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
read and completely understanding the procedures described in this
manual.
ONLY qualified personnel, trained on the
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
EMS
system without having first
EMS
, should perform
EMS
P/N 0191401
April 1997 - revised September 2000
Printed in the USA
IMPORTANT INFORMATION
Before performing
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)
EMS
trouble shooting or calibration,
TABLE OF CONTENTS
SECTION I
CALIBRATIONTB 120 machines manufactured before September 1994
and have not been updated to three point computers.
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.
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.
WARNING
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.
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 flashfour (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
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
SECTION II
CALIBRATION
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.
WARNING
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.
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 flashfour (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
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 FORBACKUP 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
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.
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.
Page no. 2 - 4
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