Calibration Procedure and Fault Finding Guide For 815920 and 838141 Electronic Control Box Groups Installed On RT50SA, RT50, RTC60 and RT60 Telescopic Material Handlers{5725} Caterpillar


Calibration Procedure and Fault Finding Guide For 815920 and 838141 Electronic Control Box Groups Installed On RT50SA, RT50, RTC60 and RT60 Telescopic Material Handlers{5725}

Usage:

RT50SA (8DJ1-Up) RT50 (5PF1-Up) RT60 (5DG1-Up) RTC60 (4XG1-Up)

Introduction

This instruction provides the information necessary to calibrate the 815920 and 838141 Control Boxes.

The purpose of the calibration is to set zero positions and speeds of the boom and attachment motions.

Calibration may be required following repairs, replacement or adjustments to the machine hydraulic or electrical systems. Before returning the machine to service, operate all motions slowly until the hydraulic oil is at normal operating temperature and then check the boom and attachment motions for smoothness of operation and maximum speed. If the speeds are not to specification, or the control response is not correct, calibration of the electronic control box may be necessary.

Machines equipped with type 1 boom and attachment controller have an 815920 Electronic Control Box. Machines with type 2 boom and attachment controller have an 838141 Electronic Control Box. Type 1 and Type 2 boom and attachment controller arrangements are described in the Operation and Maintenance Manual SEBU6390.

Reference: Parts Book. SEBN8600 Service Manual, SENB8376 Operation and Maintenance Manual, SEBU6390

6V7070 Digital Multimeter, or equivalent.4C4029 Trimmer Adjustment Tool for potentiometers.A stopwatch or wrist watch with sweep second hand.6T9021 Adhesive.1U8846 Sealant.

Preparation

------ WARNING! ------

Diesel engine exhaust contains products of combustion which may be harmful to your health. Always start and operate the engine in a well ventilated area. If in an enclosed area, vent the exhaust to the outside.

-------WARNING!-------

1. Park the machine on firm level ground in a well ventilated area with enough space to fully elevate and extend the boom. The machine must be positioned so that the boom can be lowered below ground level (on a loading bay for example). The hydraulic oil should be at operating temperature.

2. Determine which boom and attachment controller arrangement is installed by refering to the decal next to the controller before attempting to operate the machine.


Decal on machines equipped with type 1 boom and attachment controller arrangement. This arrangement is commonly found in North America.


Decal on machines equipped with type 2 boom and attachment controller arrangement. This arrangement is commonly found in Europe.

3. Remove the control box mounting hardware and pull the box forward from under the seat in order to gain access.


815923 Circuit Board (part of 815920/838141 Electronic Control Box Group). (1) LK1. (2) LK2. (3) LK3. (4) LK4. (5) CON2. (6) CON3. (7) CON4. (8) RV2 Potentiometer. (9) RV3 Potentiometer. (10) RV4 Potentiometer. (11) RV5 Potentiometer. (12) RV6 Potentiometer. (13) RV7 Potentiometer. (14) RV8 Potentiometer. (15) RV9 Potentiometer. (16) RV10 Potentiometer. (17) RV11 Potentiometer. (18) Switch 1. (19) Switch 2. (20) V REF Pin. (21) Screw. (22) RV1 Potentiometer. (23) LED 1. (24) LED 2. (25) LED 3. (26) LED 4. (27) LED 5. (28) LED 6. (29) LED 8. (30) LED 9.

4. Remove the control box lid. If installing a new control box, examine the pins of the link components (1), (2) and (3).

Links (1), (2) and (3) have two pins each. There must be a link installed on each pair of pins.

If any of the links are missing, either return the complete control box for exchange or install links at the necessary locations. The link part number is 907249.

5. Ensure the connectors (5), (6) and (7) are correctly installed.

Potentiometers have ten turns of electrical adjustment range but are capable of continuous mechanical rotation. When the end of the adjustment range is passed, in either direction, a "click" will be heard.

NOTE: If the "click" is not heard, potentiometer may NOT be defective, proceed with calibration procedure.

6. Turn the adjusting screws on potentiometers (8), (9), (10), (11), (12), (13), (14), (15) (16) and (17) counterclockwise until the click is heard.

7. Turn potentiometers (10), (11), (12), (14), (16) and (17), seven turns clockwise for initial speed settings. Ensure that potentiometers (8), (9) (13) and (15) are not moved.

8. If control box is disconnected from machine, ensure that power is turned OFF by turning off key switch before making the connection and tightening the plug.

9. Position the boom horizontal and extended approximately 150 mm (6 in). Rotate the attachment carriage to the midway position.

10. Install the voltmeter between the V REF pin (20) and screw (21) in the VR1 component. The voltmeter should indicate 2.50 - 2.60 volts. If the voltage is not correct, carefully turn potentiometer RV1 (22) until the voltage indication is exactly 2.55 volts then lock the adjuster with a small drop of 6T-9021 Adhesive.

Zero Positions

This stage of calibration sets up the directional control valve spool opening positions (the position where oil starts to flow to the boom and attachment motion cylinders). In normal operation mode, switches (18) and (19) are in the OFF position.

During calibration, either switch (18) or switch (19) will be switched ON at various times. Switch (18), which will cover the number 2 when turned on, allows setting of the zero positions for one set of motions (boom raise, boom extend and carriage tilt back). Switch (19), which covers the number 1 when turned on, allows setting of the opposite motions (boom lower, boom retract and carriage tilt forward).

If, during calibration, a motion reaches the mechanical limit of travel, the boom or attachment carriage can be moved back in the opposite direction by reverting to both switches OFF. Calibration can then be resumed by returning the appropriate switch to ON.

NOTE: There is only one adjustment for the boom raise and boom lower zero positions, and one adjustment for the boom extend and boom retract zero positions. The zero will be set for the axis which moves most readily. Carriage tilt back and carriage tilt forward have independent zero adjustments, (8) and (9).


(8) Carriage Tilt Back. (9) Carriage Tilt Forward. (13) Boom Extend/Retract. (15) Boom Raise/Lower. (18) Switch 1. (19) Switch 2.

NOTE: The zero positions must be adjusted with the hydraulic oil at normal operating temperature.

11. Move switch (18) to ON, and switch (19) to OFF.

12. Turn potentiometer (15) clockwise until the boom starts to rise, then counterclockwise until the motion just stops.

13. Move switch (18) to OFF, and switch (19) to the ON position. If the boom starts to lower, turn potentiometer (15) slowly counterclockwise until the boom motion just stops. Note how many turns are needed.

If the boom does not move when switch (19) is turned ON, turn potentiometer (15) clockwise until the boom starts to lower. Note how many turns are needed. Turn potentiometer (15) counterclockwise to its previous position and move switch (19) to OFF.

If more than 2 turns were needed to either stop or start the motion, the control box or the directional control valve EHP group for this axis may be defective.

14. Choose the direction which moved most readily from steps 12 or 13. Set the relevant switch (18) or (19) ON to select that motion. Turn potentiometer (15) slowly clockwise until the boom starts to move, then turn very slowly counterclockwise until the motion just stops.

The boom raise/lower zero position is now set.

15. Move switches (18) and (19) to OFF and then operate the boom raise and lower functions. Check that the boom can be started smoothly and operated at a very slow creep speed. If it cannot, the zero positions may have been incorrectly set, the controller may be defective or require adjustment or the control box may be defective.

Check that the controller deadband (the area where the controller can be moved from hold without the boom moving) is not more than 12 mm (.47 in). A large deadband suggests that the zero positions are set incorrectly, or the controller is either defective or out of adjustment. If necessary, adjust or repair the controller and then repeat Steps 11 thru 15 to verify that the zero position is calibrated correctly.

16. Move switch (18) to ON and turn potentiometer (13) clockwise until the boom starts to extend, then slowly, counterclockwise until the motion just stops.

17. Move switch (18) to OFF and switch (19) to ON. If the boom starts to retract, turn potentiometer (13) slowly counterclockwise until the motion just stops. Note how many turns are needed.

If the boom does not move when switch (19) is turned to ON, turn potentiometer (13) clockwise until the boom starts to retract. Note how many turns are needed. Turn potentiometer (13) counterclockwise to its previous position and move switch (19) to OFF.

If more than 2 turns were needed to either stop or start the motion, the directional control valve EHP group for this axis or the control box may be defective.

18. Choose the direction which moved most readily from Steps 16 and 17. Set the relevant switch (18) or (19) ON to select that motion. Turn potentiometer (13) slowly clockwise until the boom starts to move, then turn very slowly counterclockwise until the motion just stops.

The boom extend/retract zero position is now set.

19. Ensure switches (18) and (19) are both OFF and then operate the boom extend and retract functions. Check that the motions can be started smoothly and operated at a very slow creep speed. If they cannot, the zero positions may have been incorrectly set, the controller may be defective or require adjustment or there is a fault in the control box.

Check that the controller deadband (the area where the controller can be moved from hold without the boom moving) is not more than 12 mm (.47 in). A large deadband suggests that the zero positions are set incorrectly, or the controller is either defective or out of adjustment. If necessary, adjust or repair the controller and then repeat Steps 16 thru 19 to verify that the zero position is calibrated correctly.

20. Move switch (18) to ON and turn potentiometer (8) clockwise until the carriage just starts to tilt back, then turn very slowly counterclockwise until the motion just stops.

The carriage tilt back zero position is now set.

NOTE: There is no need to compare zero motion with carriage tilt forward, as each direction has its own set point.

21. Move switch (18) to OFF and switch (19) to ON. Turn potentiometer (9) clockwise until the carriage just starts to tilt forward, then turn very slowly, counterclockwise until the motion just stops.

The carriage tilt forward zero position is now set.

22. Move switch (19) to OFF and check the operation of the carriage tilt motions. Ensure that they can be started smoothly and operated at a very slow creep speed. If they cannot, the zero positions may have been incorrectly set, the controller may be defective or require adjusting or there is a fault in the control box.

Check that the dead area around hold (the area where the controller can be moved without the carriage moving) is not more than 12 mm (.47 in). A large deadband suggests that the zero positions are set incorrectly, or the controller is either defective or out of adjustment. Adjust or repair the hand controller if necessary and repeat Steps 20 thru 22 to verify that the carriage zero positions are calibrated correctly.

The illustration summarizes the zero adjustment points and functions.

Motion Speed

The boom and attachment carriage speeds were set approximately at the beginning of the calibration procedure. They can now be adjusted to the machine specifications or a slower speed if this is preferred for a specific job.

NOTE: The speeds must be adjusted with the hydraulic oil at normal operating temperature.

23. Operate and time each motion over its full travel range with the engine at full speed. Compare the times with the table and note any times which require adjusting.


(10) Boom Extend. (11) Boom Raise. (12) Carriage Tilt Back. (14) Carriage Tilt Forward. (16) Boom Lower. (17) Boom Retract.

24. Adjust the potentiometers by one half turn for each motion which requires adjustment. Turn the potentiometers clockwise to increase speed or counterclockwise to decrease speed. When all adjustments have been made, check the speeds again. Repeat the operation until all speeds are within specification. Check that the speed can be varied smoothly from a very slow creep speed to maximum over the full travel of the controller.

If any of the above speeds cannot be achieved, a fault in the associated hydraulic system may be indicated.

NOTE: If a speed potentiometer is adjusted too far clockwise motion speed will not be increased, this is limited by the hydraulic system. The effect will be to deadband the final part of controller travel which will reduce fine control. The speed potentiometers should be set to obtain maximum speed at, or just before maximum controller travel.

25. Lock each potentiometer adjusting screw with a small drop of 6T-9021 Adhesive and install the lid on the control box with 1U-8846 Sealant.

NOTE: Later machines may have a gasket between the lid and the control box. If the gasket is present, the sealant is not necessary.

26. Check that all functions are operating correctly before returning the machine to service.

Fault Finding Guide

Fault Indicators

There eight Light Emitting Diodes (LED's) on the control box circuit board:


LED Indicator Positions.

During normal operation, LED's (23) through (27) should all be off and LED's (28) and (29) should both illuminate.

LED's (23) to (27) are all red in color. They illuminate in various combinations to give an indication of fault conditions.

LED (28) is yellow in color and is illuminated under normal operating conditions. If the circuit board safety check circuitry is activated under fault conditions this LED will be off, indicating a fail safe condition.

LED (29) is green in color and when illuminated indicates that there is a power supply to the box.

LED (30) is red in color. It may flash dimly during fault conditions but should be ignored.

Fault Code LED Patterns

CODE 1 indicates that the voltages coming from the controller are outside the normal operating range expected. This could indicate a problem in the wiring or controller, a fault in the control box or the controller is not in the hold position during start up.

CODE 2 indicates that the control box has a signal which indicates that the controller has been moved away from hold, but not how far. This is most likely to be a fault in the control box, but may indicate a problem in the wiring or controller. The control box should be replaced to confirm which.

CODE's 3, 4, 9, 14 and 17 indicate control box internal failures. They may be transient errors which can be cleared by switching off then restarting. These codes can also be caused by a noisy supply to the control box due to a bad alternator circuit breaker or connection. If the fault persists, the control box must be replaced. Code may also be caused by dust in the control box relay. See Code 7.

CODE's 5, 15 and 16 indicate that the battery supply to the control box is low, very low or too low to be useable, respectively. This may be caused by a fault in the battery charging system, the battery itself or a high resistance connection in the battery feed to the control box. It is possible but very unlikely that the control box itself is faulty.

The machine will be useable with codes 5 and 15 displayed but will be disabled while code 16 is showing.

NOTE: These fault codes may show for a couple of seconds after a very cold start or a start with a battery which has a low charge but may be cleared by recycling the key switch after the battery receives charge. If the codes persist, a charging/wiring problem is indicated which should be traced and rectified.

CODE 6 indicates that the drive to one or more of the directional control valve solenoids is shorted to ground. This could be due to a wiring harness fault, an internal short in a solenoid or an internal fault in the control box.

CODE 7 indicates a failure in the safety watchdog circuit which supplies power to the valve solenoid driver circuits in the control box. This could be due to dirty contacts in the watchdog relay inside the control box. The contacts can be cleaned as follows.

1. Disconnect and remove the control box from the machine.

2. Remove the clear plastic relay cover.

NOTE: Under no circumstances should any kid of abrasive or liquid cleaner be used on the soft contacts.

3. Insert a piece of clean hard white paper, such as photocopier paper, between the contacts and close the contacts by holding the armature down.

4. Move the paper gently backwards and forwards. Repeat this with clean areas of the paper until no trace of contamination is seen on the paper.

5. Install the relay cover, reconnect control box and continue testing.

If the fault persists, the control box must be replaced.

CODE's 8 and 13 indicate that the battery supply to the control box is high or too high to be useable, respectively. The most likely cause is a fault in the battery charging system. These codes would also be caused by boost charging or jump starting/operating the machine from 24 volts by mistake. The machine will be useable when code 8 is displayed, but will be disabled while code 13 is displayed.

CODE 10 indicates that the drive to one or more of the directional control valve solenoids is shorted to battery. This could be due to a wiring harness fault or an internal fault in the control box. When this code is displayed, the safety circuitry comes into operation and the amber LED is switched off.

CODE 11 indicates that the control box has two opposing motion signals such as boom raise and boom lower at the same time. This can be caused by an incorrectly adjusted or faulty controller, a wiring fault or an electronic fault in the control box.

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