462248
Oil Temp Sensor
98462245
Oil Pressure Sensor
98465557
Area Lights Jumper (Main Connector)
Common SAI Numbers:

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Primary PLC:
This is the brain of the system. This controls all the inputs and outputs of the system.
•This module has 32 inputs and 48 outputs and is IP67 with all connectors connected.
•This MUST be programmed before shipping.
Output
Con
Pin
Function
OUT00
ST
18
Concrete Pump Dump
OUT01
ST
17
Agitator Dump (Option)
OUT08
ST
2
Boom Dump
OUT00
EX
18
Stroke Limiter
OUT01
EX
17
Telescope Extend
OUT02
EX
16
Telescope Retract
OUT03
EX
15
Boom 1 Up
OUT04
EX
14
Boom 1 Down
OUT08
EX
2
Boom 2 Up
OUT09
EX
3
Boom 2 Down
OUT10
EX
4
Boom 3 Up
OUT11
EX
5
Boom 3 Down
OUT12
EX
6
Boom 4 Up
OUT13
EX
7
Boom 4 Down
OUT14
EX
8
Slew CCW
OUT15
EX
9
Slew CW
OUT16
EX
25
Boom Enable
OUT17
EX
26
Outrigger Enable
OUT18
EX
27
Water Pump
OUT19
EX
28
Compressor
OUT20
EX
29
Concrete Pump Rev
OUT21
EX
30
Concrete Pump Fwd
OUT22
EX
31
Engine Speed Down
OUT23
EX
50
Engine Speed Up
OUT24
EX
42
Tower Horn
OUT26
EX
44
Work Lights Boom
OUT27
EX
45
Agitator Fwd
OUT28
EX
46
Agitator Rev
OUT29
EX
47
Vibrator
OUT30
EX
48
Oil Cooler
OUT31
EX
49
Boom Horn
Input
Con
Pin
Function
Description
IN00
ST
55
E-Stop Ch1
Hand Valve E-Stop
IN01
ST
36
E-Stop Ch2 (Option)
IN02
ST
54
E-Stop Remote Ch1
Radio Remote E-Stop
IN03
ST
35
E-Stop Remote Ch2
IN04
ST
53
E-Stop Rear Ch1
Hopper E-Stops and Water Box E-Stop
IN05
ST
34
E-Stop Rear Ch2 (Option)
IN06
ST
52
Hopper Grate Switch
IN07
ST
33
Outrigger Enable PB
IN08
ST
24
Slew Limit Left
IN09
ST
41
Slew Limit Right
IN10
ST
23
Boom 1 Telescope Disable (Opt)
IN11
ST
40
Ram Change Mode (Option)
Only if previously equipped with Ram Change
IN12
ST
22
Maintenance Switch
Puts the system into Maintenance Mode
IN00
EX
55
Ram Change Forward (Option)
IN01
EX
36
Ram Change Rev (Option)
IN02
EX
54
Oil Filter Dirty Switch
IN03
EX
35
Oil Temp Sensor
Oil Cooler comes on at 55°c.
IN04
EX
53
Driveshaft Speed Sensor
IN05
EX
34
Water Level Sensor
IN06
EX
52
Alternator D+
IN08
EX
24
Stroke Counter (Option)
IN09
EX
41
Oil Pressure (Option)
IN10
EX
23
Horn Push Button
IN11
EX
40
Remote Enabled
Tells the system to listen to the Radio Remote

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2.8” Display:
•Displays all CPC3 information
•Simple M12 connection behind display
•Turns on with PTO.
•This MUST be programmed before shipping.
Views:
•Home Page
oRPM: Driveshift Speed
oOil Temp
oOil PSI (Option)
oStrokes/Min (Option)
oMessages and Errors are displayed at the top
oComms sections displays link statuses
oTwo Stroke Counters with individual resets
•Menu Screen
oDefault password is “1234”
•Proportional Control Settings: (See teach mode section below)
oEnables Teach Mode and can reset min/max values to factory reset.
oViewable without password entered.
•Remote Control Status Screen
•Keypad Status Screen
•Maintenance Screen
oDisplays Error messages at the bottom
oAllows resetting of hour meters
•I/O Screen
oShow troubleshooting information for the system
oShows current voltages and I/O statuses
•Configuration Screen
oOnly available at the Factory.
Homepage without options
Icons: Dirty Oil Filter,
Oil Cooler, E-Stop,
Local/Remote Icon
Messages are
displayed here
Homepage with all icons
Turns green when
properly linked
Stroke Counter
Hold to reset
stroke counter
E-Stop Request:
Press horn button
Alarm Silence
PLC I/O Pages –Use Left and Right arrows to switch between screens

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Power Distribution Module (PDM):
•One location for all fuses, relays and circuit breakers.
•This distributes power to all components.
•All Primary circuits have either self-resetting circuit
breakers or manual resetting circuit breakers.
oSelf-resetting circuit breakers reset when
power is cycled to the system.
oOnly exception is 5a circuits use lighted fuses
due to the unreliability of circuit breakers at
low amperages.
•All non-essential functions have fuses.

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Keypad:
•Provides controls for all non-boom functions that can be operated while in local mode.
•Located at rear of vehicle, near right-side hopper.
Maintenance Switch:
•Located on the side of the control panel.
•This switch puts the CPC3 system into bypass mode.
•CAUTION: Bypasses MOST safety features of CPC3. E-STOPS WILL NOT OPERATE.
•Keyed switch allows owner to remove this ability.
•Turns on all Dump Valves regardless of E-Stops.
•This switch is only intended as a backup incase a part of the CPC3 system has failed and is preventing normal operation.
oThe unit should be fixed immediately to prevent damage to equipment and personnel.
•If the PLC is still operational, the throttle can be controlled via the “Maintenance Screen” by scrolling to “Engine RPM Control” and using the +/- Buttons.
oThrottle from rear keypad will not work.
•In Maintenance Mode the Radio remote will show “NO CAN BUS MESSAGES” and will not be operational.
•Stroke Limiter buttons will still work from rear keypad if the PLC is still operational.
Scanreco Radio:
•915 MHz Mini 303 w/LCD
•“A” Light at top indicated the E-Stops are clear and the Hopper is closed. System is operating good.
•“C”Soft Stop condition –E-Stops are clear but a switch was not neutral first.
•“E” Light at top indicates an Error is present and it has not been acknowledged.
•Radio Signal Light is off when the radio is working normal. If the radio signal is poor, it will flash red. When it loses link, it goes to solid red.
Maintenance Keyswitch
Scanreco Radio Display
Battery Gauge
Error Messages
Signal Stength

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Teach mode Operation:
Teach mode calibrates the joysticks of the Radio Remote. When the joystick is barely moved the boom should start to slowly move. When the joystick is maxed out the hand
lever should be brought to the point where the hand lever is just barely maxed out and still wiggles. This will give the joysticks the most accurate and consistent range of
motion.
•To enter teach mode:
oOn the display, go to the menu screen and go down to “Proportional Settings”. A password field will show up to the right.
▪If you do not enter a password, you can still enter the screen, but you will not be able to change any values.
▪Entering the customer password (Default “1234”) allows you to change the values or restore to Schwing Factory Settings.
▪Entering the Factory password allows you to revert to either the factory settings or the default settings. Making any changes while under the Factory
password adjusts the Factory parameters. This should only be used at Schwing.
oWith a password entered, go into the Proportional screen.
oAll operations should be done at Max RPM. Raise the vehicles RPM to max.
oClick the “Teach Mode” button at the bottom.
oAt this time, you can adjust any function you need using the radio remote.
oFor each boom function you want to change:
▪Flip the Rabbit/Snail mode to appropriate position. Snail adjusts the minimum and Rabbit adjusts the maximum values.
▪Hold the joystick in the function you want to adjust. IE: To adjust Boom #1 Up move the right-hand joystick down and hold it there.
•CAUTION: THE BOOM SHOULD MOVE DURING THIS TIME.
▪Use the throttle up and down to adjust the value until you get the desired result.
▪While holding joystick, activate the horn button on the radio to save the setting. Once a setting is saved, a box will appear around the saved value on the screen.
▪Release the boom function.
oTo adjust the stroke limiter values:
▪Flip the Rabbit/Snail switch to Neutral. A “S/M” value will appear on the screen. This gives you your strokes per minute value if a stroke counter is
installed.
▪Bringing the Stroke pot below 5 will adjust the max current value.
▪Bringing the Stroke pot above 5 will adjust the min current value.
▪Use the throttle up and down to adjust the value until you get the desired result.
▪Activate the horn button on the radio to save the setting. Once a setting is saved, a box will appear around the saved value on the screen.
oTo revert to Factory settings. Hold the Factory Reset button for 5 seconds.
These two buttons may show up when in Teach Mode
and allows the operator to reset to previous settings.
A blue box (As shown with MinVol.) is the field being adjusted.
A thin orange outline (Boom 4 Up) indicates the field has been
adjusted and saved.

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How to determine the PLC Version:
1. If your system is not operating, it is best to find the version of the other component that is working (PLC or Display). This information can help to make sure the version you put into the replacement part is compatible.
a. If the display is working, go to the menu screen and look in the bottom corner for the versions.
b. If the display is not working:
1. Activate any E-Stop and leave it pushed in. Hold down the “Stroke Limiter Increase”(Bottom Right) button until the keypad lights change. The keypad is now displaying the version of the PLC. Use the chart below to find the version.
2. On the Keypad - Add up all the lights of each column then subtract 1. Each column denotes a position in the version. The example below has version 1.48.00F
v1 . 4 8 . 0 0 F
Denotes “F”
Denotes “T”
The last two lights of
the last column
denote if the version
is a Test or Final
release.
The Keypad icons will differ for CPC machines and do
not matter for telling the version.

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Fault Isolation Manual:
Use the table below to find the problem that is most relevant to your issue. Then go to that item number.
•Page 9 Section 1. Display does not turn on
•Page 9 Section 2. Primary PLC does not turn on (No lights on PLC)
•Page 9 Section 3. Throttle control does not work
•Page 9 Section 4. Oil Cooler does not turn on
•Page 9 Section 5. Slew Limits do not work
•Page 9 Section 6. Fuse F9 blows while in maintenance mode
•Page 10 Section 7. Stroke Counter and Strokes/Min do not count
•Page 10 Section 8. Work Lights do not work
•Page 10 Section 9. Hopper Light does not work
•Page 10 Section 10. System does not turn on
•Page 10 Section 11. Radio Display shows “NO CAN BUS MESSAGES”
•Page 10 Section 12. Radio Display has the “E” indicator light lit up.
•Display shows the following message at the top:
o“Slew Limit [Left/Right]” Normal message when slew limits are reached.
o“E-Stop [Rear/Boom/Remote]” An E-Stop is triggered. Check your E-Stops.
o“Hopper Grate Open” Hopper Grate circuit is open
o“Soft Stop-Neutral all switches” Appears when switching to remote mode and a remote switch is on. Take all remote switches to neutral.
o“Reset E-Stop Request” Appears when switching modes and during first startup. Honk the horn to reset the e-stops.
o“No comms Keypad<>PLC” No comms to the rear keypad. Check the CAN lines & power/ground wires to the rear keypad then replace keypad. In local mode you can reset the e-stop at the display when this error is present.
o“Dirty Oil Filter” Change the Oil Filter
o“Telescopic Boom Limit” Boom Limitation is preventing further telescoping.
o“No Driveshaft Speed Detected” Check prox sensor on drive shaft and make sure the pickup bolts are 2-4mm away from the sensor. Then replace sensor. There is a light on the prox that tells you when it is triggered.
o“No Alt D+ Voltage” This is a normal message when the vehicle is not running. This signal comes directly from the alternator.
o“Hydraulic Oil Temp High” Oil Temperature has been exceeded. Verify Oil Cooler is running and let the unit cool down.
o“Ram Change Mode Enabled” Normal message while in Ram Change Mode.
o“Teach Mode Enabled” Normal message while in Teach Mode.
o“Oil Pressure Sensor Fault” Check the connections to the sensor. Replace sensor or troubleshoot wiring. “999” will display if the circuit is shorted. “-999” will display if the circuit is open.
o“Water Tank Level Low” Normal message when no water is in the tank. Check the connections to the sensor. Replace sensor or troubleshoot wiring.
o“Maintenance Switch Enabled” The maintenance switch is activated. MOST functions of CPC3 are disabled
o“VBBS Volts Low-Check CB[#]” There is no voltage on one of the circuits. Open the PDM and check the indicated circuit breaker. Some features will not work when you get this error because it does not have full power.
o“No Comms HMI<>PLC” See Page 10 section 13. “No Comms HMI<>PLC”
o“PLC Temp High” The PLC is overheating. Open cabinet door and turn system off until cooled.
o“Pump RPM High-Check Gear” The ratio between the engine RPM and the driveshaft is not correct. Make sure you’re in the correct gear.
o“Error Code-Goto Maint. Page” Go to the Maintenance page and check the error code. Use the Error Code manual to see what it means.
o“No Comms PLC<>Receiver” There is no comms between the PLC and the receiver. Ensure Cable A and Cable C on side of panel is plugged in and the Radio Receiver is lit up.
o“Oil Temp Sensor Fault” Check the connections to the sensor. Replace sensor or troubleshoot wiring. “999” will display if the circuit is shorted. “-999” will display if the circuit is open.
o“Operate Oil Cooler Manually” If this error comes up the CPC3 system has determined an error in the Oil Cooler System. Either the D+ signal is not working, or the Oil Temp sensor is not working. Run the Oil Cooler manually.
o“[Boom/Remote/Rear] E-stop Error” See Page 11 section 14. “[Boom/Remote/Rear] E-stop Error”

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1. Display does not turn on
1.1. Go to the primary PLC. Is the PLC lit-up?
1.1.1. NO: Go to page 10 section 10. System does not turn on
1.1.2. YES: Check the connection behind the display to ensure it is seated properly. Then check fuse F18. If both are good replace display or check for power/ground at the connector. The display must be
programmed before shipping and it must be compatible with the PLC version. To find the PLC version when the display does not work, refer to the Work Instruction: “SCT Program - Finding Correct SCT
Version”
2. Primary PLC does not turn on (No lights on PLC)
2.1. Does the display turn on?
2.1.1. NO: Go to page 10 section 10. System does not turn on
2.1.2. YES: Check fuse F2 in the PDM then check both connectors for proper connection at the PLC and that it has no loose pins. Is there 12v on pins 10 and 32 and grounds on 20, 37 and 42 on ST Connector?
(Vehicle Ignition must be on)
2.1.2.1. NO: Use the system schematic to trace power back into the PDM and check the F2 circuit breaker.
2.1.2.2. YES: Replace PLC
3. Throttle control does not work
3.1. The E-Stops must be cleared and no errors/messages should be shown on the screen for throttle to work. On the SCT display, go to the I/O screen. Have someone request throttle up and down while watching
outputs 23ex (RPM+) and 22ex (RPM-). Do both outputs light up at the appropriate time?
3.1.1. NO: The system is not allowing throttle control. Check to make sure your e-stops are clear and you are properly setup.
3.1.2. YES: The system is requesting the vehicle to throttle up and down but it is not. The issue is either with the vehicle or with the harness between the vehicle and the CPC3 system.
4. Oil Cooler does not turn on
The Oil Cooler shuts off if the D+ signal from the alternator is lost. It can still be controlled manually.
If the PLC supply voltage drops below 11V for 10 seconds, the oil cooler will be disabled. Connect Jumper cables and charge batteries.
4.1. The oil cooler will turn on automatically when the temperature reaches 55°c, the engine is running and the E-Stop is cleared. You can also turn it on manually by the rear panel.
4.1.1. Go to the display and navigate to the I/O pages then check if OUT30ex (Oil Cooler) is coming on.
4.1.1.1. YES: Check the oil cooler Fuse F8. If the fuse is good, check for power and ground at the oil cooler connector.
4.1.1.2. NO: The system is not telling the oil cooler to come on. Either oil temp is not above 55° or the system believes the truck is not running. Check input 06ex (Vehicle D+). The input should be on when the vehicle is running. Is the input
on?
4.1.1.2.1. YES: Call Schwing Service Tech.
4.1.1.2.2. NO: Trace the D+ circuit from the vehicle alternator.
5. Slew Limits do not work
5.1. The slew limits are set mechanically inside the Slew Gear. Check F20 fuse in the PDM. Check that the slew counter is properly set, then trace the wires using the schematic (Inputs 08 and 09).
6. Fuse F9 blows while in maintenance mode
6.1. There is a wire with a quick disconnect located near connector “Cable C” under the control cabinet faceplate. Disconnect the quick disconnect and reset the circuit breaker. Does the circuit breaker still pop?
6.1.1. NO: Leave the quick disconnect disconnected and tape over both ends.
6.1.2. YES: There is a short in the system. Use the schematic and find the short on the “Maintenance Splits Diode Pack” (PMSD).

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7. Stroke Counter and Strokes/Min do not count
7.1. The Stroke Counter will only count when in pump forward. Do you see the Stroke Counter symbols on the Homepage?
7.1.1. NO: Go to the Configuration screen and enable the Stroke Counter option.
7.1.2. YES: Check the stroke counter proximity switch and make sure it lights up when you place something metal in front of it. Does it light up?
7.1.2.1. NO: Replace sensor or troubleshoot power/ground to the sensor.
7.1.2.2. YES: On this display, go to the I/O page and look for IN08ex (Stroke Counter). Place something metal in front of the sensor, does the input light up?
7.1.2.2.1. YES: Call Schwing Service Tech.
7.1.2.2.2. NO: Replace the sensor, then troubleshoot wiring between sensor and PLC.
8. Work Lights do not work
8.1. Go to the Display and check the I/O page. Find OUT26 (Work Lights). Does the output turn on?
8.1.1. NO: Check the Maintenance screen for error messages. If there is error messages, troubleshoot the error message. If not, then call a Schwing Service Tech.
8.1.2. YES: This circuit runs through a lot of harnesses. Troubleshoot the circuit using the schematic. A good place to start is to make sure the lights work and are properly grounded.
9. Hopper Light does not work
9.1. The Hopper Light has constant power and is not controlled by the CPC3 system. Check fuse F11 then troubleshoot circuit using schematic. The ground is provided from the chassis frame.
10. System does not turn on
10.1. Check fuses/circuit breakers: F2, F3, F4 and F18 in the PDM. Check for power and ground at the PDM terminal studs. Do you have power at the terminal studs?
10.1.1. NO: Go to the battery box and find the ignition relay. Make sure the relay is turning on and the fuses in the battery box are good. Troubleshoot as needed with the original system schematic.
10.1.2. YES: Ensure all connectors on the PDM are tight then call a Schwing Service Tech.
11. Radio Display shows “NO CAN BUS MESSAGES”
This happens when the Radio is linked but the Receiver is not able to communicate with the PLC. This is a normal message while in Maintenance Mode.
11.1. Make sure the PLC is working and then check the CAN lines between the PLC and Radio.
12. Radio Display has the “E” indicator light lit up.
This happens when there is an error message on the unit and it has not been acknowledged yet.
13. “No Comms HMI<>PLC”
13.1. This message comes up when the Comms between the PLC and the Display are not working. The system may partially still work. Look at the PLC, is there a light on the side above the connector?
13.1.1. NO: Go to page 9 section 2. Primary PLC does not turn on (No lights on PLC)
13.1.2. YES: RED Light: Either reprogram the PLC or replace it.
13.1.3. YES: GREEN Light: Does the rear keypad work?
13.1.3.1. YES: The CAN lines between the Display and the PLC are not functioning. Use the schematic and trace the pins from the Display (Pins 4 and 5) to their splices. One of those two wires is broken.
13.1.3.2. NO: Disconnect the “I/O Harness” from the control panel. Does the display error go away?
13.1.3.2.1. YES: There is problem with the rear keypad or harness. Replace the rear keypad or troubleshoot pins 3 and 4 on the I/O harness that runs to the rear keypad.
13.1.3.2.2. NO: Plug in the I/O harness. Disconnect the Display. Does the rear keypad become functional?
13.1.3.2.2.1. YES: Reprogram the Display or replace it.
13.1.3.2.2.2. NO: The problem is inside the panel. Use the schematic and trace pins 29 and 47 from the “PLCST” connector.

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14. “[Boom/Remote/Rear] E-stop Error”
This error comes up when CPC3 senses a problem with the E-Stop circuit.
14.1. Single circuit E-Stop system (Uses two wires at each e-stop) one of the wires is shorted to ground. Trace the indicated system and look for the short.
14.2. Dual circuit E-Stop system (four wires at each e-stop): There are two causes for this error. Either one of the e-stop legs are shorted to ground or the E-Stop Switch is not switching both circuits at the same time. Use the schematic and check for a
short on both legs of the e-stop. If none is found, then replace the E-Stops.