Page 1
ENVELOPE MANAGEMENT
SYSTEM (
EMS
)
CALIBRATION MANUAL
MODELS
TB 120, PRO 100 & PRO 126
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
Page 2
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,
Page 3
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
Full speed/half speed calibration . . . . . . . . . . . . . . . . . . . . . . 1 - 3
Half speed calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 4
Valve calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5
Backup
SECTION II
CALIBRATION TB 120 machines manufactured before September 1994
EMS
calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6
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.
1-3
1-4
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
SECTION III
CALIBRATION All PRO 100 and PRO 126 machines
Joystick calibration – (lift and extend) . . . . . . . . . . . . . . . . . . . 3 - 1
Sensor calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 3
Ramp calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 5
Speed calibration table (factory settings) . . . . . . . . . . . . . . . . . 3 - 6
Full speed calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 7
Half speed calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 8
Valve calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 9
EMS
calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 7
and TB 120 machines manufactured after September 1994
3-2
3-4
3-6
Page 4
TABLE OF CONTENTS
SECTION IV
GENERAL CALIBRATION NOTES
Primary and backup
Common mistakes in the calibration . . . . . . . . . . . . . . . . . . . . 4 - 2
Calibration overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 2
Primary joystick and sensor calibration overview . . . . . . . . . . . . 4 - 2
Ramp calibration overview . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 3
Full/Half speed calibration overview . . . . . . . . . . . . . . . . . . . . 4 - 4
Valve calibration overview . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 5
EMS
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
Primary
Primary
Backup
Trouble shooting for system calibration errors . . . . . . . . . . . . . . 5 - 13
calibration modes & tables . . . . . . . . . . . . . . . . . . . . . . 4 - 6
EMS
EMS
EMS
EMS
errors during power-up . . . . . . . . . . . . . . . . . . . 5 - 3
errors when joystick is at center . . . . . . . . . . . . . . 5 - 6
errors during normal operation . . . . . . . . . . . . . . . 5 - 8
errors (TB 120 and PRO 126 only) . . . . . . . . . . . . . 5 - 11
EMS
system . . . . . . . . . . . . . . . . . . . . . 4 - 1
4-3
5-4
5-5
5-7
5-8
5-9
5-10
5-11
5-12
Page 5
SECTION I
CALIBRATION
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.
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
Page 6
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
Page 7
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
Page 8
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
Page 9
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
Page 10
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
Page 11
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.
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
Page 12
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
Page 13
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
Page 14
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
Page 15
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. 2 - 5
Page 16
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. 2 - 6
Page 17
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.
Sensor Calibration:
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. 2 - 7
Page 18
SECTION III
CALIBRATION
Use this section to calibrate - all PRO 100 and PRO 126 machines and
TB 120 machines manufactured after September 1994.
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.
PRIMARY JOYSTICK AND SENSOR CALIBRATION (TB 120, PRO 100, PRO 126)
BACKUP SENSOR CALIBRATION (TB 120, PRO 126)
JOYSTICK CALIBRATION — (LIFT AND EXTEND):
1. Turn platform Master switch ON, pull Emergency Stop switch button OUT.
2. At ground control, set Platform/Ground Selector switch to GROUND, pull
Emergency Stop button OUT and turn Master switch ON but do not start engine.
3. Turn the battery disconnect switch on the left side of the turntable to the OFF
position. Open junction box located below the battery disconnect switch.
4. The primary and backup BDU's (Basic Display Units) [PRO 100 has a primary
BDU only], are located on the inside of the junction box lid. With your left hand,
press and hold the CALIBRATE and ERROR RESET buttons located on the
primary BDU (the left one) and activate the toggle switch located between
(below) the BDU's.
5. With your right hand, turn the battery disconnect switch to the ON position.
Note: The SYSTEM NORMAL and the AUTO MODE lights on the primary
BDU should illuminate and remain on. The CAL MODE light should
flash four times and then remain on.
6. With your right hand, press and hold the CALIBRATE and ERROR RESET
buttons located on the backup BDU (the right one) [TB 120 & PRO 126 only].
7. Release the primary CALIBRATE and ERROR RESET buttons and the toggle
switch located between the BDU's with your left hand.
Note: The SYSTEM NORMAL and the AUTO MODE lights on the backup
BDU should illuminate and remain on. The CAL MODE light on the
backup BDU should flash three times and then remain on.
Page no. 3 - 1
Page 19
JOYSTICK CALIBRATION — (LIFT AND EXTEND) (Continued):
8. Release the backup CALIBRATE and ERROR RESET buttons with your right
hand [TB 120 & PRO 126 only].
9. IMMEDIATELY proceed to the ground station and start the engine. Do not turn
the master switch off first.
Note: You have 30 seconds to start the engine from the time the battery
disconnect switch is turned on. If the engine will not start, repeat
this procedure from step 2.
If 30 seconds in not long enough disconnect wire number one (1) to
anti-restart relay in lower control box. Reconnect wire after you
start engine.
10. At the ground control station, set the Platform/Ground Control switch to
PLATFORM.
11. Proceed to the platform. DO NOT ACTIVATE THE FOOT SWITCH. Fully deflect
each of the following controller, (full “ON” each direction).
Extend\Retract\Up\Down. Make sure you hold each controller on for a few
seconds in each direction.
12.
At the junction box, push the CALIBRATE button on the PRIMARY BDU ONLY.
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.
If the joysticks only are being calibrated, stop here and shut the engine off with
out pressing any more buttons. If the sensors are also being calibrated
continue on to sensor calibration without shutting engine OFF.
Page no. 3 - 2
Page 20
SENSOR CALIBRATION:
Note: Sensor calibration cannot be performed with out performing a
joystick calibration.
OPTIONAL STEP:
Follow this optional step to reduce the time it takes to perform the sensor
calibration. Open the ground control wiring box and locate the 175 terminal
post on the wiring box panel. Locate the PWM module on the right side of the
wiring box. Remove the purple PWM module wire from the 175 terminal and
position it so it won't make contact with any wires. Connect the orange wire
from the PWM module to the 175 terminal. After calibration is complete return
wiring to original configuration.
WARNING
FAILURE TO RETURN WIRING TO ORIGINAL
CONFIGURATION WILL RESULT IN EXCESS SWING
SPEED FROM GROUND CONTROL OR DAMAGE TO THE
PWM MODULE.
1. Disconnect
control valve. Install the Calibration Harness by matching numbers and
connecting the calibration harness leads to proportional control valve. Finish
installation by matching all of the numbers of the remaining harness leads and
connecting them to the corresponding terminals in the junction box.
2. At ground control station, perform the following boom operations:
1. Set Platform/Ground Selector switch to “GROUND”.
2. Fully retract boom.
3. Lower jib boom fully [PRO 100 & PRO 126 only].
4. Lower main boom.
TB 120 – Lower main boom completely.
PRO 100 & PRO 126 only – Lower main boom so that
bottom of platform mount frame is approximately 6 inches
above the ground.
1. Raise boom until it stops.
EMS
harness leads labeled 14, 15, 21 and 22 from proportional
2. Keep boom raised, extend boom fully.
3. Raise and extend booms fully (hold switch on for 30 seconds).
4. Press primary 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.
Page no. 3 - 3
Page 21
SENSOR CALIBRATION (Continued):
5. Press backup CALIBRATE button.
[TB 120 & PRO 126 only]
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.
6. Retract the boom fully.
7. Locate the third point indicator arm inside of the turntable on
the right near the boom pivot pin. Raise the arm so that the
indicator pin touches the bottom of the main boom side plate.
8. Lower the boom until the indicator pin is aligned with the mark
on the main boom side plate.
9. Press backup CALIBRATE button.
[TB 120 & PRO 126 only]
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.
10. Press primary 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.
After the three (3) calibration data sets are accepted, (joystick and sensor), the
primary system may error out right away. This will indicate that other
calibration data has not been done or more data needs 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 the
EMS
harness to the proportional control valve. Retract and lower boom.
Page no. 3 - 4
Page 22
RAMP CALIBRATION – ( FACTORY SET AT FOUR (4) CLICKS):
1. At ground control, set Platform/Ground Selector switch to GROUND, pull
Emergency stop button OUT and turn Master switch ON but do not start engine.
2. Turn the battery disconnect switch on the left side of the turntable to the OFF
position. Open junction box located below the battery disconnect switch.
3. The primary and backup BDU's (Basis Display Units) [PRO 100 has a primary
BDU only] are located on the inside of the junction box lid. With your left hand,
press and hold the CALIBRATE and ERROR RESET buttons located on the
primary BDU (the left one only).
4. With your right hand, turn the battery disconnect switch to the ON position.
Note: The SYSTEM NORMAL and the AUTO MODE lights on the primary
BDU should illuminate and remain on. The CAL MODE light should
flash two times and then remain on.
5. Release the primary CALIBRATE and ERROR RESET buttons with your left
hand.
6. 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).
7. 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.
8. 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.
Page no. 3 - 5
Page 23
RAMP CALIBRATION (Continued):
9. 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 5 through 9, the system will beep twice, indicating
the calibration has been completed for ramp. There will not be an error is 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.
SPEED CALIBRATION TABLE – (Factory Settings):
The table below lists the settings of the
EMS
functions for full speed and half
speed when your unit was shipped from the factory. Should adjustment of
these speeds be required, follow the procedures listed under (SPEED
CALIBRATIONS) on pages3-7and3-8ofthis manual to reset the desired
function speed.
EMS
FUNCTION SPEED CALIBRATION TABLE - FACTORY SETTINGS
FULL SPEED HALF SPEED
MODEL EXTEND RETRACT LIFT LOWER LIFT LOWER
TB 120 1 CLICK 1 CLICK 1 CLICK 1 CLICK 2 CLICKS 2 CLICKS
PRO 100 4 CLICKS 1 CLICK 8 CLICKS 4 CLICKS 7 CLICKS 5 CLICKS
PRO 126 1 CLICK 1 CLICK 1 CLICK 1 CLICK 2 CLICKS 2 CLICKS
Page no. 3 - 6
Page 24
SPEED CALIBRATIONS:
FULL SPEED CALIBRATION:
1. At ground control, set Platform/Ground Selector switch to GROUND, pull
Emergency Stop button OUT and turn Master switch ON but do not start the
engine.
2. Turn the battery disconnect switch on the left side of the turntable to the OFF
position. Open junction box located below the battery disconnect switch.
3. The primary and backup BDU's (Basis Display Units) [PRO 100 has a primary
BDU only] are located on the inside of the junction box lid. With your left hand,
press and hold the CALIBRATE button located on the primary BDU (the left one)
and activate the toggle switch located between (below) the two BDU's.
4. With your right hand, turn the battery disconnect switch to the ON position.
Note: The SYSTEM NORMAL and the AUTO MODE lights on the primary
BDU should illuminate and remain on. The CAL MODE light should
flash three times and then remain on.
5. Release the primary CALIBRATE button and the toggle switch with your left
hand.
6. One (1) beep will be heard, indicating that 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).
7. 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.
8. 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.
9. Four (4) beeps will be heard, indicating 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 will 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 changed (calibration) if any.
Page no. 3 - 7
Page 25
HALF SPEED CALIBRATION:
10. 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.
11. 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 6 through 11, 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. 3 - 8
Page 26
VALVE CALIBRATION:
Note: MAKE SURE the hydraulic oil is at operating temperature before calibration.
1. At the ground control, raise the boom to within 30 degrees above horizontal with
boom partially extended, (two to three feet), to allow for valve calibration. Turn
engine OFF.
2. At ground control, set Platform/Ground Selector switch to GROUND, pull
Emergency Stop button OUT and turn Master switch ON but do not start the engine.
3. Turn the battery disconnect switch on the left side of the turntable to the OFF
position. Open junction box located below the battery disconnect switch.
4. The primary and backup BDU's (Basic Display Units) [PRO 100 has a primary
BDU only] are located on the inside of the junction box lid. With your left hand,
press and hold the CALIBRATE button located on the primary BDU (the left
one).
5. With your right hand, turn the battery disconnect switch to the ON position.
Note: The SYSTEM NORMAL and the AUTO MODE lights on the primary
BDU should illuminate and remain on. The CAL MODE light should
flash once and then remain on.
6. Release the primary CALIBRATE button with your left hand.
7. IMMEDIATELY proceed to the ground control station and start the engine. Do
not turn the master switch off first.
Note: You have 30 seconds to start the engine from the time the battery
disconnect switch is turned on. If the engine will not start, repeat
this procedure from step 1.
8. Operate the Extend control switch and Ground operation switch allowing the
boom to extend. It can take a few minutes 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 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 for the boom to move and come to a
stop or at the end of the valve calibration procedure it will error out.
Observe the motion of the boom carefully, especially in cold oil conditions. If
the boom fails to move within three minutes or moves for more than a minute,
turn OFF the machine and start the valve calibration again.
If the data is accepted for all four functions, two (2) short beeps will be heard;
otherwise a long been will sound. If a long beep sounds, turn OFF the machine
and start the valve calibration again.
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.
At this stage, all data should have been calibrated. The system should go to
normal operation and SYSTEM NORMAL and AUTO MODE lights should stay ON.
Page no. 3 - 9
Page 27
SECTION IV
GENERAL CALIBRATION NOTES
PRIMARY AND BACKUP
Note: The exact calibration sequence should be followed for any new
EMS
1. If the system does not allow a requested calibration procedure, the operator
should try to calibrate the previous functions. For example, if the system does
not allow Full/Half speed calibration, then start the Ramp speed calibration. If
the Ramp speed calibration is not allowed either, then start with Joystick and
Sensor calibration.
2. Once the initial calibration is done and accepted, the operator can calibrate any
of the four calibration functions in any order.
3. Primary and backup
4. Note: [PRO 100 has a primary
COMMON MISTAKES IN THE CALIBRATION:
1. The operator does not count number of light flash when entering calibration
mode.
controller.
EMS
SYSTEMS:
EMS
may be calibrated individually or simultaneously.
EMS
only]
2. The operator does not hold the buttons or joystick long enough(2 seconds) when
entering calibration mode.
3. Valve calibration is not done within the high speed zone and less than 30°
above horizontal.
4. In Joystick and Sensor calibration, the operator does not exercise the joystick
and boom to their full extremes.
5. In Valve calibration, the operator does not wait for boom to move and stop or
change direction before the system completes the calibration.
6. In Sensor calibration, the operator does not hold boom Lift on long enough for
boom to travel through the hydraulic cushion and reach its maximum boom
angle.
Page no. 4 - 1
Page 28
CALIBRATION OVERVIEW:
The calibration mode is utilized to initialize the complete system or to optimize
the vehicle's performance. Complete system calibration is required whenever a
system has been installed onto a vehicle. Each individual system calibration
routine can be used in the event a component has been replaced or if vehicle
application conditions change. (See Sections I, II and III for specific calibration
instructions.
Calibration routines must be conducted in the following sequence:
1. Joystick, Sensor and Third Point calibration.
2. Ramp Speed Calibration.
3. Full/Half Speed Calibration.
4. Valve Calibration.
PRIMARY JOYSTICK AND SENSOR CALIBRATION OVERVIEW:
The joystick and sensor calibration routine can be entered by starting the
vehicle under the following conditions:
1. Drive controller deflected forward.
2. Reset button activated.
3. Calibrate button activated.
If this criteria is detected during power up, the Electronic Control Unit (ECU)
will illuminate the CAL MODE, AUTO MODE and SYSTEM NORMAL indicators,
(the CAL MODE light fill flash four (4) times before remaining lit). The operator
can execute the joystick calibration procedure. To calibrate the joystick, the
operator needs only to move the extend/retract joystick and lift/lower joystick to
its extreme positions. While the operator is doing this, the ECU is learning the
usable voltage range of the joysticks. The upper and lower limits will then be
auto scaled for maximum resolution.
Upon completion of the joystick calibration procedure, the operator must
depress the CALIBRATE button to continue. Depressing the CALIBRATE
button will acknowledge the ECU that the joystick calibration is complete. The
data obtained will then be evaluated. 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 (1) long beep.
Once an audible acknowledgment has been given the CAL MODE, AUTO
MODE and SYSTEM NORMAL indicators will be illuminated. The sensor
calibration may now be executed. The joysticks control switches for boom
functions will not move the boom in this procedure.
To calibrate the sensors, the operator needs to manually exercise the boom to
it's extreme operating positions using a calibration harness and the procedure
that follows. While the operator is doing this, the ECU is learning the usable
range of the sensors. The upper and lower limits will then be auto scaled for
maximum resolution. It is important that when calibrating the sensors that they
are exercised through their extreme operating range. Upon completion of the
sensor calibration procedure, the operator must depress the CALIBRATE
button to continue.
Page no. 4 - 2
Page 29
PRIMARY JOYSTICK AND SENSOR CALIBRATION OVERVIEW (Continued):
WARNING
During sensor calibration, the envelope management system in the primary
EMS
should be careful not to operate the platform outside of the working envelope.
Depressing the CALIBRATE button will acknowledge the ECU that the sensor
calibration is complete. Upon completion of this, the data obtained will be
evaluated. 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 (1) long beep.
To calibrate the third point calibration, fully retract the boom. Locate the third
point indicator arm inside of the turntable on the right near the boom pivot pin.
Raise the arm so that the indicator pin touches the bottom of the main boom
side plate. Lower the boom until the indicator pin is aligned with the mark on
the main boom side plate.
Depressing the CALIBRATE button will acknowledge the ECU that the
calibration is complete. Upon completion of this, the data obtained will be
evaluated. 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 (1) long beep.
controller DOES NOT limit the position of the platform. The operator
Once an audible acknowledgment has been given, the SYSTEM NORMAL
indicator will be illuminated signifying that the vehicle is ready for normal
operation.
The joystick and sensor calibration error can not be reset by pressing the reset
button in the display unit. The operator has to recalibrate again.
RAMP CALIBRATION OVERVIEW:
To enter the Ramp Calibration mode, the operator must depress the
CALIBRATE and ERROR RESET buttons on power-up. When this is done, the
CAL MODE, AUTO MODE and SYSTEM NORMAL indicators will be
illuminated, (the CAL MODE indicator will flash two (2) times before remaining
lit). At this point, one (1) short beep will be heard to indicate that the Extend
ramp speed should be selected. Depress the ERROR RESET button zero (0) to
eight (8) times in succession, the number of times corresponding to the desired
ramp with one (1) being minimum ramp and eight (8) being maximum ramp,
(the CAL MODE indicator will go off with each depression of the ERROR
RESET button), and then depress the CALIBRATE button. This enters the ramp
scaling factor into the ECU for the Extend function, (0 essentially skips
calibration for this function, leaving the previously calibrated value intact). At
this point, two (2) short beeps will be heard and the procedure should be
repeated for the retract function. Similarly, the lift (3 beeps) and lower
(4 beeps) functions should be calibrated. Upon completion of this, the audible
alarm will sound two (2) short beeps and the SYSTEM NORMAL indicator will
be illuminated signifying that the vehicle is ready for operation.
Page no. 4 - 3
Page 30
FULL/HALF SPEED CALIBRATION OVERVIEW:
To enter Full/Half Speed Calibration mode, the operator must depress the
CALIBRATE button and deflect the drive controller forward on power-up. When
this is done, the CAL MODE, AUTO MODE and SYSTEM NORMAL indicators
will be illuminated, (the CAL MODE indicator will flash three (3) times before
remaining lit). At this point, one (1) short beep will be heard to indicate that the
Extend speed should be selected. Depress the ERROR RESET button zero (0)
to eight (8) times in succession, the number of times corresponding to the
desired speed with one (1) being maximum speed and eight (8) being minimum
speed, (the CAL MODE indicator will go off with each depression of the
ERROR RESET button), and then depress the CALIBRATE button.
This enters the max speed scaling factor into the ECU for the Extend function,
(0 essentially skips calibration for this function, leaving the previously
calibrated value intact). At this point, two (2) short beeps will be heard and the
procedure should be repeated for the retract function. Similarly, the lift
(3 beeps) and lower (4 beeps) functions should be calibrated. Upon completion
of this, the audible alarm will sound two (2) short beeps, pause, three (3) beeps
and SYSTEM NORMAL, AUTO MODE and CAL MODE indicators will be
illuminated.
Upon completion of the Full Speed calibration, the
EMS
will automatically go
into the Half Speed calibration, with lift having (3 beeps) and lower (4 beeps).
Upon completion of this, the audible alarm will sound two (2) short beeps and
the SYSTEM NORMAL indicator will be illuminated signifying that the vehicle is
ready for operation.
Page no. 4 - 4
Page 31
VALVE CALIBRATION OVERVIEW:
The boom must be retracted well within the high speed operating range and the
angle must be less than 30 degrees for this procedure to work, or else the
error light will illuminate immediately. It is important to calibrate all functions
when in the valve calibration mode. The following is recommended for proper
valve calibration. To enter the Valve calibration mode, the operator must
depress the calibrate switch “ON” while powering-up. When this is done the
CAL MODE, AUTO MODE and SYSTEM NORMAL indicators will be
illuminated, (the CAL MODE light will flash once before remaining lit). The
valve calibration may now be executed. To calibrate the valve the operator
must activate each function being controlled by the ECU, in this case the four
(4) boom motions. As the operator moves the joystick off center, a command is
generated and sent to the valve. This command is continually increased by the
electronic control unit until motion is detected. The ECU will allow the specific
boom function to move for about two (2) seconds to assure successful
calibration.
1. Calibrate one function at a time.
2. Allow sufficient cylinder travel for the function chosen.
3. Hold the joystick in the desired direction until the cylinder
has traveled for two (2) seconds, and stopped.
4. Calibrate all functions each time the valve calibration
mode is entered.
5. Vehicle oil temperature should be at normal operating
temperature.
Upon completion of this, the data obtained will be evaluated. Should the data
be acceptable, the audio 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 (1) long beep. Once an audible acknowledgment had been given, the
SYSTEM NORMAL indicator will be illuminated signifying that the vehicle is
ready for operation.
Page no. 4 - 5
Page 32
EMS
CALIBRATION MODES:
EMS
The
up of the system, the
with the self-check the
EMS
is powered up each time the ignition switch is turned on. Upon power
EMS
conducts a self-diagnostic check. In conjunction
EMS
monitors the status of three switch inputs. The
checks the status of each switch to determine if a calibration mode is
being requested by the operator. The following table will describe the switch
combinations and the resulting power up mode.
TB 120 BEFORE SEPTEMBER 1994
SWITCH CONDITION UPON POWER UP
ERROR RESET
BUTTON
POWER UP MODE PRESSED PRESSED
NORMAL CONDITION
SYSTEM WAITING
JOYSTICK AND SENSOR
CALIBRATION
RAMP
CALIBRATION
SPEED
CALIBRATION
VALVE CALIBRATION NO YES NO
NO NO NO
YES YES YES
YES YES NO
NO YES YES
CALIBRATE
BUTTON
GROUND OPERATION SWITCH “UP”
OR
DRIVE CONTROLLER FULL FORWARD
PRO 100, PRO 126 & TB 120 AFTER SEPTEMBER 1994
SWITCH CONDITION UPON POWER UP
ERROR RESET
BUTTON
POWER UP MODE PRESSED PRESSED
NORMAL CONDITION
SYSTEM WAITING
JOYSTICK AND SENSOR
CALIBRATION
RAMP
CALIBRATION
SPEED
CALIBRATION
VALVE CALIBRATION NO YES NO
NO NO NO
YES YES YES
YES YES NO
NO YES YES
CALIBRATE
BUTTON
CENTER TOGGLE SWITCH
BETWEEN BDU'S
Page no. 4 - 6
Page 33
TROUBLESHOOTING DESCRIPTION INDEX
0.0 General Description
EMS
1.0 Primary
errors during power-up
1.1 All lights, except error light, and alarm flash on, but then error light
and alarm remain on - self test fails
1.2 ERROR and CAL MODE light on after self test
1.3 ERROR light on after self test
1.4 All lights flash and error on but no alarm
1.5 Lights and alarm never turn on
1.6 All lights except ERROR on - system dead
1.7 Light and alarm pulse on and off
EMS
2.0 Primary
errors that occur when joystick is at center
2.1 ERROR light on and the boom can not be operated
2.2 ERROR and AUTO MODE lights on and the boom retract/lower only
2.3 Undesired motion and system error out
2.4 Errors caused by a backup system error
EMS
3.0 Primary
errors during normal operation
3.1 Envelope control issues
3.2 No motion error
3.3 Slow motion in manual mode
3.4 Intermittent errors
EMS
4.0 Backup
errors
4.1 Power-up and normal operation errors
4.2 Wake-up check and warning
5.0 Troubleshooting for calibration errors
Page no. 5 - 1
Page 34
0.0 General Description
The envelope management system consists of a primary and a backup set.
[PRO 100 has a primary
EMS
set only]. Each set has its own controller
(electronic unit or ECU) and its own boom length and boom angle sensors.
BACKUP
SET
PRIMARY
SET
Primary and backup set location illustration
PRIMARY SET:
The primary set receives input from the joysticks its boom sensors and
controls the proportional valve for the lift/lower and extend/retract functions
to keep the platform within the primary working envelope. When the
operator moves a joystick to request motion, the primary controller
compares that request with the booms current position with respect to the
primary envelope. If the requested motion would not cause the platform to
go beyond the primary envelope the controller sends a pulse width
modulated signal to the proportional valve to move the boom in the
requested fashion. When the platform nears the primary envelope, the
controller slows the platform to a stop at the envelope.
Upon power-up (key switch on) - sequence of operation
ECU (Primary) Looks For:
1. Power on wire #E-32 must be above 9 volts - (from ECU 3 amp fuse)
2. Chassis ground on C-32
3. Ground on E-18 (ground signal for CAL MODE)
4. Checks center position on Extend controller wire E-14 (minimum 2.352 to maximum 2.666)
5. Checks center position on Lift controller wire E-16 (minimum 2.352 to maximum 2.666)
6. Checks voltage from length sensor wire E-2
7. Checks voltage from angle sensor wire A-2
8. Checks power from backup ECU wire A-16-B (12 volts)
Page no. 5 - 2
Page 35
BACKUP SET:
The TB 120 and the PRO 126 have a backup
EMS
set. This backup set is
active at all times and receives input only from its boom sensors and
controls the blocking valves for the lift/lower and extend/retract functions to
keep the platform within the backup working envelope. If the backup
controller determines that the platform is at the backup envelope, it closes
the blocking valves to stop motion in the directions that would cause the
platform to go beyond the backup envelope.
Upon power-up (key switch on) - sequence of operation
ECU (Backup) Looks For:
1. Power on wire #E-32-B must be above 9 volts - (from ECU 3 amp fuse)
2. Chassis ground on C-32-B
3. Checks voltage from length sensor wire E-2-B
4. Checks voltage from angle sensor wire A-2-B
The PRO 100 has a limit switch back up system that requires no calibration.
EMS
1.0 Primary
errors during power-up
Power up the system by starting the engine on the vehicle. Observe what
the display lights and the audible alarm do for the first couple of seconds.
During the system's internal self test, the lights should all flash on and the
alarm should beep once, the SYSTEM NORMAL and AUTO MODE lights
should be left on. The control system goes to normal operation mode.
Note: NEVER Deflect any joystick or press any button during power-up,
unless a calibration procedure is to be performed.
1.1 All lights, except error light, and alarm flash ON first. The error
light, and alarm remain on. System appears dead and can not be
reset. The self-test fails. Replace the
EMS
controller.
1.2 All lights are on first. System normal light is on but off shortly. Then
ERROR and CAL MODE lights remain on. This indicates to the
operator that some data has not been properly calibrated and
stored into the permanent memory of the
SYSTEM NORMAL ERROR AUTO MODE CAL MODE ALARM
ON ON ON
EMS
controller.
Page no. 5 - 3
Page 36
Primary
EMS
errors during power-up (Continued):
The following steps should be followed in order to ensure proper system
performance, but the operator has the ability to enter normal system operation
using default values.
1.2.1 Press the ERROR RESET button. If the ERROR light is off and
the system is operable after releasing the button, then some of
stored data is not correct and default data will be used for normal
operation.
SYSTEM NORMAL ERROR AUTO MODE CAL MODE ALARM
ON ON ON
The CAL MODE indicates that a calibration procedure is required.
1.2.2 If the error can not be reset by pressing ERROR RESET button,
then perform joystick and sensor calibrations. If the system does
not enter the joystick and sensor calibration mode, check wires
A-18, A-20, and E-18 for continuity to wire.
Refer to section 5.0 for trouble shooting on system calibrations.
1.3 All lights, except error light, and alarm flash on first. System normal
light is on but, about 0.5 second later, off again. Then only the
ERROR light remains on and the alarm continues to sound.
SYSTEM NORMAL ERROR AUTO MODE CAL MODE ALARM
ON ON
First thing to do is press the reset button.
1.3.1 The
EMS
does not respond to the reset button, i.e., the alarm still
sounds when the reset button is being pressed.
1.3.1.1 Check both BDU's (Basic Display Unit) to see if the reset button
is functioning properly and connected to the
EMS
properly.
1.3.1.2 Check wire A-20 for continuity to ground.
(Should have continuity when not pushed)
If Calibration and Error Reset button is stuck in,
will go into CAL MODE. If Error Reset button is stuck in,
EMS
system
EMS
system will error out on power-up.
1.3.1.3 Replace the
EMS
controller.
1.3.2 If the system goes to normal, operation mode and the error is
cleared, then the error is an intermittent error. Intermittent errors
may occur during power-up. If intermittent errors occur frequently,
the system components such as sensors, joysticks, battery and
harness should be checked. Replace them if necessary.
Page no. 5 - 4
Page 37
Primary
EMS
errors during power-up (Continued):
1.3.3 The error is cleared by pressing the error reset button, but the
system errors out again after releasing the reset button. Refer to
section 2.0 for trouble shooting.
1.4 All lights, except error light, and alarm flash on first. Then the
ERROR light remains on with no alarm.
SYSTEM NORMAL ERROR AUTO MODE CAL MODE
ON
ALARM
1.4.1 Check the alarm and its connection, replace the alarm or harness.
1.4.2 Check the reset button. A stuck ERROR RESET button will
continue resetting the system and the alarm will sound a short
beep in every second. Replace the BDU (Basic Display Unit).
1.5 Display lights never on and alarm never turns on.
1.5.1 Check the power and ground connection to the
EMS
controller.
1.5.2 Check E-32 for above 9 volts, check C-32 for ground.
1.5.3 If power is getting to the
EMS
controller, then check for power
going to the display unit on wire A-32 (9-12 volts). If correct
power is not going to the display, then replace the harness. If
correct power is going to the display, then replace the display
unit.
1.5.4 If problem is still not fixed at this point, then replace the
EMS
controller and perform full calibration on the system.
1.6 Alarm and all display light except ERROR turn on and stay on.
System otherwise seems dead.
1.6.1 Check and/or replace the
EMS
1.6.2 If condition still exists after checking or replacing
controller harness.
EMS
controller
harness, then replace the controller.
1.7 Lights and alarm keep turning on and off at the rate of once every
1/2 to 1 second. Replace
EMS
controller.
Page no. 5 - 5
Page 38
2.0 Primary
EMS
errors that occur when joystick is at center
This section provides troubleshooting information for the primary
EMS
errors
that occur when the operator is not operating the boom, i.e., the joysticks are
not deflected.
2.1 Errors that stop the control system. Error light and alarm will be on.
Operator will not be able to move the boom. This can be verified by
deflecting the joystick to see if the boom is moving.
SYSTEM NORMAL ERROR AUTO MODE CAL MODE ALARM
ON ON
Example: Premature boom bleed down or retraction of boom
(caused by cylinder packing or holding valve.
2.1.1 Press the ERROR RESET button. If the ERROR light goes out,
then the problem was an intermittent fault. Continue with normal
operation.
2.1.2 When the reset button is being pressed, the alarm will be off but
the error light remains on. If the alarm is on while the reset button
is pressed, check the display unit and its connection. Replace the
harness and the display unit if necessary. If the harness and the
display unit are OK, restart the system. If
to be dead, then replace the
EMS
controller.
EMS
controller appears
2.1.3 The ERROR is cleared, but it comes right on after the reset
button is released.
2.1.3.1 Joystick problem - check the joysticks and their connections,
replace them if necessary. The joystick reading should be within
the following range:
MAX MIN
FULLY EXTEND 4.921v 4.392v
EXTEND/RETRACT
LIFT/LOWER
CENTER 2.666v 2.352v
FULLY RETRACT 0.784v 0.117v
FULLY LOWER 4.921v 4.392v
CENTER 2.666v 2.352v
FULLY LIFT 0.784v 0.117v
Check voltages on: Extend/Retract controller - wire E14
Lift/Lower controller - wire E-16
(use wire C-16 for ground on meter)
2.1.3.2 Joystick A/D converter problem - if joystick is checked to be OK
and reset button and the harness are OK, replace
EMS
controller.
Page no. 5 - 6
Page 39
Primary
EMS
errors that occur when joystick is at center (Continued):
2.1.3.3 Sensor error - Check the boom length and angle sensors and
their connections to the
EMS
controller. Adjust or replace them
if necessary. The sensor reading should be within the following
range.
MAX MIN
FULLY
EXTENDED *
LENGTH SENSOR
FULLY
RETRACTED *
* Using Calibration Harness part no. 0191008 - (retract fully)
4.865v 4.375v
0.313v 0.098v
Recommend initial value is 0.125v on the Apitech unit and
0.200v on the Celesco unit. Length sensor adjustment is only
required IF the initial voltage readings are OUTSIDE the
fully retracted and/or fully extended range.
MAX MIN
PRO 100 & PRO 126
FULLY LIFTED *
ANGLE SENSOR
** Using Calibration Harness part no. 0191008 (lowered fully)
** Using Calibration Harness part no. 0191008 lower boom,
** (with Jib boom down) to within 6 inches of ground
TB 120
FULLY LOWERED *
PRO 100 & PRO 126
FULLY LOWERED**
4.865v 4.375v
0.352v 0.098v
1.015v .547v
Install test plug part no. 0191025 in-line with sensor checking,
use black for ground - white for power.
2.2 Errors that allow boom to retract only at high attitude and to lower
only at low attitude. This can be verified by deflecting the joysticks
to see if the boom can be lowered or retracted. Note that AUTO
MODE light is on.
SYSTEM NORMAL ERROR AUTO MODE CAL MODE ALARM
ON ON ON
2.2.1 Reset the error by following the same procedure as 2.1.1 and 2.1.2.
2.2.2 Error is cleared by come right on after the reset button is
released. The boom can still be retracted or lowered.
2.2.2.1 Sensor A/D converter problem - check the sensors and its
connections. If they are OK, replace the
EMS
controller.
Page no. 5 - 7
Page 40
Primary
EMS
errors that occur when joystick is at center (Continued):
2.2.2.2 Sensor error - check the boom length and angle sensors and
their connections to the
EMS
controller. Replace them if
necessary. The sensor reading should be within the appropriate
ranges as shown in section 2.1.3.3. Note that a
beep-beep-beep-beep sound may be heard before the system
errors out. The out-of-range sensor readings tend to make the
EMS
controller “think” that the platform is out of the working
envelope.
2.3 Undesired motion - the joystick is not at center or just released to
center, but the platform continues to move. The system will error
out. See section 3.1.1.2 for trouble shooting.
2.4 Errors caused by a backup system error. The primary system
monitors the system normal of the backup system all the time. If
the backup system errors out, the primary system will also error
out. The primary system then allows only lower and retract
functions. The error can be reset but will occur again unless the
backup system is normal again. See section 4.1 for details.
EMS
3.0 Primary
errors during normal operation
The primary
EMS
errors occurs when the operator is deflecting the joysticks.
This sections is broken up according to problem descriptions.
3.1 Envelope control issues. The
EMS
controller automatically slows
down the platform when the platform is approaching the envelope
edge. It will limit the functions which move the platform out of the
envelope. Normally, the operator will not hear any warning alarm,
since the functions will be stopped automatically before reaching
the alarm envelope, (the alarm envelope is generally 3-4 inches
away from the working envelope).
If the boom is lowered and approaching the front envelope edge,
the boom control system will activate a coordinated lower function.
The coordinated lower function generally starts with a retract
function to prevent the platform from going out of the envelope and
then continues with a coordinated vertical lower function. When the
boom extension becomes less than maximum horizontal extension,
the boom will switch back to uncoordinated lower function. The
operator can disable the coordinated control anytime by releasing
the joystick to center.
3.1.1 If the operator should hear the beep-beep-beep-beep warning
alarm when the platform is near the edge of the working
envelope, he should release the joystick and the pedal
immediately. The platform should stop immediately.
3.1.1.1 If the platform stops after joystick and pedal are released. The
operator should operate the platform to the ground by only
lowering or retracting the platform. Should any undesired
motion occur, stop the operation and turn off the engine.
Page no. 5 - 8
Page 41
Primary
EMS
errors during normal operation (Continued):
3.1.1.2 If the platform continues to move, the operator should not try to
activate the system. Turn off the engine immediately. The
backup
EMS
will close the blocking valves to prevent the
platform from moving further out of the backup envelope. For
such emergency, follow the emergency bleed down procedure.
The trouble shooting should be done on the ground.
3.1.1.2.1 On the ground, check the joysticks voltage output, see 2.1.3.1
for values. The reading should be quite proportional to the
deflection angle. Replace the joysticks if necessary.
EMS
3.1.1.2.2 Disconnect the valves to the
EMS
EMS
zero replace
wires to the valves when the joysticks are at center, (the
should be turned on for testing). If the voltage is not
EMS
.
3.1.1.2.3 Disconnect the valves to the
. Check the voltage across
EMS
. Turn on the engine, use a
9 volt battery to test valves to see if the platform moves and
stops according to the input signal. Replace the failed
components.
3.2 The joystick is deflected fully and the platform is not moving.
3.2.1 The
EMS
controller does not error out with joystick fully deflected
for more than 5 seconds. Check the joystick and the harness,
replace them if necessary.
3.2.2 The
EMS
SYSTEM NORMAL ERROR AUTO MODE CAL MODE ALARM
controller errors out after five seconds.
ON ON
3.2.2.1 Cold weather - Need to recalibrate valves or warm up the oil
before operation.
3.2.2.2 Use a wrench on the manual override. If the boom still will not
move, then replace the valve. If the boom will not move with a
new valve, then check the rest of the hydraulic circuit for
problems.
3.2.2.3 If the manual override moved the boom then disconnect the
harness from the valve and connect a 9 volt battery across the
solenoid leads. If the boom does not move, check the pilot
pressure. If the pilot pressure is not 400-425 PSI, adjust
accordingly. If the pilot pressure is correct, then replace that
particular solenoid.
Page no. 5 - 9
Page 42
Primary
EMS
errors during normal operation (Continued):
3.2.2.4 If all functions move with a 9 volt battery, then reconnect
everything and check the voltage going to each solenoid from
the
EMS
controller one at a time.
A two prong test lead (part no. 0191024), should be used so
voltages can be checked while the solenoid is connected. A 12
volt pulse width modulated signal is being sent to the solenoid,
but most volt meters will display a steady voltage. Voltage
should be 0 volts when the joystick is centered or when the
joystick is deflected for another solenoid and the voltage should
be in the range of 3-10 volts when the joystick is deflected in
the direction corresponding to the solenoid being tested.
3.2.2.4.1 If there is no voltage anytime, then check the harness for
continuity. Replace harness if any wire is broken. If the
harness is good, then replace the
EMS
controller.
3.2.2.4.2 If there was a slight voltage change (less than 0.5 v) when
the joystick was deflected in the direction corresponding to
the solenoid being tested, then check the center switch in the
joystick. The solenoid grounds are routed through the center
switch for safety reasons. Check the continuity between pins
E18 and C26. There should be an open condition when the
joystick is centered and closed when the joystick is deflected.
Repair or replace joystick if bad. Check harness continuity to
and from the joystick. Replace harness if bad.
3.3 Slow motion in normal operation.
3.3.1 Perform a valve calibration. If the problem is fixed, then proceed
with normal operation.
3.3.2 Move the boom using a wrench on the manual override. If the
speed does not increase, check the pilot override pressure. The
pilot pressure should be adjusted to 4005-425 PSI. If the pilot
pressure was adjusted correctly, then inspect, repair or replace
the following hydraulic components: pump, filters, control valve,
valves, hoses.
3.3.3 Connect a 9 volt battery across the solenoid leads for any slow
function. If the speed does not increase, then replace that
solenoid and it's downstream orifice and o-ring, (new solenoids
have o-ring and orifice built in). If still not faster, then replace the
control valve.
3.3.4 Recalibrate the joystick. If the joystick will not calibrate
successfully, check and/or replace the joystick, (joystick
information may be found at 2.1.3.1). If the joystick is calibrated
successfully but speeds are still slow, then replace the
EMS
controller.
Page no. 5 - 10
Page 43
Primary
EMS
errors during normal operation (Continued):
3.4 Intermittent errors.
Intermittent errors may occur during normal operation. These errors
can be reset by pressing the reset button. Continuing intermittent
errors indicate that system should be checked.
3.4.1 Check the sensors and joysticks voltage ranges as shown in
section 2.1.3.3, replace the failed components or the failed resistor
associated with each of the failed components. Make sure that the
readings are close to the middle of the max and the min values.
Check the harness connections. Replace it if necessary.
4.0 Backup
The backup
EMS
errors (TB 120 and PRO 126 only)
EMS
has a secondary (backup) envelope check. If the
boom is out of the second envelope (generally 2-3 feet from the primary
envelope). The backup system will close the blocking valves to prevent
the boom from moving further out of the second envelope. Also, a
urgent and continuous beep-beep sound will be heard. The backup
system also checks its own sensor readings and reports errors
accordingly.
4.1 Power-up and normal operation errors:
Error handling for the backup
primary
EMS
, except that it does not have joystick readings. It
EMS
is similar to the one for the
checks its own angle and length sensors.
The trouble shooting is similar to that for primary system. However,
when an error is detected in the backup system, it will send an
error signal to the primary system. The primary system will error
out and allow the operator to lower or retract only. Hence, to reset
the error, the operator has to reset the backup system first and
then reset the primary system.
4.1.1 Sensor error: Check the boom length and angle sensors and their
connections to the EMS controller. Adjust or replace them if
necessary. The sensor reading should be within the following range.
MAX MIN
FULLY
EXTENDED *
LENGTH SENSOR
FULLY
RETRACTED *
* Using Calibration Harness part no. 0191008 - (retract fully)
4.865v 4.375v
0.313v 0.098v
Check E-2-B on controller test connector or white wire on test
plug (3 prong) part no. 0191025.
If length sensor adjustment is required, the recommended
starting value is 0.125v.
Page no. 5 - 11
Page 44
Backup
EMS
errors (TB 120 and PRO 126 only) (Continued):
MAX MIN
PRO 100 & PRO 126
FULLY LIFTED *
ANGLE SENSOR
** Using Calibration Harness part no. 0191008 (lowered fully)
** Using Calibration Harness part no. 0191008 lower boom,
** (with Jib boom down) to within 6 inches of ground
TB 120
FULLY LOWERED *
PRO 100 & PRO 126
FULLY LOWERED**
4.865v 4.375v
0.352v 0.098v
1.015v .547v
Check E-2-B on controller test connector or white wire on test
plug (3 prong) part no. 0191025.
4.2 Wake-up check and warning:
The backup system will monitor the sensor readings after power-up.
If the system does not detect any changes is BOTH sensor
readings after 10 minutes, it will give a 5-beep warning to the
operator. Also, the CAL MODE light will be on. It continues to do so
every minute, until it detect changes in BOTH sensor readings.
This is to make sure that backup system is functioning properly.
The operator must move the boom in both functions, (lower or lift
extend or retract), to disable the wake-up check. If the backup
system continues to beep 5 times every minute even though both
sensors are apparently moved, both sensors and the harness
should be checked.
Page no. 5 - 12
Page 45
5.0 Trouble shooting for system calibration errors
Generally, the operator need not and should not calibrate the control system.
However, the valve calibration can be performed if the weather condition
changes. The valve calibration is generally calibrated at oil temperature of
30 degrees above outside temperature for best performance.
If a calibration error is detected, the display unit will show:
SYSTEM NORMAL ERROR AUTO MODE CAL MODE ALARM
ON ON ON
All calibration errors, except joystick and sensor calibration error, can
be reset by pressing the reset button in the display unit. After the reset
button is pressed, default values are used and the system goes to
normal operation mode with CAL MODE light on. If the system
performance is not satisfactory, the system needs to be calibrated
again. Note that if more than one set of calibration data is not correct,
the reset button needs to be pressed more than once to clear all the
incorrect data error.
SYSTEM NORMAL ERROR AUTO MODE CAL MODE ALARM
ON ON ON
5.1 After the system passes the check on the calibrated data, the
system will beep two times. The calibration procedure is completed.
However, the system continues to check other data sets. If other
calibration data error occurs, the system will error out with CAL
MODE light on. The operator should recognize that the calibration
procedure has been properly done. He should calibrate other
functions.
5.2 Joystick and sensor calibration error. If errors occur, the calibration
procedure should be repeated once.
Make sure to follow the proper calibration procedures.
If calibration fails again, check the joystick and sensor voltage
ranges and harness, (refer to 2.1.3.1 and 2.1.3.3).
5.3 Valve calibration error. Make sure to follow the proper calibration
procedure. The platform should be placed within 30 degrees above
horizontal and inside of high speed switch. If the
EMS
can not
complete the calibration, check valves and the joystick voltage
range.
Page no. 5 - 13
Page 46
NOTES:
Page no. 5 - 14
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