Service

RCL Safety System

08.01
 Service and Troubleshooting - TCC

Contents

1. Introduction 3
1.1 Error code reading by means of the ECT5050 ........................................................4
1.2 RCL error messages on the RCL indicator panel ....................................................4
1.2.1 RCL indications illustrated as follows: ...............................................................4
1.3 Error code reading RCL – Indicator panel ...............................................................5
2. Reading of RCL-Black Box Data 7
2.1 Operational Data .....................................................................................................7
2.2 Registration of errors ...............................................................................................7
2.3 Table - Reading of RCL-Black Box Data (A) ...........................................................8
2.4 Table - Reading of RCL-Black Box Data (B) ...........................................................9
3. Block Diagram RCL 5100 10
4. Block Diagram RCL 5200 11
5. Block Diagram EJB 5080 12
6. Technical Data, Pressure Transducer 13
6.1 Electric Diagram ....................................................................................................13
6.2 Signal conditions on pressure transducer .............................................................14
7. Technical Data, Danfoss PVDI spool sensor 15
8. Technical Data, Nordhydraulik spool sensor 16
9. AIC 5061/5062 17
10. EJB 5080 17
11. Connection, External Emergency Stops RCL 5100/5200 18
12. Troubleshooting Sheet 19

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1. Introduction

This chapter contains documentation for service technicians who are to carry out
service/retro-fitting/troubleshooting on HMF loaders. The chapter contains e.g. error code
indications on the RCL indicator panel, as well as diagrams on all components.

As HMF is currently developing and improving the RCL system, the chapter will currently
be updated and extended with new pages.
If new documentation of greater importance to service or other should occur, updating
sheets will be sent out; otherwise the chapter will only be updated in connection with
training.

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1.1 Error code reading by means of the ECT5050

This is described in the ECT 5050 manual.

1.2 RCL error messages on the RCL indicator panel

If the RUN-diode is flashing after pushing the green button on the RCL-box, it is indicated
that there is an error in the RCL safety system, or by one of the components connected to
the safety system.
Push the red button and use the table next page to find the error.

RUN is flashing

The buzzer gives a periodic or constant

signal

1.2.1 RCL indications illustrated as follows:

Push the button

The diode is constantly lit

The diode is flashing

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1.3 Error code reading RCL – Indicator panel

01010 01020 03020 04040

CAN-bus connected parts Initialization of CAN-bus Pressure transducer Fly-Jib Error, oil cooler
connected parts output side

03050 12010 12020 12030

Pressure transducer, comp., Spool sensor, winch Spool sensor, Fly-Jib extension Spool sensor, Fly-Jib
boom

12040 12050 12060 14050

Spool sensor, extension Spool sensor, jib Spool sensor, boom Error, HDL-valve

22070 23010 23030 23040

Spool sensor, slewing Pressure transducer, winch Pressure transducer, Fly-Jib Pressure transducer, boom
input side

24010 24020 24030 24060

Output OUT1 Output OUT 2 Output OUT 3 Dump valve

25010 26020 26030 27070

Critically high oil temperature Incorrect set up of RCL No internal set up Internal error in AIC

27090

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Error in signal from AIC CAN-bus communication (IRC) No RF-signal (IRC) Stop button pushed in (IRC)

Start up error, CAN-Bus (IRC) Missing dump signal (IRC) Check sum error, start up (IRC) Emergency operation (IRC)

Unknown error (IRC)

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2. Reading of RCL-Black Box Data

• At the 3 months/100 hours and the annual/1000 hours service overhauls, reading of
black box data from the RCL takes place.
• The ECT 5050 Service Terminal can be used for this purpose (please see further on
this subject in the ECT 5050 Instruction Manual).
• Please note that in case of warranty claims concerning e.g. fractures on the structural
components of the loader, the HMF Technical Service Dept. will ask for these black box
data which may be of importance to the settlement of the warranty claim.

2.1 Operational Data

• Run.time: The time the RCL has been activated.
• Load time: The time the loader has been loaded converted to 100%.
• Max. pressure: The max. pressure the boom cylinder has been exposed to.
• Dynamic count.: Summing up of points depending on the load on the loader.
• O.load t.: The number of times the loader has been overloaded
• Emerg. t.: The time the loader has been working in emergency mode.
• Max. oil temp.: The highest temperature the oil has been exposed to.
• O.ride t.: The time the loader has been working in override mode.
• O.load t.: The time the loader has been overloaded.
• Stab. time: The time the loader has been in stability test mode.

2.2 Registration of errors

Error code Explanation Error Explanation

code
01010 CAN-bus connected parts 23010 Pressure transducer, winch
01020 Initialization of CAN-bus 23030 Tryktransducer, Fly-Jib primær
connected parts
03020 Tryktransducer Fly-Jib 23040 Pressure transducer, boom
sekundær side
04040 Error, oil cooler 24010 Output OUT1
03050 Pressure transducer, boom, 24020 Output OUT2
output side
12010 Spool sensor, winch 24030 Output OUT3
12020 Spool sensor, Fly-Jib 24060 Dump valve
extension
12030 Spool sensor, Fly-Jib 25010 Critically high oil temperature
12040 Spool sensor, extension 26020 Incorrect set up of RCL
12050 Spool sensor, jib 26030 No internal set up
12060 Spool sensor, boom 27070 Internal error in AIC
14050 Error, HDL-valve 27090 Error in signal from AIC
22070 Spool sensor, slewing

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2.3 Table - Reading of RCL-Black Box Data (A)

Loader type: RCL type:

Loader no.: RCL no.:

Operational Data
Overhaul 3 months 1st annual nd
2 annual
rd
3 annual
th
4 annual
or or or or or
100 hours
Variable 1000 hours 2000 hours 3000 hours 4000 hours
[date:month:year] [date:month:year] [date:month:year] [date:month:year] [date:month:year]
Date of overhaul
[hours:min:sec] [hours:min:sec] [hours:min:sec] [hours:min:sec] [hours:min:sec]
Run.time:
[hours:min:sec] [hours:min:sec] [hours:min:sec] [hours:min:sec] [hours:min:sec]
Load time:
[bar] [bar] [bar] [bar] [bar]
Max. pressure:
[°C] [°C] [°C] [°C] [°C]
Max. oil temp.

[point] [point] [point] [point] [point]

Dynamic count.:
[-] [-] [-] [-] [-]
O.load t.:
[hours:min:sec] [hours:min:sec] [hours:min:sec] [hours:min:sec] [hours:min:sec]
O.load t.:
[hours:min:sec] [hours:min:sec] [hours:min:sec] [hours:min:sec] [hours:min:sec]
O.ride t.:
[hours:min:sec] [hours:min:sec] [hours:min:sec] [hours:min:sec] [hours:min:sec]
Emerg. t.:

[hours:min:sec] [hours:min:sec] [hours:min:sec] [hours:min:sec] [hours:min:sec]

Stab. time

Registration of errors
1.Code / Time

2.Code / Time

3.Code / Time

4.Code / Time

5.Code / Time

6.Code / Time

7.Code / Time

8.Code / Time

9.Code / Time

10.Code / Time

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2.4 Table - Reading of RCL-Black Box Data (B)

Loader type: RCL type:

Loader no.: RCL no.:

Operational Data
th th th th th
Overhaul 5 annual 6 annual 7 annual 8 annual 9 annual
or or or or or
Variable 5000 hours 6000 hours 7000 hours 8000 hours 9000 hours
[date:month:year] [date:month:year] [date:month:year] [date:month:year] [date:month:year]
Date of overhaul
[hours:min:sec] [hours:min:sec] [hours:min:sec] [hours:min:sec] [hours:min:sec]
Run.time:
[hours:min:sec] [hours:min:sec] [hours:min:sec] [hours:min:sec] [hours:min:sec]
Load time:
[bar] [bar] [bar] [bar] [bar]
Max. pressure:

[°C] [°C] [°C] [°C] [°C]

Max. oil temp.
[point] [point] [point] [point] [point]
Dynamic count.:
[-] [-] [-] [-] [-]
O.load t.:
[hours:min:sec] [hours:min:sec] [hours:min:sec] [hours:min:sec] [hours:min:sec]
O.load t.:
[hours:min:sec] [hours:min:sec] [hours:min:sec] [hours:min:sec] [hours:min:sec]
O.ride t.:

[hours:min:sec] [hours:min:sec] [hours:min:sec] [hours:min:sec] [hours:min:sec]

Emerg. t.:
[hours:min:sec] [hours:min:sec] [hours:min:sec] [hours:min:sec] [hours:min:sec]
Stab. time

Registration of errors
1.Code / Time

2.Code / Time

3.Code / Time

4.Code / Time

5.Code / Time

6.Code / Time

7.Code / Time

8.Code / Time

9.Code / Time

10.Code / Time

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3. Block Diagram RCL 5100

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4. Block Diagram RCL 5200

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5. Block Diagram EJB 5080

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6. Technical Data, Pressure Transducer

6.1 Electric Diagram

Transducer No. 28339

+ Supply (pin 2)

10 - 30 Vdc
+ Signal 1-6VDC (Pin 3)

- Signal 1 (VDC)
- Supply (pin 1) (pin E)

Transducers no. 28235, 28366

- Supply (Pin 3)

10 - 30 Vdc + signal 1-6VDC

(pin 2)

- signal (1VDC)
+ Supply (pin
(pin E)
1)

Pin E is not connected

The signal area from the transducer is 1-6Volt DC

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6.2 Signal conditions on pressure transducer

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7. Technical Data, Danfoss PVDI spool sensor

4 2

1 3

Neutral A-port signal B-port signal

PVDI PVDI PVDI

4 (+) 4 (+) 4 (+)

A B

- - - - - -
(Ground) (Ground) (Ground) (Ground) (Ground) (Ground)
3 2 3 2 3 2

K3xx K4xx RCL K3xx K4xx RCL K3xx K4xx RCL

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8. Technical Data, Nordhydraulik spool sensor

1 3

4 2

Neutral A-port B-port

Nordhydraulic Nordhydraulic Nordhydraulic
4 (+) Spool Sensor 4 (+) Spool Sensor 4 (+) Spool Sensor

1 (-) 1 (-) 1 (-)

- - - - - -
(Ground) (Ground) (Ground) (Ground) (Ground) (Ground)

+ 5VDC + 5VDC + 5VDC

A B A B A B

3 2 3 2 3 2

K3xx K4xx RCL K3xx K4xx RCL K3xx K4xx RCL

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9. AIC 5061/5062

GND DC +
Inc. X Can LO
Vcc Can HI
GND GND
Inc. X EM OUT
Vcc EM IN
DC +
Can LO
Can HI
GND
EM OUT
EM IN

10. EJB 5080

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11. Connection, External Emergency Stops RCL 5100/5200

Assembled with conductor joint

in the RCL box.

Plug, Buzzer and Emergency Stop – Indicator Panel RCL 5100/5200

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12. Troubleshooting Sheet

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