Control System - ICS Direct · The party-completed machine also meets the requirements in EC Directive 2014/30/EC in respect of electromagnetic compatibility. The partly-completed

2018-04-22 _7225

Control System - ICS Direct

2200401

Wheel Control

Translation of the Original Instructions _EN

© Rototilt Group AB 2018-04-27

ICS Direct Wheel

English

Declaration of conformity for the incorporation of a partly-completed machine.In accordance with Machinery Directive 2006/42/EC. Appendix II B.

Rototilt Group Systems ABBox 56SE-922 21 VindelnSWEDEN

declare under our sole responsibility that the following product:

a) is manufactured in accordance with and meets all applicable provisions in EC Directive 2006/42/EC,

b) is manufactured in accordance with the following standards: ISO 5010:2007 Earth-moving machinery—Rubber-tyred machines—Steering requirements, EN 474-1:2006+A5:2018 Earth-moving machinery – Safety – General requirements and EN 474-5:2006+A3:2013 Earth-moving machinery – Safety – Requirements for hydraulic

excavators.

The party-completed machine also meets the requirements in EC Directive 2014/30/EC in respect of electromagnetic compatibility.

The partly-completed machine may not be put into operation before the completed machinery in which it is to be incorporated is in accordance with the provisions in 2006/42/EC.

An avoidance maneuver test in accordance with 10.4 in ISO 5010:2007 must be carried out for the alternate steering function. The test determines the authorized speed with the alternate steering active, to a maximum of 20 km/h.

We confirm that the relevant technical documentation has been compiled in accordance with Appendix 7B. The authorized individual to compile the technical documentation is:

Niklas BjuhrVP Engineering

Upon reasoned request from national authorities, we undertake to provide relevant information in respect of the partly-completed machine. This provision is made by the requested information being sent in writ-ing by post to the national authority within a reasonable timeframe following the request, unless otherwise agreed.

Place and date: Vindeln, Sweden 2018-04-27

Name and signature of authorized person:

Anders JonssonCEO

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1 2

3

4 5

EN English

Overview

Control system of the ICS Direct typeA base machine/excavator equipped with ICS Direct wheel control has the following components installed:

1. Indicator lamp Decal - wheel control

2. Handles with controls to operate the base machine/excavator, ordered separately

3. Display - included in the control system ICS, ordered separately

4. Valve block - Wheel control

5. Control unit Buzzer

!IMPORTANT - Read through the instructions for the control system, tiltrotator and base machine/excavator use before starting work. Pay particular attention to the safety instructions.

!IMPORTANT - If you suspect alternative control if malfunctioning, always use the base machine/excavator's controls.

The product described in the document consists of components for the ICS Direct wheel control system. The overviews show standard equipment and options. Refer to the illustrations and lists below and on the following pages.

ICS Direct is design to facilitate the movement of the base machine/excavator when working. ICS Direct wheel control is manoeuvred using switches and or rollers in the handles. In most cases this permits the operator to work in a more ergonomic position.

RestrictionThe system can and may not be used to drive the base machine/excavator at a higher than approved speed.

The speed restriction must be tested during evasive action testing in accordance with ISO 5010:2007, 10.4.

The test determines the approved speed for alternative steering.

The highest permitted speed may never exceed 20 km/h.

The base machine/excavator’s controls for operation always have master priority over alternative steering.

Steering wheel movement must under all circumstances shut-off alternative control.

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Alternative steering inactive

ICS Direct activated

ICS Direct installed

EN English

Control unitThe control unit has two diodes and is connected to a buzzer.

The buzzer sounds in the event of a system error and twice during start-up.

When the system works correctly, the green diode lights with a fixed light and the buzzer is silent.

When a system malfunction occurs the LEDs light and the buzzer sounds in various combinations. See Trouble shooting ICS Direct

The control unit can be connected to a PC for reprogramming, calibration and detailed trouble shooting.

Lamp and decalA lamp and decal are installed on the right-hand console. The decal shows alternative control is installed on the base machine/excavator.

When ICS Direct is activated the lamp lights.

When the operation inhibitor is activated the lamp flashes to warn that the system is switched off.

Valve block, wheel controlThe valve block is connected in parallel to the base machine/excavator's orbitrol control of the hydraulic flow.

The operator controls the operation and steering of the base machine/excavator via the rollers and switches fitted in the handles.

Alternative operation is only active when the base machine/excavator’s:

• control inhibitor is deactivated

• drive mode switch is set to work mode

• and any additional drive mode switch is set to low speed mode

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S3

R3

T5

Left Handle

Right Handle

EN English

!IMPORTANT - The base machine/excavator’s factory mounted handles have been replaced with handles adapted for ICS Direct. Carefully check the changed functions, for both the base machine/excavator and alternative control.

DisplayThe symbol on the display comes on when alternative operation is activated.

HandlesThe handles are equipped with switches and rollers to control the functions on the base machine/excavator and for alternative control.

The rollers in the handles must have proportional control.

The handle functions are configured by an authorised installer.

One of several possible examples of connection to the alternative control is described below.

Left HandleS3 Activate alternative control

R3 Steering Right = Turn right Left = Turn left

Right HandleT5 Drive

Up = Drive forward Middle = Neutral Down = Drive backwards

Information about functionsInformation concerning the handles' current configuration is available in three places: On the decal, on the display and in the instructions for the base machine/excavator.

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Inactivate

5

Activate

Sound

1

3

4Shut off Lever

Light

Warning Flashing light Sound 3 sec.

6

Drive Mode Switch

Travel Limit

2

EN English

Operation

Activate alternative control1. The operation inhibitor must be

deactivated, (usually occurs in the horizontal position).

2. Turn the drive mode switch to work mode. If there is a drive mode switch for the speed, this should be turned to low speed mode.

3. Activate alternative control with the connected switch in the handle.

4. The control system's indicator lamp lights to indicate that alternative control is activated. The alternative control symbol on the display is shown.

The base machine/excavator’s controls for operation always have master priority over alternative steering.

DeactivateICS Direct is deactivated as follows:

5. Switch off alternative control with the switch in the handle. The control system's indicator lamp goes out to indicate that alternative control is deactivated. The symbol is not shown on the display.

or

6. Use the base machine/excavator’s control for steering (wheel). Alternative steering always has a lower priority than the base machine/excavator’s control. The control system's indicator lamp flashes and the buzzer sounds for 3 seconds to warn that the system is switched off.

or

7. Turn the drive mode switch to transport mode. Warning signals as above.

! IMPORTANT - If you suspect alternative control if malfunctioning, always use the base machine/excavator's controls.

iINFO - If the voltage to the base machine/excavator fails, the drive mode switch must be turned to work and transport mode, as a function control.

!WARNING! Alternative steering must not be possible to use at a higher than permitted and tested speed. Max. 20 km/h.

!WARNING! Steering wheel movement must under all circumstances shut-off alternative control.

OperationWhen alternative control is activated the base machine/excavator is operated as follows:

Drive (forwards and backwards) with the right-hand handle. Steering (left and right) with the left-hand handle.

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Inactivate

3

Activate

Sound

2

Shut off Lever

Light

201

EN English

MalfunctioningWhen an error code is generated from a function, all functions are blocked.

Once the error code has been identified in the trouble shooting table, the buzzer can be temporarily switched off.

The buzzer stops if the activation switch is pressed and held for 3 seconds. Restarting activates the buzzer again.

Alternative connectionICS Direct Wheel control can also be connected to a frequency sensor in the base machine/excavator’s transmission. Once contact has been established between the control system and the frequency sensor, the system can be activated.

Activate alternative control1. Deactivate the operation inhibitor and

drive at a low speed, max 20 km/h.

2. Activate alternative control with the connected switch in the handle.

Deactivate3. ICD Direct is deactivate with the

connected switch in the handle.

4. Use the base machine/excavator’s control for steering (wheel). Alternative steering always has a lower priority than the base machine/excavator’s control. The control system's indicator lamp flashes and the buzzer sounds for 3 seconds to warn that the system is switched off.

Safety latchThe speed must not exceed the permitted limit, that is why alternative steering is shut-off when the speed limit is exceeded.

The control system's indicator lamp flashes and the buzzer sounds for 3 seconds to warn that the system is switched off.

If the speed is lowered immediately the system continues to be active.

Connection to the frequency sensor is used on base machines/excavators not fitted with a drive mode switch.

iINFO - If the voltage to the base machine/excavator fails, the base machine/excavator must first be driven at a low speed so that the system can be reactivated.

!IMPORTANT - The speed must not exceed the permitted limit, that is why alternative steering is shut-off when the speed limit is exceeded.

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© Rototilt Group AB 2018-03-26 trouble:1

EnglishENEN -

Troubleshooting ICS Direct

Fundamental signal combinations

The control unit has two diodes and a buzzer, which indicate how the control system is working. The components light and sound at different intervals and combinations. The components are controlled by the signals that pass between the control unit and the other parts of the control system.

Correct function - When the green LED lights with a fixed light the control system works correctly.

System inactive - When the green and red LEDs light with a fixed light the drive mode switch is not activated.

Calibration - When the green and red LEDs flash quickly and the buzzer sounds the rollers are not calibrated correctly.

Input signal - When the green and red LEDs flash slowly and the buzzer sounds the input signal does not work correctly.

Output signal - When the green LED flashes and the Red LED lights with a fixed light and the buzzer sounds the output signal does not work correctly.

Detailed troubleshooting

CalibrationRed LED Green LED Buzzer Possible cause Action

Flashes quickly.

1 flash Sounds at the same rate as the red LED.

Roller left not calibrated. The control system clears the roller’s calibration and stops output signals.Cable breakage, connector play or roller fault.

• Calibrate the roller by pulling it to each end position for at least 3 seconds.

• Change the roller and perform the calibration as set out above.

• Contact the service workshop.Flashes quickly.

2 flashes Sounds at the same rate as the red LED.

Roller right not calibrated. The control system clears the roller’s calibration and stops output signals.Cable breakage, connector play or roller fault.

Red LED Green LED Buzzer Possible cause Action

Extin-guished

Fixed light Silent System works. None

Correct function

Red LED Green LED Buzzer Possible cause Action

Fixed light Fixed light Silent System inactive. Activate the system

System inactive.

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EnglishENEN -

Input signalRed LED Green LED Buzzer Possible cause Action

Flashes slowly.

1 flash Sounds at the same rate as the green LED.

The supply to roller left broken, caused by an open or short circuit on the harness.

• Check the harness to the joystick in terms of crush damage or open circuit.

• Restart the system.• Contact the service workshop.

Flashes slowly.

2 flashes Sounds at the same rate as the green LED.

Roller left activated during start-up of the control system. The rollers’ output signal and the output signal to the proportional valve is blocked by the system.

• Return the roller to its zero position.• Check that none of the rollers are

mechanically blocked.• Check the condition of the rollers.• Restart the system.• Contact the service workshop.

Flashes slowly.


The supply to roller right broken, caused by an open or short circuit on the harness.

• Check the harness to the joystick in terms of crush damage or open circuit.

• Restart the system.• Contact the service workshop.

Flashes slowly.


Roller right activated during start-up of the control system. The rollers’ output signal and the output signal to the proportional valve is blocked by the system.

• Return the roller to its zero position.• Check that none of the rollers are

mechanically blocked.• Check the condition of the rollers.• Restart the system.• Contact the service workshop.

Flashes slowly.


Deviations in signal state on full deflection of roller left.

Error from the roller’s output signals discovered by the system after 0.2 seconds.

In the event of deviations, the system blocks the roller’s output signal and the output signal to the proportional valve.

• Check the condition of the harness and rollers.

• The fault lasts less than two seconds:Return the roller to its zero position.

• The fault lasts longer than two seconds: Return the roller to its zero position. Restart the control system. Contact the service workshop.

Flashes slowly.


Deviations in signal state on full deflection of roller right. Error from the roller’s output signals discovered by the system after 0.2 seconds. In the event of deviations, the system blocks the roller’s output signal and the output signal to the proportional valve.

• Check the condition of the harness and rollers.

• The fault lasts less than two seconds:Return the roller to its zero position.

• The fault lasts longer than two seconds: Return the roller to its zero position. Restart the control system.Contact the service workshop.

Flashes slowly.


Left roller activated during start-up of the system.

• Return the roller to its zero position.

• Contact the service workshop.

Flashes slowly.


Input signal fault from the pressure sensor.

• Check the harness in terms of crush damage or open circuit.

• Check the sensor

• Contact the service workshop.

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EnglishENEN -

Output signalRed LED Green LED Buzzer Possible cause Action

Fixed light 1 flash Sounds at the same rate as the green LED.

Functional fault on output signal wire 1.Output signal blocked.


• Check the condition of the valve.• Return the roller to the zero position.• Contact the service workshop.

To reset the fault indication, restart the system by disconnecting the voltage on the base machine.

Fixed light 2 flashes Sounds at the same rate as the green LED.
















Start-up check that indicates whether one of the valves is not connected to the control system.


• Check the condition of the valves.• Restart the control system.• Contact the service workshop.



Functional fault on output signal wire Auxiliary.Output signal blocked.


• Check the condition of the valves.• Restart the control system.• Contact the service workshop.


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© Rototilt Group AB 2018-04-27 schema:1

Schematics and Overwievs for hydraulic as well as electrical systems, in the following pages are meant to serve mainly as a guide for Troubleshooting.

! WARNING! More extensive adjustments and repairs must be done by an authorized service workshop.

Schematics

Valve Block, Wheel Control

1. Port T1

2. Port T

3. Port P IN

4. Port LSO

5. Port A

6. Port B

7. Connector 3

8. Connector 4

9. Connector 2

10. Pressure Sensor, PT

11. Port EF

12. Port LSP

13. Pressure Relief

9

125

7

8

10

11

1

2

3

4

6

13

EnglishENEN -

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Open Center

ICS Direct Wheel Control can be adapted with two alternative options for Valve Block. Both Valve Blocks are connected to the same functions for the system. Illustration below shows the Open Center Version.

Valveblock, Wheel Control - Open Center

EnglishENEN -

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Statisk / Dynamisk Inkoppling

ICS Direct Wheel Control can be adapted with two alternative options for Valve Block. Both Valve Blocks are connected to the same functions for the system. Illustration below shows the the Static / Dynamic Version.

Valveblock, Wheel Control - Static / Dynamic

EnglishENEN -

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LSO

LSP

EFT

TP P IN

A BR L

ADAPTER

HOSE 3⁄8”HOSE ¼”

BYPASS

PLUG

Hydraulic connections, Open Center

EnglishENEN -

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LSO

LSP

LS

CF

EF

TTP

P

P IN

A BR L

ADAPTER

HOSE 3⁄8”HOSE ¼”

BYPASS

EF

LS

Hydraulic connections, Static / Dynamic

EnglishENEN -

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Har

ness

ICS

Dire

ct

Harness ICS Direct General version

iIN

FO -

Sch

emat

ic re

fers

to th

e ge

nera

l ver

sion

of I

CS

D

irect

. Ada

pted

ver

sion

s of

the

syst

em m

ay d

iffer

.

EnglishENEN -

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Harness, Pressure Sensor

EnglishENEN -

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Documents

Control System - ICS Direct · The party-completed machine also meets the requirements in EC Directive 2014/30/EC in respect of electromagnetic compatibility. The partly-completed