Snorkel Pro 126 Use and care manual

ENVELOPE MANAGEMENT

SYSTEM (

EMS

)

CALIBRATION MANUAL

MODELS

TB 120, PRO 100 & PRO 126

P/N 0191401

April 1997 - revised September 2000

Printed in the USA

Use this manual to calibrate all PRO 100, PRO 126 and TB 120

machines.

See table of contents for section that is for your machine.

DO NOT attempt to calibrate the

EMS

system without having first

read and completely understanding the procedures described in this

manual.

ONLY qualified personnel, trained on the

EMS

, should perform

EMS

calibration procedures.

Should there be any question concerning anything covered in this

manual, contact the Snorkel Customer Service Department, telephone

816-364-0317 or for additional information.

Snorkel

P O Box 1160

St Joseph Mo 64502-1160

Phone: 816-364-0317

IMPORTANT INFORMATION

Before performing

EMS

trouble shooting or calibration,

we recommend that you have the following tools at

your disposal:

1. Fluke 88 or equivalent.

2. Calibration harness - Snorkel part no. 0191008

3. Three prong test plug - Snorkel part no. 0191025

4. Two prong test plug - Snorkel part no. 0191024

5. EZ Cal (when available)

TABLE OF CONTENTS

SECTION I

CALIBRATION TB 120 machines manufactured before September 1994

and have not been updated to three point computers.

Joystick calibration – (lift and extend) . . . . . . . . . . . . . . . . . . . 1 - 1

Sensor calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2

Ramp calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2

1-3

Full speed/half speed calibration . . . . . . . . . . . . . . . . . . . . . . 1 - 3

1-4

Half speed calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4

Valve calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5

Backup

EMS

calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6

SECTION II

CALIBRATION TB 120 machines manufactured before September 1994

and have been updated to three point computers.

To determine if machine has been updated, look

inside turntable under base boom on right side for angle

indicator arm.

Joystick calibration – (lift and extend) . . . . . . . . . . . . . . . . . . . 2 - 1

Sensor calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2

Three point calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2

Ramp calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 3

Full speed/half speed calibration . . . . . . . . . . . . . . . . . . . . . . 2 - 4

Half speed calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 5

Valve calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 6

Backup

EMS

calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 7

SECTION III

CALIBRATION All PRO 100 and PRO 126 machines

and TB 120 machines manufactured after September 1994

Joystick calibration – (lift and extend) . . . . . . . . . . . . . . . . . . . 3 - 1

3-2

Sensor calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3

3-4

Ramp calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5

3-6

Speed calibration table (factory settings) . . . . . . . . . . . . . . . . . 3 - 6

Full speed calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 7

Half speed calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 8

Valve calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 9

TABLE OF CONTENTS

SECTION IV

GENERAL CALIBRATION NOTES

Primary and backup

EMS

system . . . . . . . . . . . . . . . . . . . . . 4 - 1

Common mistakes in the calibration . . . . . . . . . . . . . . . . . . . . 4 - 2

Calibration overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2

Primary joystick and sensor calibration overview . . . . . . . . . . . . 4 - 2

4-3

Ramp calibration overview . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3

Full/Half speed calibration overview . . . . . . . . . . . . . . . . . . . . 4 - 4

Valve calibration overview . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 5

EMS

calibration modes & tables . . . . . . . . . . . . . . . . . . . . . . 4 - 6

SECTION V

TROUBLE SHOOTING FOR ENVELOPE MANAGEMENT SYSTEM

Trouble shooting description index. . . . . . . . . . . . . . . . . . . . . 5 - 1

General description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 2

Primary and backup set location illustration . . . . . . . . . . . . . . . 5 - 2

Primary set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 2

Backup set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 3

Primary

EMS

errors during power-up . . . . . . . . . . . . . . . . . . . 5 - 3

5-4

5-5

Primary

EMS

errors when joystick is at center . . . . . . . . . . . . . . 5 - 6

5-7

5-8

Primary

EMS

errors during normal operation . . . . . . . . . . . . . . . 5 - 8

5-9

5-10

5-11

Backup

EMS

errors (TB 120 and PRO 126 only) . . . . . . . . . . . . . 5 - 11

5-12

Trouble shooting for system calibration errors . . . . . . . . . . . . . . 5 - 13

Use this section to calibrate - TB 120 machines manufactured before

September 1994 and have not been updated to three point computers.

Before performing the sensor calibration make sure the unit is on a flat, firm

and level surface with the turntable in the stowed position, boom over rear

axle, counter weight over the steer axle.

Primary and backup

EMS

may be calibrated individually or simultaneously.

During sensor calibration, the envelope management

system DOES NOT limit the position of the platform. The

operator should follow the calibration instructions carefully

to prevent positioning the platform outside of the working

envelope.

JOYSTICK CALIBRATION - (LIFT AND EXTEND):

1. Turn platform Master switch “OFF”, pull Emergency Stop switch button “OUT”.

2. At ground control, set Platform/Ground Selector switch to “PLATFORM”, pull

Emergency Stop button “OUT” and turn Master switch “ON”.

Note: Engine and all EMS status lights should be “OFF”.

3. At platform, move the Drive Controller to full “ON” forward while pressing and

holding the CALIBRATE and ERROR RESET buttons and starting the engine.

Note: Wait for approximately, two (2) seconds until SYSTEM NORMAL

light remains on. Also note that the CAL MODE light will flash

four (4) times and then remain on.

4. Let go of controller and buttons.

5. DO NOT ACTIVATE THE FOOT SWITCH. Fully deflect each of the following

controllers, (full “ON” each direction). Extend\Retract\Up\Down. Make sure you

hold each controller “ON” for a few seconds in each direction. Push the

CALIBRATE button.

Note: If the calibration is accepted - two (2) short beeps will be heard.

The system will then go into the sensor calibration. If a long beep

sounds - TURN OFF the machine and start the controller and

sensor calibration again.

6. Continue on to sensor calibration without shutting engine “OFF”.

Page no. 1 - 1

SECTION I

CALIBRATION

WARNING

SENSOR CALIBRATION:

1. Open junction box on left side of turntable and install calibration harness to all

matching numbered terminals.

Note: Disconnect

EMS

harness leads labeled 14, 15, 21 and 22 from

proportional control valve. Match numbers and connect the

remaining calibration harness leads to proportional control valve.

2. Make sure boom is fully lowered and fully retracted before proceeding.

3. At ground control station, perform the following boom operations:

1. Set Platform/Ground Selector switch to “GROUND”.

2. Fully retract boom.

3. Lower boom fully.

4. Raise boom until it stops.

5. Keep boom raised, extend boom fully.

6. Raise boom fully.

7. Press CALIBRATE button.

If the data is accepted, there will be two (2) short beeps. One (1) long beep

indicates incorrect data has been entered. If one (1) long beep is heard, turn

“OFF” the machine and repeat the joystick and sensor calibrations again.

If the backup

EMS

has been calibrated and is currently effective, the boom will

stop at the backup envelope during step 4 above, causing continuous repeating

beeps, indicating the backup envelope has been reached.

After the two (2) calibration data sets are accepted, (joystick and sensor), the

system may error out right away. This will indicate that other calibration data

has not been done or more data need to be calibrated.

If other data is calibrated and is acceptable, the system will go to normal

operation. Turn engine “OFF”. Remove calibration harness and reconnect

EMS

to proportional control valve. Retract and lower boom.

RAMP CALIBRATION - (FACTORY SET AT FOUR (4) CLICKS:

(At ground control, perform the following).

1. Press and hold both the CALIBRATE and ERROR RESET buttons firmly.

Turn “ON” the power - (DO NOT start engine). Wait for approximately two (2)

seconds until SYSTEM NORMAL, AUTO MODE and CAL MODE lights remain

on. Note that the CAL MODE light will flash two (2) times.

Let go of the two buttons.

2. One (1) short beep will be heard, indicating that the ramp speed for extend is to

be set. To set the ramp speed for extend, press the ERROR RESET button the

number of times for the desired ramp speed, with one (1) being the minimum

ramp or fastest and eight (8) being the maximum ramp or slowest. When

finished, press the CALIBRATE button. (0 essentially skips calibration for this

function, leaving the previous calibration value intact).

Page no. 1 - 2

RAMP CALIBRATION (Continued):

3. Two (2) short beeps will be heard, indicating that the ramp speed for retract is to

be set. To set ramp speed for retract, press the ERROR RESET button the

number of times for the desired ramp speed, with one (1) being the minimum

ramp or fastest and eight (8) being the maximum ramp or slowest. When

finished press the CALIBRATE button.

4. Three (3) short beeps will be heard, indicating that the ramp speed for lift is to

be set. To set the ramp speed for lift, press the ERROR RESET button the

number of times for the desired ramp speed, with one (1) being the minimum

ramp or fastest and eight (8) being the maximum ramp or slowest. When

finished press the CALIBRATE button.

5. Four (4) short beeps will be heard, indicating that the ramp speed for lower is to

be set. To set the ramp speed for lower, press the ERROR RESET button the

number of times for the desired ramp speed, with one (1) being the minimum

ramp or fastest and eight (8) being the maximum ramp or slowest. When

finished press the CALIBRATE button.

Note: If the system has a calibration error or has never been calibrated,

MAKE SURE to press the ERROR RESET button at least once for

each ramp speed, otherwise the pre-programmed data will not

change (calibrate).

Upon completion of steps 2 through 5, the system will beep twice, indicating

the calibration has been completed for ramp. There will not be an error in this

calibration because the system will always accept the change (calibration), if

any. If the system errors out immediately after ramp calibration, other data has

not been calibrated. Turn “OFF” machine and proceed to the FULL Speed/Half

Speed calibration procedure.

FULL SPEED/HALF SPEED CALIBRATION - (Factory set at 1 click):

1. Deflect the Drive joystick forward while pressing and holding the CALIBRATE

button firmly. Then turn the power “ON”, (DO NOT start the engine). Wait for

approximately two (2) seconds until the SYSTEM NORMAL, CAL MODE and

AUTO MODE lights are “ON”. Note, the CAL MODE light will flash three (3)

times. Release the CALIBRATE button and joystick.

2. One (1) beep will be heard, indicating that the extend speed is to be set. To set

the extend speed, press the ERROR RESET button the number of times for the

desired speed with one (1) being the fastest and eight (8) being the slowest.

When finished press the CALIBRATE button. (0 essentially skips calibration for

this function, leaving the previous calibration value intact).

3. Two (2) beeps will be heard, indicating that the retract speed is to be set. To set

the retract speed, press the ERROR RESET button the number of times for the

desired full speed, with one (1) being the fastest and eight (8) being the slowest.

When finished press the CALIBRATE button.

4. Three (3) beeps will be heard, indicating that the full lift speed is to be set. To

set the full lift speed, press the ERROR RESET button the number of times for

the desired full speed, with one (1) being the fastest and eight (8) being the

slowest. When finished press the CALIBRATE button.

Page no. 1 - 3

FULL SPEED/HALF SPEED CALIBRATION (Continued):

5. Four (4) beeps will be heard, indicating that the full lower speed is to be set. To

set the full lower speed, press the ERROR RESET button the number of times

for the desired full speed, with one (1) being the fastest and eight (8) being the

slowest. When finished press the CALIBRATE button.

The system bill beep twice, indicating that calibration has been completed for

full speed. There will not be an error in this calibration because the system will

always accept the change (calibration) if any.

HALF SPEED CALIBRATION - (Factory set at 4 clicks):

6. The system will immediately go to half lift speed calibration, three (3) beeps will

be heard. Set the half lift speed by pressing the ERROR RESET button the

number of times corresponding to the desired speed with one (1) being the

fastest and eight (8) being the slowest speed. Then press the CALIBRATE

button.

7. Four (4) beeps will be heard, indicating that the half lower speed is to be set. To

set the half speed for lower, press the ERROR RESET button the number of

times for the desired speed, with one (1) being the fastest and eight (8) being

the slowest. When finished press the CALIBRATE button.

Note: If the system has a calibration error or has never been calibrated,

MAKE SURE to press the ERROR RESET button at least once for

each Full/Half speed, otherwise the pre-programmed data will not

change (calibrate).

Upon completion of steps 2 through 7, the system will beep twice, indicating

the calibration has been completed for Full/half speed. There will not be an

error in this calibration because the system will always accept the change

(calibration), if any. If the system errors out immediately after Full/Half speed

calibration, other data has not been calibrated. Turn “OFF” machine and

proceed to the valve calibration procedure.

If other data is calibrated and acceptable, the system will go to normal

operation.

Page no. 1 - 4

VALVE CALIBRATION:

Note: MAKE SURE the hydraulic oil is at operating temperature (80° F.),

before calibration.

1. At the ground control, raise the boom to approximately horizontal height with

boom partially extended, (two to three feet), to allow for valve calibration.

Turn engine “OFF”.

2. Press and hold the CALIBRATE button firmly, then start the engine, wait for

approximately two (2) seconds until the SYSTEM NORMAL, AUTO MODE and

CAL MODE lights are “ON”. Note that the CAL MODE light will flash once. Let

go of the CALIBRATE button.

3. Operate the Extend control switch and Ground Operation switch allowing the

boom to extend at full speed. It takes more than a few seconds before the boom

starts to move. Continue to hold the Extend control switch until the boom stops.

Operate the Retract control switch and Ground Operation switch to retract the

boom at full speed until the boom comes to a full stop. Then do the same for Lift

and Lower, releasing the Ground Operation switch after each function.

MAKE SURE that when performing the valve calibration that you hold the

function switch for Extend, Retract, Lift and Lower on long enough or at the end

of the valve calibration procedure it will error out.

4. Observe the motion of the boom carefully, especially in cold oil conditions. If the

boom fails to move for more than 120 seconds or two minutes, turn “OFF” the

machine and start the valve calibration again.

5. If the data is accepted for all four functions, two (2) short beeps will be heard;

otherwise a long beep will sound. If a long beep sounds, turn “OFF” the machine

and start the valve calibration again.

6. If the system accepts the calibration data and then errors out immediately after

calibration, return to the joystick and sensor calibration and repeat all of the

above procedures.

7. At this stage, all data should have been calibrated. The system goes to normal

operation and SYSTEM NORMAL and AUTO MODE lights should stay “ON”.

Page no. 1 - 5

BACKUP

EMS

CALIBRATION:

1. Before calibration, power up the machine. If the calibration data stored in the

EMS

controller has been calibrated before and is currently within acceptable

limits, the system will go to normal operation with SYSTEM NORMAL on.

2. If the system errors out with ERROR and CAL MODE lights on, then the data

stored in the

EMS

controller is not correct or has not been calibrated.

3. It is required to calibrate the sensor when it is initially installed into the

TB 120 machine.

4. Install Cal harness.

Sensor Calibration:

(Make sure boom is fully lowered and fully retracted before proceeding).

1. Press and hold back-up CALIBRATE and ERROR RESET buttons while starting

the engine, (requires two persons). Wait for approximately two (2) seconds until

SYSTEM NORMAL and CAL MODE lights are on. Note that CAL MODE light

will flash four (4) times. Let go of the two buttons.

2. To calibrate sensors, length and angle sensors are moved through the full

extremes of boom lift and extend movements.

3. Using The ground controls, move the boom in the following sequence:

1. Retract boom fully.

2. Lower boom fully.

3. Raise boom until it stops.

4. Keeping boom raised, extend boom fully.

5. Raise boom fully.

6. Press CALIBRATE button.

If the calibration data is accepted, there will be two (2) short beeps; else, a

long beep (2 seconds). If a long beep should sound, turn “OFF” machine and

start sensor calibration again.

Note: When the calibration data is accepted, the system will go to normal

operation.

Page no. 1 - 6

Use this section to calibrate - TB 120 machines manufactured before

September 1994 and have updated to three point computers. To determine if

machine has been updated, look inside turntable under base boom on right

side for angle indicator arm.

Before performing the sensor calibration make sure the unit is on a flat, firm

and level surface with the turntable in the stowed position, boom over rear

axle, counter weight over the steer axle.

Primary and backup

EMS

may be calibrated individually or simultaneously.

During sensor calibration, the envelope management

system DOES NOT limit the position of the platform. The

operator should follow the calibration instructions carefully

to prevent positioning the platform outside of the working

envelope.

JOYSTICK CALIBRATION - (LIFT AND EXTEND):

1. Turn platform Master switch “OFF”, pull Emergency Stop switch button “OUT”.

2. At ground control, set Platform/Ground Selector switch to “PLATFORM”, pull

Emergency Stop button “OUT” and turn Master switch “ON”.

Note: Engine and all EMS status lights should be “OFF”.

3. At platform, move the Drive Controller to full “ON” forward while pressing and

holding the CALIBRATE and ERROR RESET buttons and starting the engine.

Note: Wait for approximately, two (2) seconds until SYSTEM NORMAL

light remains on. Also note that the CAL MODE light will flash

four (4) times and then remain on.

4. Let go of controller and buttons.

5. DO NOT ACTIVATE THE FOOT SWITCH. Fully deflect each of the following

controllers, (full “ON” each direction). Extend\Retract\Up\Down. Make sure you

hold each controller “ON” for a few seconds in each direction. Push the

CALIBRATE button.

Note: If the calibration is accepted - two (2) short beeps will be heard.

The system will then go into the sensor calibration. If a long beep

sounds - TURN OFF the machine and start the controller and

sensor calibration again.

6. Continue on to sensor calibration without shutting engine “OFF”.

Page no. 2 - 1

SECTION II

CALIBRATION

WARNING

SENSOR CALIBRATION:

1. Open junction box on left side of turntable and install calibration harness to all

matching numbered terminals.

Note: Disconnect

EMS

harness leads labeled 14, 15, 21 and 22 from

proportional control valve. Match numbers and connect the

remaining calibration harness leads to proportional control valve.

2. At ground control station, perform the following boom operations:

1. Set Platform/Ground Selector switch to “GROUND”.

2. Fully retract boom.

3. Lower boom fully.

4. Raise boom until it stops.

5. Keep boom raised, extend boom fully.

6. Raise boom fully.

7. Press CALIBRATE button.

If the data is accepted, there will be two (2) short beeps. One (1) long beep

indicates incorrect data has been entered. If one (1) long beep is heard, turn

“OFF” the machine and repeat the joystick and sensor calibrations again.

If the backup

EMS

has been calibrated and is currently effective, the boom will

stop at the backup envelope during step 4 above, causing continuous repeating

beeps, indicating the backup envelope has been reached.

THREE POINT CALIBRATION:

The following addition to the sensor calibration procedure is required for the

TB 120 machines with

EMS

electronic control units identified by Apitech part

number MC21320019 for the primary system and part number MC21320020 for

the backup system. These units require a “third point” or step to complete the

calibration of the boom angle software. This added step to the calibration

procedure verifies the angle at which the

EMS

system begins coordinate

movement of the boom down and retract functions. The “third point” indicator

arm is located on the inside of the right side of the turntable.

1. Once the Joystick and Sensor Calibration is successfully completed, the

EMS

now goes directly into the third point calibration mode.

2. The operator must retract the boom then lower the boom until the pin contacts

the boom at the mark stamped on the boom. Care must be taken to align the pin

and the mark as close as possible. It is recommended that the contact be

inspected up close as opposed to from ground level.

3. In this position the operator must depress the CALIBRATE button. Should the

data be acceptable, the audible alarm will sound two (2) short beeps. If the data

is bad, the ERROR indicator will be illuminated and the audible alarm will sound

one long beep. Turn “OFF” the machine and repeat the joystick. sensor and

three point calibration again. The

EMS

will only allow 2° ±for this calibration.

Once and audible acknowledgment has been given, the SYSTEM NORMAL

indicator will be illuminated signifying that the vehicle is ready for operation.

This procedure must be also REPEATED at the end of the BACKUP SYSTEM

calibration as outlined on page2-7ofthis manual.

Page no. 2 - 2

THINGS THE PRIMARY LOOKS FOR AND THAT THE BACKUP LOOKS FOR

PRIMARY LOOKS FOR BACKUP LOOKS FOR

1. JOYSTICK CALIBRATION

2. SENSOR CALIBRATION

3. THREE POINT CALIBRATION (IF EQUIPPED WITH)

1. SENSOR CALIBRATION

2. THREE POINT CALIBRATION

After the three (3) calibration data sets are accepted, (joystick, sensor and

three point), the system may error out right away. This will indicate that other

calibration data has not been done or more data need to be calibrated.

If other data is calibrated and is acceptable, the system will go to normal

operation. Turn engine “OFF”. Remove calibration harness and reconnect

EMS

to proportional control valve. Retract and lower boom.

RAMP CALIBRATION - (FACTORY SET AT FOUR (4) CLICKS:

1. Press and hold both the CALIBRATE and ERROR RESET buttons firmly.

Turn “ON” the power - (DO NOT start engine). Wait for approximately two (2)

seconds until SYSTEM NORMAL, AUTO MODE and CAL MODE lights remain

on. Note that the CAL MODE light will flash two (2) times. Let go of the buttons.

2. One (1) short beep will be heard, indicating that the ramp speed for extend is to

be set. To set the ramp speed for extend, press the ERROR RESET button the

number of times for the desired ramp speed, with one (1) being the minimum

ramp or fastest and eight (8) being the maximum ramp or slowest. When

finished, press the CALIBRATE button. (0 essentially skips calibration for this

function, leaving the previous calibration value intact).

3. Two (2) short beeps will be heard, indicating that the ramp speed for retract is to

be set. To set ramp speed for retract, press the ERROR RESET button the

number of times for the desired ramp speed, with one (1) being the minimum

ramp or fastest and eight (8) being the maximum ramp or slowest. When

finished press the CALIBRATE button.

4. Three (3) short beeps will be heard, indicating that the ramp speed for lift is to

be set. To set the ramp speed for lift, press the ERROR RESET button the

number of times for the desired ramp speed, with one (1) being the minimum

ramp or fastest and eight (8) being the maximum ramp or slowest. When

finished press the CALIBRATE button.

5. Four (4) short beeps will be heard, indicating that the ramp speed for lower is to

be set. To set the ramp speed for lower, press the ERROR RESET button the

number of times for the desired ramp speed, with one (1) being the minimum

ramp or fastest and eight (8) being the maximum ramp or slowest. When

finished press the CALIBRATE button.

Note: If the system has a calibration error or has never been calibrated, MAKE

SURE to press the ERROR RESET button at least once for each ramp

speed, otherwise the pre-programmed data will not change (calibrate).

Upon completion of steps 2 through 5, the system will beep twice, indicating

the calibration has been completed for ramp. There will not be an error in this

calibration because the system will always accept the change (calibration), if

any. If the system errors out immediately after ramp calibration, other data has

not been calibrated. Turn “OFF” machine and proceed to the FULL Speed/Half

Speed calibration procedure.

Page no. 2 - 3