Professional Documents
Culture Documents
TABLE OF CONTENTS
Section One System Information
Warranty
System Specifications
Operators Manual
Commissioning and Diagnostic Procedures
SECTION ONE
SYSTEM INFORMATION
Page 1 of 13
Page 2 of 13
SYSTEM OVERVIEW
Modern mining techniques rely extensively on radio remote control systems. Radio remote
controlled LHDs provide a safe and productive means to move large amounts of ore. The
complete radio remote control system has a Remote Unit and a Vehicle Unit. The control
package should be modular, compact, easy to work with, and adaptable to all types of
equipment, regardless of manufacturer. HARD-LINE Solutions MUCKMASTER control
package provides this solution.
FEATURES
MUCKMASTER control systems can be configured On/Off, proportional, or a combination
on any manufacturer's LHD, regardless of machine configuration. MUCKMASTER control
systems enhance safety and operating features by the use of a Microprocessor.
PROGRAMMABLE FEATURES
Operators are forced to follow set procedures when operating the radio remote controlled
LHD. The LHD will shutdown if the correct steps are not followed. MUCKMASTER control
systems force the operator to use safe operating procedures.
SYSTEM COMPONENTS
This system is made of four basic blocks:
1.
2.
3.
4.
Master Unit
Slave Unit
Hydraulic Interface
Electric Interface
1. Master Unit
Master Unit contains:
-
One Microprocessor
One 900 MHz Radio
One Enclosure
Master Unit LED Board
Mounting Plate
900 MHz Whip Antenna
One Driver Board
One Master Unit 10 Socket Connector Wiring Harness
One Master Unit 19 Socket Connector Wiring Harness
Connector(s) with LED
Page 3 of 13
Wireless Medium:
Operating Frequency Range:
Approvals:
Radio Data Rate:
Maximum Radio Data Rate:
Frequency Resolution:
Frequency Stability:
Chipping Rate:
Spread Ratio (Min / Max):
Processing Gain (Min / Max):
Output Power:
Enclosure
2. Slave Unit
Slave Unit contains:
-
One Microcontroller
Two Joysticks
One 900 MHz Radio
One auxiliary Board
One Antenna Board
Four On/Off Switches
Three Momentary On Switches
One Mushroom Switch
One Enclosure
One Skid Plate
Slave Unit LED Board
Page 4 of 13
Wireless Medium:
Operating Frequency Range:
Approvals:
Radio Data Rate:
Maximum Radio Data Rate:
Frequency Resolution:
Frequency Stability:
Chipping Rate:
Spread Ratio (Min / Max):
Processing Gain (Min / Max):
Output Power:
Enclosure
3. Hydraulic Interface
-
Hydraulic Manifold(s)
On/Off Cartridge(s)
Proportional Cartridge(s)
Slave Cylinders (if necessary)
4. Electric Interface
-
Page 5 of 13
INTRODUCTION:
Modern mining techniques rely extensively on radio remote control systems. Radio
remote controlled LHDs provide a safe and productive means to move large amounts
of ore. The complete radio remote control system consists of a Joystick Unit and a
Vehicle Unit. Both the Joystick Unit and the Vehicle Unit are in constant 2-way
communication. The control package should be compact, modular, easy to work with,
and adaptable to all types of equipment, regardless of manufacturer. HARD-LINE
Solutions MUCKMASTER control package provides this solution.
FEATURES:
PROGRAMMABLE FEATURES:
Operators are forced to follow set procedures when operating the radio remote
controlled LHD. The LHD will shutdown if the correct steps are not followed.
MUCKMASTER control systems force the operator to use safe operating procedures.
INSTALLATION:
DIAGNOSTIC INDICATORS:
There are indicators at critical points in the system, including inside the radio and in
the MUCKMASTER control package. Indicators on the MUCKMASTER control box
provide status on the machine operating mode, the engine, and the brake systems.
With minimum training, operators or maintenance personnel can use the indicators
to quickly find the source of a malfunction and provide reliable information to
management.
Listed below are the main features that are programmed as standard operating
procedures in MUCKMASTER control systems.
Page 6 of 13
OPERATING PROCEDURES:
MANUAL TO REMOTE MODE:
Page 7 of 13
While in remote mode the following functions are available to the operator: Remote
start function with park brake interlock - The park brake toggle on the Joystick Unit
must be in ON position to start the machine.
E-Stop function Shuts down the engine, stops the machine and applies the
brakes when the E-stop function is activated.
Delayed shutdown - Allows the machine to run for a predetermined time (60
seconds) before the engine is shutdown. This feature is used when changing from
remote to manual mode.
Service brake application - They are applied automatically after half a second delay
when the left hand joystick is in NEUTRAL position.
Service brake application - They can be applied as required using the toggle switch
on top of the right hand joystick.
Forward/Reverse park brake interlock - The control system will not allow the
transmission to go into forward or reverse with the park brake switch on the
Joystick Unit in the Applied or ON position.
Engine Start - apply the park brake and press the start button until engine is
running.
The front and rear lights on the LHD can be turned on or off from the light switch on
the Joystick Unit.
Engine throttle - The engine throttle can be controlled proportionally from the
Joystick Unit. The engine speed increases as the left-hand joystick is moved from
the NEUTRAL position. Applying the Park Brake and moving the left-hand joystick
to the top or bottom can activate engine throttle proportionally while maintaining a
parked LHD.
Forward/Reverse - The directions are obtained by moving the left-hand joystick in
the direction as indicated.
Steering - The steering functions are activated by moving the left-hand joystick left
to right.
Boom and bucket functions are activated using the right hand joystick.
Fire suppression - The fire suppression is activated by the toggle switch on the
Joystick Unit. When the fire suppression switch is activated and maintained for
three seconds the park brake and service brakes are applied, the engine is shut off
with the transmission in neutral. The switch must be held for 3 seconds to activate
the fire suppression output.
Page 8 of 13
EMERGENCY STOP:
Press down on the Joystick Unit EMERG. STOP switch. * Note: The LHD
will shift into NEUTRAL, park and service brake will activate, and engine
will shut down immediately.
If the Joystick Unit is tilted over for one-quarter of a second. * Note: The
LHD will shift into NEUTRAL, park and service brake will activate, and
engine will shut down immediately.
Pull pin and hold the Joystick Unit FIRE SUPPRESS switch for 3 seconds.
* Note: The LHD will shift into NEUTRAL, park and service brake will
activate, engine will shut down immediately, and fire suppression will
activate.
To reset system, the Joystick Unit system power has to be switched off and
then on.
The Park Brake Switch activates the Park Brake Valve to release the Park
Brakes when the switch is in the OFF position. When the Park Brake switch
is moved to the ON position, the Park Brake Valve applies the brakes.
The Service Brakes can be applied by using the Service Brake Switch on
top of the right hand joystick or by allowing the left hand joystick go to the
neutral position. The brakes will apply after a half second delay when the
joystick is in neutral or immediately when pressing the switch. This valve is
the Service Brake Valve.
OPERATOR TRAINING:
Page 9 of 13
Page 10 of 13
Never carry Slave unit by the joysticks. They are not built for such a purpose.
Do not wash the Slave unit or Master unit when washing the LHD.
Never boost or weld on LHD without disconnecting the Vehicle Unit.
Do not carry any HLS RRC equipment in the bucket of the LHD.
Do not continue to use RRC package if in ill repair and/or the RRC Slave or Master unit is not
functioning properly. Advise any maintenance staff and the equipment will be repaired.
f) Be sure to use the proper antennas for each application, 900MHz whip for Master and if
Slave unit is modified for external antenna. Use 2.4GHz antenna for the video unit only.
g) Check to verify that all antenna connections are solid, center pin is not pulled back, and that
cables are in good order.
h) If using batteries to power Slave unit, be sure to use a fully charged battery before each shift.
If using power brick adapters, make sure power cables are in safe condition and have not
been modified in any way. The Slave unit operates on 5vdc only.
Page 11 of 13
Page 12 of 13
Page 13 of 13
FALSE
FALSE
3. When the selector switch is moved to the remote position, the operator has 60 seconds to turn
the Joystick Unit on.
TRUE
FALSE
4. If the park brake switch on the Joystick Unit is in the on position (i.e. brakes applied), the
transmission will not engage in forward or reverse.
TRUE
FALSE
5. If the park brake switch on the Joystick Unit is in the off position (i.e. brakes released), the LHD
will not start in remote mode.
TRUE
FALSE
FALSE
FALSE
8. Before any welding or boosting is done on a machine, the dash cable must be disconnected
from the machine control unit (Vehicle unit).
TRUE
FALSE
9. The green light on the dash is used to verify proper communication between the Joystick Unit
and Vehicle unit.
TRUE
FALSE
Page 1 of 35
CONTENTS:
Safety considerations when commissioning / troubleshooting.
Terminology
Description of remote control interlocks and timeouts
Radio control overview
Commissioning procedures
Troubleshooting guide
APPENDICES:
Vehicle Unit connector pin-outs
Joystick Unit controls
Joystick Unit control SAFE positions
Proportional output scaling table
Proportional control output measurements
Commissioning checklist
Problem report form
Revision history
Revised 2001-04-04
Page 2 of 35
Terminology
LHD - Load Haul Dump (LHD)
Vehicle Unit the MUCKMASTER control box which plugs into the LHD via 10- and 19-pin
CANON bayonet connectors.
Joystick Unit the radio control box, which the operator uses to control the LHD when it is in
radio remote control.
Radio Control System the Vehicle and Joystick Unit pair.
Radio Control Link the two-way communication link which is maintained between the Vehicle
and Joystick Units.
HIGH Input any input voltage levels above 5 volts.
LOW input any input voltage level below 2 volt.
Continuity resistance measurement under 2 ohms.
Open Circuit any resistance measurement over one Megaohms.
D/H Indicates boom up, down & bucket roll, dump functions
Revised 2001-04-04
Page 3 of 35
Revised 2001-04-04
Page 4 of 35
Commissioning procedures
Perform each test in the Commissioning Checklist in order.
Place a check in the PASS or FAIL column when each test is completed.
When performing a test, follow the steps in the order indicated.
Example
*** COMMISSIONING EXAMPLE ***
One or more items from the checklist which are tested during this procedure.
Name of Test Procedure
Description of test.
ACTION
1
Action to be taken in step 1
OBSERVATION
Output is HIGH
2
;
Check the PASS column of this item before proceeding to do the next step
Action to be taken in step 3
Step 1
Step 2
Output is LOW
Troubleshooting
When a problem occurs in step 1, this box lists possible causes and tests to perform:
Output is LOW: The voltage measured between the output and chassis ground is
below 6 volts.
Output is HIGH: The voltage measured between the output and chassis ground is
within 2 volts of the input voltage.
Revised 2001-04-04
Page 5 of 35
OBSERVATION
READY light OFF
DIAG. light OFF
Apply LHD manual park brake.
READY light OFF
DIAG. light OFF
Put LHD manual gear selector into NEUTRAL position.
READY light OFF
DIAG. light OFF
Switch MANUAL / REMOTE SELECTOR to REMOTE position.
READY light ON
DIAG. light OFF
*** REMOTE SELECT SWITCH FUNCTION TEST completed ***
Switch MANUAL / REMOTE SELECTOR to MANUAL position.
Step 1
Step 2
Step 3
Troubleshooting
READY light ON: Check that the Remote Select input (CANON-19 pin S; Blue wire) is
LOW when MANUAL / REMOTE SELECTOR is in MANUAL position.
READY light ON: Verify that the Park Brake Confirm input (CANON-19 pin U - Orange
wire) is HIGH when LHD park brake is applied.
READY light ON: Verify that the Neutral input (CANON-19 pin T; Black/White wire) is
HIGH when MANUAL / REMOTE SELECTOR is in REMOTE position.
Revised 2001-04-04
Page 6 of 35
Step 5
Step 6
Troubleshooting
READY light ON:
1) Verify that the Park Brake Confirm (CANON-19 pin U; Orange wire) is LOW
when LHD park brake is released.
2) Perform the Neutral Status Input Test.(Pg. 7)
DIAG. light ON:
1) Perform the Remote Select Switch Function Test.(Pg. 5)
2) Perform the Neutral Status Input Test.(Pg. 7)
Revised 2001-04-04
Page 7 of 35
Step 6
Step 9
Step
10
Troubleshooting
READY light ON:
1) Verify that the Neutral Confirm (CANON-19 pin T; Black/White wire) is LOW when
manual gear selector is set to FORWARD position.
2) Perform the Park Brake Status Input Test.(Pg. 6)
DIAG. light ON:
1) Perform the Remote Select Switch Function Test.(Pg. 5)
2) Perform the Park Brake Status Input Test.(Pg. 6)
3) Verify that the Neutral Confirm (CANON-19 pin T - Black/White wire) is HIGH when
manual gear selector is set to NEUTRAL position.
READY light ON:
1) Verify that the Neutral Confirm (CANON-19 pin T; Black/White wire) is LOW when
manual gear selector is set to REVERSE position.
2) Perform the Park Brake Input Test.(Pg. 6)
DIAG. light ON:
1) Perform the Remote Select Switch Function Test.(Pg. 5)
2) Perform the Park Brake Status Input Test.(Pg. 6)
3) Verify that the Neutral Confirm (CANON-19 pin T; Black/White wire) is HIGH when
manual gear selector is set to NEUTRAL position.
Revised 2001-04-04
Page 8 of 35
Step 5
Troubleshooting
Engine shuts down:
1) Check that the Run output (CANON-19 pin E; Blue/Red wire) has not been tied
LOW or disconnected.
2) Perform the Park Status Input Test.(Pg. 6)
3) Perform the Neutral Status Input Test.(Pg. 7)
4) Verify if the Joystick unit is powered up before the Manual/Remote Selector is
switched to the Remote position.
Engine does not shut down:
1) Check that the Run output (CANON-19 pin E; Blue/Red wire) has not been tied
HIGH between the Normally Open switch (Manual/Remote Selector) and the
Engine Shutdown Solenoid or DDEC Shutdown Input.
2) Check that the Normally Open switch (Manual/Remote Selector) opens the
Shutdown circuit between the Key Switch and the Engine Shutdown Solenoid or
DDEC Shutdown Input.
Revised 2001-04-04
Page 9 of 35
Step 3
Troubleshooting
POWER light is not ON:
1) The EMERGENCY STOP mushroom switch is in the DOWN position.
2) The CAP LAMP battery or POWER SUPPLY is not connected.
3) See the Joystick Unit Wiring schematic for any breaks or shorts in the Power Up
circuit.
Revised 2001-04-04
Page 10 of 35
Troubleshooting
DIAG light OFF/ Engine continues to run: Return the radio control to the service depot
for servicing.
DIAG light OFF: Return the radio control to the service depot for servicing.
Revised 2001-04-04
Page 11 of 35
8
9
;
10
OBSERVATION
DIAG light ON
DIAG light OFF
Step 7
Step 8
Step 9
Troubleshooting
DIAG light ON:
Continue test but look for the control that leaves the DIAG light ON in step 9. If no
control leaves the DIAG light ON, then one of the controls may have been improperly
set at the start of the test. If all controls appear to be set correctly, then one of the
toggle switches may have been spun around 180.
DIAG light OFF:
1) Control that was tested was in its initial control test position.
2) Two or more controls are not in their initial control test position.
3) Check for a break or short in the Joystick Unit for the control being tested.
DIAG light ON:
1) One control is not in its initial test position.
2) If the DIAG light was ON in step 8, check for a break or short in the Joystick Unit
for the control just tested.
Revised 2001-04-04
Page 12 of 35
7
8
9
10
;
11
12
DIAG light ON
LINK light OFF
Restore the control to its previous position.
DIAG light OFF
LINK light ON
*** JOYSTICK UNIT POWER UP SWITCH TEST completed ***
Turn the Joystick Unit POWER switch to OFF position.
Switch MANUAL / REMOTE SELECTOR to MANUAL position.
Step 6
Step 9
Troubleshooting
LINK light OFF:
Perform the Joystick Unit Switch Closure Test to verify controls are functioning
correctly.(Pg. 11)
LINK light ON:
Perform the Joystick Unit Switch Closure Test to verify controls are functioning
correctly.(Pg. 11)
Revised 2001-04-04
Page 13 of 35
Troubleshooting
LINK light ON / Engine running:
See the Joystick Unit Wiring schematic for any breaks or shorts in the Power Up
circuit.
Revised 2001-04-04
Page 14 of 35
6
7
8
9
10
11
;
12
Step
10
Troubleshooting
Engine running
Perform the Joystick Unit Switch Closure Test to verify controls are functioning
correctly.(Pg. 11)
Revised 2001-04-04
Page 15 of 35
Step 9
Step
10
Troubleshooting
Engine shuts down:
1) Perform the Joystick Unit Switch Closure Test (Pg. 11) and repeat this test.
2) The 3 second timeout when the Delayed Shutdown switch was activated had
expired before turning off the Joystick Unit.
Engine running:
1) Perform the Joystick Unit Switch Closure Test to verify if the controls are
functioning correctly.(Pg. 11)
2) Wait an additional 30-seconds. If the engine still does not shut down, return the
radio control to the service depot.
Revised 2001-04-04
Page 16 of 35
8
9
;
10
11
Step 7
Troubleshooting
LINK light ON :
Return the radio control to the service depot.
Revised 2001-04-04
Page 17 of 35
8
9
10
11
12
;
13
14
Step 7
Step
11
Troubleshooting
Engine does not start:
1) Perform the Joystick Unit Switch Closure Test to verify if the controls are
functioning correctly.(Pg. 11)
2) Verify that the Start output (CANON-19 pin G; White/Red wire) is HIGH when
the Park Brake button on the Joystick Unit is in the Applied or ON position.
3) See the LHD wiring schematics for any breaks or shorts in the Start circuit.
Engine starts:
1) Perform the Joystick Unit Switch Closure Test to verify if the controls are
functioning correctly.(Pg. 11)
2) See the Joystick Unit Wiring schematic for any breaks or shorts in the circuit of the
controlled position, which activates the starter.
3) See the LHD wiring schematics for any breaks or shorts in the Start circuit.
Revised 2001-04-04
Page 18 of 35
Step 9
Troubleshooting
Engine continues to run:
1) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Fire Suppression
function.
2) See the Joystick Unit Wiring schematic for any breaks or shorts in the Fire
Suppression circuit.
3) Perform the Unattended Vehicle Timeout Test. (Pg. 8)
Fire Suppression output stays low:
1) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Fire Suppression
function.
2) Verify that the Fire Suppression output (CANON-19 pin F; Orange/Red wire) is
HIGH when the Fire Suppression switch on the Joystick Unit is held for over 3
seconds.
3) See the LHD wiring schematics for any breaks or shorts in the Fire Suppression
circuit.
Revised 2001-04-04
Page 19 of 35
Step 7
&8
Step 9
& 11
Troubleshooting
No RPM increase:
1) Verify that the Throttle output (CANON-19 pin L; Blue/Black wire or CANNON-10
pin K) is HIGH when the FWD/REV/STEER Joystick is moved to the up or down
positions.
2) See the LHD wiring schematics for any breaks or shorts in the Throttle circuit.
LHD moves FWD or REV:
1) Verify if the Joystick Unit PARK BRAKE switch is in the APPLIED or ON
position.
2) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Park Brake function.
No RPM increase:
1) Verify that the Throttle output (CANON-19 pin L; Blue/Black wire or CANNON-10
pin K) is HIGH when the Throttle toggle switches on the FWD/REV/STEER joystick
are activated.
2) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Throttle functions.
3) See the LHD wiring schematics for any breaks or shorts in the Throttle circuit.
Revised 2001-04-04
Page 20 of 35
Troubleshooting
LHD not moving in Forward:
1) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Park Brake and
Forward functions.
2) Verify if the Park Brake output (CANON-19 pin J; Blue/White wire) goes HIGH
when Joystick Unit Park brake is set to RELEASED or OFF position.
3) Verify if the Service Brake output (CANON-19 pin H; Red/White wire) goes HIGH
when left joystick is moved to the FORWARD or REVERSE positions.
4) See the LHD wiring schematics for any breaks or shorts in the Park Brake, Service
Brake Throttle and Forward circuits.
Revised 2001-04-04
Page 21 of 35
Step
14
Steps
10, 12,
15 &
17
Troubleshooting
LHD not moving in Reverse:
1) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Park Brake and
Reverse functions.
2) Verify if the Park Brake output (CANON-19 pin J; Blue/White wire) goes HIGH
when Joystick Unit Park brake is set to RELEASED or OFF position.
3) Verify if the Service Brake output (CANON-19 pin H; Red/White wire) goes HIGH
when left joystick is moved to the FORWARD or REVERSE positions.
4) See the LHD wiring schematics for any breaks or shorts in the Park Brake, Service
Brake Throttle and Forward circuits.
LHD Service Brakes not Applying:
1) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Service Brake
functions.
2) Verify if the Service Brake output (CANON-19 pin H; Red/White wire) goes LOW
when either toggle on the Right joystick are activated.
3) See the LHD wiring schematics for any breaks or shorts in the Service Brake
circuit.
Revised 2001-04-04
Page 22 of 35
Steps 9
& 11
Troubleshooting
If the LHD does not steer left, verify that:
1) The Steer Left Solenoid on the 6 bank manifold illuminates when the steer left
function is activated.
2) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Steer Left
function.
3) Steer Left Output (CANON-10 pin A) varies between dead band and maximum
RMS voltage for steering function.
If the LHD does not steer right, verify that:
1) The Steer Right Solenoid on the 6 bank manifold illuminates when the steer right
function is activated.
2) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Steer Right
function.
3) Steer Right Output (CANON-10 pin B) varies between dead band and maximum
RMS voltage for steering function.
If the LHD steers fast in one direction; slow in the other direction:
See APENDIX Joystick Potentiometer Calibration Procedures (on page 31 near
the end of this manual.)
Revised 2001-04-04
Page 23 of 35
Steps 9
& 11
Troubleshooting
If the boom does not raise verify that:
1) The Boom Up Solenoid on the 6 bank manifold illuminates when the boom up
function is activated.
2) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Boom Up
function.
3) Boom Up Output (CANON-10 pin D) varies between dead band and maximum
RMS voltage for boom function
If the boom does not lower verify that:
1) The Boom Down Solenoid on the 6 bank manifold illuminates when the boom
down function is activated.
2) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Boom Down
function.
3) Boom Down Output (CANON-10 pin F) varies between dead band and maximum
RMS voltage for boom function.
If the LHDs Boom moves fast in one direction; slow in the other direction:
See APENDIX Joystick Potentiometer Calibration Procedures (on page 31 near
the end of this manual.)
Revised 2001-04-04
Page 24 of 35
11
12
;
;
13
14
15
Steps 9
& 11
Steps 10
& 12
Troubleshooting
If the bucket does not roll verify that:
1) The Bucket Roll Solenoid on the 6 bank manifold is illuminated when the bucket
roll function is activated.
2) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Bucket Roll
function.
3) Bucket Roll Output (CANON-10 pin C) varies between dead band and maximum
RMS voltage for bucket function.
If the bucket does not dump verify that:
1) The Bucket Dump Solenoid on the 6 bank manifold is illuminated when the
bucket dump function is activated.
2) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Bucket Dump
function.
3) Bucket Dump Output (CANON-10 Pin E) varies between dead band and
maximum RMS voltage for bucket function.
If the LHDs Bucket moves fast in one direction; slow in the other direction:
See APENDIX Joystick Potentiometer Calibration Procedures (on page 31 near
the end of this manual.)
Note: Some RRCs are configured to roll and dump the bucket quickly.
Revised 2001-04-04
Page 25 of 35
Step 8
Step 9
Step
10
Troubleshooting
Front lights off:
1) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Front Lights
function.
2) Check that the Front Lights output (CANON-19 pin P) is not shorted to ground or
disconnected.
3) See the LHD wiring schematics for any breaks or shorts in the Front Lights circuit.
Front lights on:
1) Verify if the Front Lights switch in the operators cab is not in the On position.
2) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Front Lights
function.
3) Check that the Front Lights output (CANON-19 pin P) is not tied HIGH.
4) See the LHD wiring schematics for any breaks or shorts in the Front Lights circuit.
Rear lights off:
1) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Rear Lights
function.
2) Check that the Rear Lights output (CANON-19 pin K) is not shorted to ground or
disconnected.
3) See the LHD wiring schematics for any breaks or shorts in the Rear Lights circuit.
Rear lights on:
1) Verify if the Rear Lights switch in the operators cab is not in the On position.
2) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Rear Lights
function.
3) Check that the Rear Lights output (CANON-19 pin K) is not tied HIGH.
4) See the LHD wiring schematics for any breaks or shorts in the Rear Lights circuit.
Revised 2001-04-04
Page 26 of 35
B A M
C P N L
D R V U K
E S T J
F G H
Pin location
Front view
Revised 2001-04-04
Page 27 of 35
b a h
c j k g
d e f
Pin location
Front view
b a h
c j k g
d e f
Pin location
Front view
N/C
WHT/RED
H
J
K
BLK
N/C
N/C
RED/WHT
BLU/WHT
RED/BLK
Revised 2001-04-04
Page 28 of 35
b a h
c j k g
d e f
Pin location
Front view
b a h
c j k g
d e f
Pin location
Front view
YEL
PUR
GRY
RED/WHT
BLU/WHT
RED/BLK
Ground
Forward (Output)
Throttle (Output)
RED/WHT
BLU/WHT
RED/BLK
RED/WHT
BLU/WHT
RED/BLK
Ground
Forward (Output)
Throttle (Output)
Revised 2001-04-04
Page 29 of 35
Operation
Main power.
Emergency shutdown. Interrupts main power by shutting
the Joystick unit down and terminating the control link.
Pull down before turning off joystick unit and boarding
LHD.
Up to release park brake
Down to apply park brake
Up to turn on front lights
Down to turn off front lights
Up to turn on rear lights
Down to turn off rear lights
Pull down to turn on starter motor.
Remove ring pin and hold down for 3 seconds to activate
the Ansul fire suppression system on the LHD.
Move joystick up for forward movement
Move joystick down for reverse movement
Move joystick left to steer to the left
Move joystick right to steer to the right
Move joystick up for bucket dump
Move joystick down for bucket roll
Move joystick left to lower boom
Move joystick right to raise boom
Press to bring engine to 50% of maximum throttle.
Press to bring engine to maximum throttle.
Press to apply service brake when the LHD is in motion.
Revised 2001-04-04
Page 30 of 35
Revised 2001-04-04
SAFE
POWERUP
APPLIED
or ON
Released
Released
Released
Centered
SAFE
RESTART
APPLIED
or ON
Released
Held down
Centered
SAFE
SHUTDOWN
APPLIED
or ON
Held down
Released
Centered
Released
Released
Centered
Centered
Centered
Released
Released
Released
Released
Released
Released
Page 31 of 35
Fig. 1
CT
CCW
Revised 2001-04-04
Page 32 of 35
BOT.
$3F60 255
$3F68 0
$3F70 0
$3F78 0
$3F80 0
$3F88 0
$3F90 0
$3F98 0
$3FA0 $3FA8 $3FB0 $3FB8 $3FC0 $3FC8 $3FD0 $3FD8 -
Service Brake
Proportional Throttle
Proportional Boom Down
Proportional Boom Up
Proportional Bucket Dump
Proportional Bucket Roll
Proportional Steer Right
Proportional Steer Left
TOP
0
255
255
255
255
255
255
255
-
(in)
20
20
20
20
20
20
20
20
-
MIN
(out)
255
146
128
128
255
255
128
128
-
MID
(in)
(out)
115
255
115
166
86
255
115
255
115
255
115
255
115
255
115
255
-
MAX
(in)
(out)
115
255
115
166
86
255
115
255
115
255
115
255
115
255
115
255
-
Decimal
0
13
26
39
51
64
76
89
102
115
128
Hexadecimal
00
0D
1A
27
33
40
4C
59
66
73
80
Percentage
Decimal
Hexadecimal
55%
60%
65%
70%
75%
80%
85%
90%
95%
100%
140
153
166
179
191
204
217
230
242
255
8C
99
A6
B3
BF
CC
D9
E6
F2
FF
x0
0
16
32
48
64
80
96
112
128
144
160
176
192
208
224
240
x1
1
17
33
49
65
81
97
113
129
145
161
177
193
209
225
241
x2
2
18
34
50
66
82
98
114
130
146
162
178
194
210
226
242
x3
3
19
35
51
67
83
99
115
131
147
163
179
195
211
227
243
x4
4
20
36
52
68
84
100
116
132
148
164
180
196
212
228
244
x5
5
21
37
53
69
85
101
117
133
149
165
181
197
213
229
245
x6
6
22
38
54
70
86
102
118
134
150
166
182
198
214
230
246
x7
7
23
39
55
71
87
103
119
135
151
167
183
199
215
231
247
x8
8
24
40
56
72
88
104
120
136
152
168
184
200
216
232
248
Revised 2001-04-04
x9
9
25
41
57
73
89
105
121
137
153
169
185
201
217
233
249
xA
10
26
42
58
74
90
106
122
138
154
170
186
202
218
234
250
xB
11
27
43
59
75
91
107
123
139
155
171
187
203
219
235
251
xC
12
28
44
60
76
92
108
124
140
156
172
188
204
220
236
252
xD
13
29
45
61
77
93
109
125
141
157
173
189
205
221
237
253
xE
14
30
46
62
78
94
110
126
142
158
174
190
206
222
238
254
xF
15
31
47
63
79
95
111
127
143
159
175
191
207
223
239
255
Page 33 of 35
Mine:
Vehicle ID:
Date:
Input voltage
Forward Throttle Dead Band
Forward Throttle Full
Reverse Throttle Dead Band
Reverse Throttle Full
Full Throttle
Half Throttle
Steer Full Left
Steer Full right
Boom Full Up
Boom Full Down
Bucket Full Roll
Bucket Full Dump
PWM
(%)
N/A
Expected
(RMS)
24VDC
Bench
(RMS)
Field
(RMS)
First printing.
Based upon: Rockbreaker Radio Remote Control Commissioning and
Troubleshooting
1998-09-29
Second printing.
Replaces pages 10, 11, 12, 15, 18, 23, and 24 in previous edition.
Corrected commissioning order p.10 and 11
Replaced references to HOIST with BOOM and TILT with BUCKET (pages 11,
12, 15, and 18)
Added missing commissioning steps for BOOM and BUCKET tests (pages 24
and 24)
1998-10-18
Third printing.
Replaces page 30 in previous edition.
Added Percentage to decimal and hexadecimal conversion table
Added Hexadecimal to decimal conversion table
Revised 2001-04-04
Page 34 of 35
FROM:
Company:
Mine:
Vehicle ID:
Date:
Technician:
Position:
Problem resolution:
( ) Radio Being Returned For Service
( ) Requesting a service call
( ) Found a work-around (Please describe below)
Revised 2001-04-04
Revised 2001-04-04
Page 35 of 35
SECTION TWO
BILLS OF MATERIAL, DRAWINGS & SCHEMATICS
Parts List
Assembly Number -- ASLHDS-2 -- MUCKMASTER LHD Slave Unit Standard Assembly Version 2 -- 3098
Item
Part Number
Item
1 ASLHDS-2-04
Part Number
11 ASLHDS-1-03
Qty: 1 Each
Qty: 1 Each
3781
2 8500K9
8500 Series SPST On-None-Off Switch
Qty: 4 Each
1133
3 8500K11
1131
4 8492K1-MOD1
Qty: 1 Each
2978
Qty: 1 Each
2016
6 090-008-MOD1
Qty: 1 Each
Qty: 1 Each
Qty: 2 Each
2324
7 10250T5
1107
8 10250T51
Qty: 2 Each
785
18 NUTSSNYLOC#04
1108
9 10250TC47-MOD1
Qty: 2 Each
844
19 V10-PRO-T/S-MOD1
2889
10 ASLHDS-1-02
Qty: 1 Each
5373
20 V10-PRO-D/H
Qty: 1 Each
827
17 WFN#04
Qty: 1 Each
2799
16 MSSSFP0440-0.75
Qty: 1 Each
3215
15 ASA10B
Qty: 1 Each
1707
5 N1030B
Qty: 7 Each
1709
14 ASLHDS-1-08
Qty: 1 Each
Qty: 1 Each
13 ASLHDS-1-07
Qty: 3 Each
1710
12 ASLHDS-1-04
1708
Qty: 1 Each
repMFBOMCatalog
3026
Page 1 of 2
Item
Part Number
Item
21 ASA01E
PCB Assembled - V10-Joystick Auxiliary Board
Version E
Qty: 1 Each
3999
22 ASM02D
3997
23 A095-2
5861
Qty: 1 Each
2187
34 MSSSFP10-0.5
Qty: 1 Each
420
24 MSSSPP0256-0.75
Qty: 4 Each
823
35 NUTSSNYLOC#10
Qty: 4 Each
832
25 WLITSS#02
Qty: 4 Each
763
36 SHCS0.25/20x0.75
Qty: 4 Each
Qty: 1 Each
33 099-140
Qty: 1 Each
Part Number
32 BR18-MOD2
1689
26 SRA0256x0.375-0.1875
Qty: 4 Each
797
37 191-400
Qty: 4 Each
Qty: 4 Each
2104
1703
27 762159
Weather Pack Nylon 2 Cavity for Socket Terminals
Qty: 1 Each
194
28 ASLHDS-2-10
MUCKMASTER LHD Slave Unit Electric Accessory
Plug Assembly with Weather Pack Socket Terminal
Qty: 1 Each
5226
29 762162
Weather Pack Wire Seals for 14-16AWG
Qty: 2 Each
197
30 762153
Weather Pack Pin Terminal 14-16AWG
Qty: 2 Each
151
31 762158
Weather Pack Nylon 2 Cavity for Pin Terminals
Qty: 1 Each
193
repMFBOMCatalog
Page 2 of 2
Parts List
Assembly Number -- ASLHDM-2 -- MUCKMASTER LHD Master Unit Standard Assembly Version 2 -3081
Item
Part Number
Item
1 ASLHDM-2-01
Part Number
30 A095-2
Qty: 1 Each
Qty: 1 Each
3082
2 ASLHDM-1-02
31 ASLHDM-1-05
Qty: 1 Each
2507
3 ASLHDM-1-01
Qty: 1 Each
2505
11 ASD02C
Qty: 4 Each
Qty: 1 Each
Qty: 11 Each
3955
12 ASA02B
Qty: 1 Each
Qty: 8 Each
2565
13 ASM02D
1649
44 MSSSPP1032-1.25
3997
20 25.621.1453.0
Qty: 4 Each
1870
45 SRA0256x0.375-0.1875
3979
21 25.621.1053.0
Qty: 4 Each
2104
46 MSSSCPM68
Qty: 1 Each
844
43 MSSSPP0440-0.5
Qty: 3 Each
845
42 NUTSSNYLOC#04
Qty: 1 Each
101
41 NUTSSNYLOC#02
Qty: 1 Each
420
3978
22 25.621.0753.0
Qty: 6 Each
1678
47 WLETSS#06
Qty: 1 Each
Qty: 6 Each
3977
23 25.621.0353.0
3913
48 WFN#04
Qty: 1 Each
Qty: 4 Each
3976
repMFBOMCatalog
785
Page 1 of 2
Item
Part Number
Item
Part Number
50 1.5KE33A
TVS 33V 1500W UNI-DIR TH/H
Qty: 1 Each
345
51 BR22-MOD1
Bracket for Master Unit Enclosure 021222209-00 c/w
Holes
Qty: 1 Each
5135
54 H18-COMM-H45
Teflon Hook Up Wire 1KV 200C 18AWG Blue/Red
Striped
3423
55 83029-6
Teflon Hook Up Wire 1KV 200C 18AWG Blue
84
56 83029-9
Teflon Hook Up Wire 1KV 200C 18AWG White
87
57 83029-3
Teflon Hook Up Wire 1KV 200C 18AWG Orange
81
58 83029-5
Teflon Hook Up Wire 1KV 200C 18AWG Green
83
59 83029-4
Teflon Hook Up Wire 1KV 200C 18AWG Yellow
82
60 H18-COMM-H82
Teflon Hook Up Wire 1KV 200C 18AWG Black/Red
Striped
3420
61 HSTT12-48-Q
Heat Shrink Thin Wall 1/8" Black
108
repMFBOMCatalog
Page 2 of 2
Parts List
Part Number
Item
1 10250T3011
Part Number
11 10250T1
Qty: 1 Each
Qty: 1 Each
2025
2 ASCH-02
Assembled Cable Harness 19 Pin Dash Cable
Qty: 1 Each
11
3 VF4-15H11
1169
Qty: 4 Each
304
5 26A1348A
Qty: 20 Each
162
6 10250T3
1398
1386
1103
7 10250T47
3127
17 24-6040-0061
2927
8 AGC-15
2778
18 BVYR-100707TTT
1858
9 HHB
Qty: 1 Each
1265
19 BFAD-P070
1908
10 1N5408
Qty: 2 Each
2632
20 BFN2-07T
Qty: 10 Each
16 HSTT75-48-5
Qty: 1 Each
108
15 HSTT25-48-Q
Qty: 1 Each
14 HSTT38-48-Q
Qty: 1 Each
2444
4 VCF4-1002
Qty: 2 Each
Qty: 1 Each
13 HSTT12-48-Q
Qty: 4 Each
1099
12 NP-MR2
350
Qty: 7 Each
repMFBOMCatalog
1939
Page 1 of 2
Item
Part Number
Item
21 BFN2-09T
Part Number
32 HSTT19-48-Q
Qty: 7 Each
1940
22 NVN3-07
33 P18-10R
Qty: 7 Each
1962
23 NVN3-09
Qty: 12 Each
1963
24 BVNL-P07MT
Qty: 1 Each
4694
35 MSSSFP14-1.5
Qty: 2 Each
Qty: 2 Each
1774
25 GMM-07
3223
36 NUTSSNYLOC0.25/20
Qty: 2 Each
1515
34 BR08-MOD1
Qty: 7 Each
1385
1387
Qty: 2 Each
800
26 SFN4-07
PMA Flat Gasket PG07 Thread
Qty: 2 Each
1773
27 BVYR-101010TTT
PMA Connector "Y", IP68 seal, 3 Size 10 "T" Profile
Tube
Qty: 1 Each
1470
28 BVNL-P090T
PMA Connector Straight, IP67 seal, PG09 Thread,
Size 10 "T" Profile Tube
Qty: 1 Each
279
29 GMM-09
PMA Nut PG-09 Thread
Qty: 1 Each
281
30 SFN4-09
PMA Flat Gasket PG09 Thread
Qty: 1 Each
1325
31 P14-6R
Terminal Non-Insulation Ring 16-14AWG #6
Qty: 10 Each
1478
repMFBOMCatalog
Page 2 of 2
Parts List
Assembly Number -- ASLHDS-2-11 -- MUCKMASTER LHD Slave Unit Weather Pack Electric Accessory
Power\Charger\Battery Cables -- 5247
Item
Part Number
Item
Part Number
1 ASLHDS-2-09
MUCKMASTER LHD Slave Unit Electric Accessory
Plug Assembly with Weather Pack PinTerminal
Qty: 3 Each
5225
2 ASLHDS-2-10
MUCKMASTER LHD Slave Unit Electric Accessory
Plug Assembly with Weather Pack Socket Terminal
Qty: 3 Each
5226
3 762158
Weather Pack Nylon 2 Cavity for Pin Terminals
Qty: 1 Each
193
4 762162
Weather Pack Wire Seals for 14-16AWG
Qty: 2 Each
197
5 762153
Weather Pack Pin Terminal 14-16AWG
Qty: 2 Each
151
repMFBOMCatalog
Page 1 of 1