Hetronic-IRC Instruction Manual PDF
Hetronic-IRC Instruction Manual PDF
Hetronic-IRC Instruction Manual PDF
HMF- IRC
INSTRUCTION MANUAL
Contents
Chapter Page
1. Introduction 3
2. The Components of the IRC-system 4
3. Description of the system 5
3.1 The IRC-system, general Description 5
3.2 IRC-Remote Control Box 6
3.2.1 General Description of the Remote Control Box 6
3.2.2 Control Levers 7
3.2.2.1 Operating Symbols 7
3.2.2.2 Lever Sequence, 6 Loader Functions 8
3.2.2.3 Lever Sequence, 5 Loader Functions 8
3.2.2.4 Lever Sequence, 4 Loader Functions 9
3.2.2.5 Lever Sequence, 6+2 Loader Functions 9
3.2.3 Press Buttons and Tumbler Switches 10
3.2.3.1 Remote Control of RCL functions 10
3.2.3.2 Engine Throttle Control (Option) 11
3.2.3.3 Engine start-stop (Option) 12
3.2.3.4 Electric Reverser Function, 7 or 8 Loader Functions 13
3.2.3.5 Choice of Engine Revolutions (Option) 15
3.2.4 The Remote Control Box in Stand-by Mode 16
3.3 IRC-Electronic Box 16
3.4 IRC-battery and battery Charger 17
3.4.1 Replacement of the battery 17
3.4.2 Charging of the Battery 18
3.4.3 Good Advice about the Battery 18
3.5 Remote control cable (option) 19
3.6 Transmitter System, frequencies 19
4. Safety Regulations 20
5. Starting Up of the Loader 21
5.1 Starting Up from the Indicator Panel of the RCL 21
5.2 Starting Up of the IRC-System 22
5.3 Starting Up from the IRC-Remote Control Box 22
6. Signalling during Loader Operation 23
7. Emergency Stop during Loader Operation 23
8. Stopping the IRC-system 23
1. Introduction
This instruction manual on HMF-IRC radio remote control is meant for the user
of the loader and must be considered as a supplement to:
• the Instruction Manual for the individual Loader Series and
• the RCL Instruction Manual
It is important to read these instruction manuals before starting up and using the
radio remote control. This should give the best starting point for an
unproblematic use of the system.
The designation IRC is short for Integrated Radio Control, which means that the
transmission of data from the radio remote control is an integrated part of the
loader’s RCL safety system.
During loader operation, the IRC-system sends signals to the RCL 5100/5200
controller which monitors which loader functions that are activated.
The electronic box is connected to the electric activations on the valve block by
means of electric cables.
During loader operation, the control levers on the remote control box are
operated. Digitally coded control information is thus sent via radio signals to the
electronic box. The radio signals are converted to electric voltage, which is sent
to the electric activations of the valve block.
In the electric activations the electric voltage controls small hydraulic solenoid
valves. These solenoid valves control a hydraulic oil pressure, which activates
the control levers of the valve block.
The control levers on the valve block move at the same speed and in the same
direction as the control levers on the remote control box.
The remote control box can be equipped with up to 6 control levers (pos. 1)
depending on how many loader functions are to be operated.
The left tumbler switch (pos. 2) and the right tumbler switch (pos. 3) for
operating extra functions are placed in front of the control levers. Please note:
extra functions related to the engine control of the vehicle, are only active when
the vehicle body builder has carried out the necessary electric connections.
In front of the control levers there is also a stop button (pos. 4) as well as an
indicator lamp (pos. 5). The indicator lamp as well as the built-in buzzer
currently keep the operator informed of the functional condition of the system.
On the right side of the remote control box is built in a key switch (pos. 6). The
press buttons (pos. 7) remote control functions in the RCL controller.
On the left side of the remote control box are built in some press buttons (pos.
8) for extra functions.
The remote control box is powered by a battery (pos. 9) placed at the bottom of
the box.
The control levers have stepless activation to both sides. They are spring-
loaded and therefore they automatically go back into neutral position when they
are released.
The control levers on the valve block move at the same speed and in the same
direction as the control levers on the remote control box.
The signal from a control lever is proportional, i.e. the more it is operated
towards the extreme position, the more speed is increased on the loader
function in question.
Please note that all control levers must be in neutral position before starting up
the system.
The number of control levers depends on the number of loader functions, which
are to be remote controlled. From HMF the positioning of the individual control
lever as well as the direction of travel of the loader in relation to the direction of
travel of the control levers are determined as standard configurations.
Loaders equipped with IRC-system are delivered from HMF with operating
symbols labelled on the remote control box.
In the following pages are indicated the different standard configurations of the
remote control boxes with their corresponding operating symbols.
All press buttons and tumbler switches on the remote control box only control
“ON/OFF”-functions in the IRC-system.
The functions of the green and red press buttons are operated directly, while
the function of the yellow press button is operated by pushing the left tumbler
switch to the right (opt. 1) and at the same time pushing the red press button.
These RCL functions are thoroughly described in the RCL Instruction Manual.
Throttle control of the engine of the vehicle can be carried out from the remote
control box. The regulation area is between idling and a max. number of
revolutions fixed by the HMF service point and programmed in the EDC-engine
control by the supplier of the vehicle.
The engine of the vehicle can be started and stopped from the remote control
box as follows:
• Push the left tumbler switch to the right (opt 1). The tumbler switch must be
kept in this position because it is spring-loaded and automatically goes back
into neutral position
• The engine is started by pushing the right press button
• The engine is stopped by pushing the left press button
The remote control box has 6 proportionally acting control levers for operating 6
loader functions.
Example:
The loader is fitted with Fly-Jib. The 5th control lever operates the jib function of
the Fly-Jib and the 6th control lever operates the extension function (the two
levers to the extreme right) .
The Fly-Jib is fitted with extra valves for grab and rotator (7th and 8th function).
If you require the 7th or 8th loader function to be activated permanently, carry out
as follows:
Now the “grab”- or “rotator”-function is a direct function in the 6th control lever.
By repeating the procedure, the functions of the control levers are changed
back to their original functions.
The change from the engine running idle to its number of revolutions being
increased into working level, can be remote controlled.
By means of the right tumbler switch on the remote control box, you can choose
between two types of engine revolutions.
• If the right tumbler switch is in central position, the engine revolutions are not
activated and the engine is running idle.
• If the right tumbler switch is pushed to the left (FULL RPM), the engine is
continuously running at high working speed.
• If the right tumbler switch is pushed to the right (AUTO RPM), the high
engine revolutions are automatically engaged and disengaged.
I.e. when one of the control levers is being operated, the high engine
revolutions are engaged. When the control levers are back in neutral
position, the high engine revolutions are disengaged and the engine is
running idle.
To optimise the running time of the battery as well as for safety reasons, the
remote control box is pre-programmed to go into stand-by mode after approx.
10 minutes. At the same time the indicator lamp turns off.
I.e. if there has been no operation from the remote control box for the last 10
minutes, it goes into stand-by mode, where the power consumption is very
limited.
Please note! To reactivate the remote control box, push the green press
button.
A radio receiver is built into the electronic box, which by means of the external
antenna receives radio signals from the remote control box.
The electronic box is connected to either 12 or 24 volts power supply from the
accumulator of the vehicle. There are outputs for cable connection to the
electric activations of the valve block as well as to the RCL-system.
On the right side of the electronic box there is a small square with four diodes
signalling whether or not the system functions
correctly.
Diode Function
OPERATION The diode is flashing when the hydraulic pump of the vehicle has been
(yellow diode) activated and the electric system is powered.
SIGNAL The diode is flashing when the remote control box is activated and the
(green diode) decoder in the electronic box receives a correct radio signal.
NORMAL The diode indicates that the system is ready for operation. The diode is
(yellow diode) lit while the SIGNAL diode is flashing.
ERROR When the system functions normally, the diode must be turned off. In
(red diode) connection with system errors, the diode is flashing at the same
interval as the OPERATION diode. Please see chapter on
troubleshooting.
The battery charger must by mounted in the driver’s cab where it is protected
against dirt and humidity. The charger must via a fuse be connected to 12 or 24
volts power supply directly to the battery of the vehicle. This is how charging is
made possible, also when the ignition is turned off.
Please note: It takes approx. 3.5 hours to recharge a battery that has been
completely discharged.
The transmitter electronics in the remote control box currently monitor the
battery voltage. When the voltage comes below a certain value after approx. 8
hours of operation, the following is indicated:
• The buzzer in the remote control box gives a periodic signal during 30
seconds.
• Then the remote control box is disconnected
Now the battery has to be replaced by a recharged battery from the battery
charger.
Follow the procedure below:
• Move the loader into a safe position within the 30 seconds of the periodic
signal from the buzzer
• Turn the key switch on the right side of the remote control box into position
“0”
• Take out the discharged battery from the remote control box
• Clean the battery compartment and make sure that the pole connectors are
normally spring-loaded and not corroded
• Put a recharged battery from the battery charger up into the battery
compartment and press it into position so that it is fixed and has a good
electric connection
• Start up the remote control box according to the chapter: “Starting Up of the
IRC-System”
The radio remote control is now ready for operation.
Right after a discharged battery has been taken out of the remote control box, it
has to be recharged in the battery charger according to the following procedure:
• Put the battery into the battery compartment of the battery charger and press
it into position so that it is fixed and has a good electric connection.
• The green diode on the charger is lit, indicating that the battery is being
charged.
• The battery charger registers when the battery is completely charged
• After approx. 3.5 hours the charging is completed, and the green diode starts
flashing
• The battery charger now change to “maintenance charging”, ensuring that
the battery does not discharge after some time
• A completely charged battery is thus always available in the battery charger
To ensure the longest possible working time of the batteries, the following must
be respected:
The remote control box can be connected to the electronic box by means of a
remote control cable.
Please note! The cable is not delivered together with the IRC-system as
standard.
The remote control cable can be used if the remote control box cannot
communicate with the electronic box in case of battery failure, interruption in the
radio communication, errors in radio transmitter/receiver, or the like,
The cable has an adapter in one end, which is inserted in the battery
compartment on the remote control box.
Every time the IRC-system is started up, one out of 16 frequencies in the ISM-
band is chosen.
In the self-test phase during start up of the remote control box, the system is
testing whether the chosen frequency can be used or whether it collides with
other radio transmitters. If it cannot be used, repeat the starting up procedure
and the next frequency will be chosen.
A coded data telegram is now transmitted from the remote control box with an
address that must be in accordance with a corresponding data telegram with its
address in the electronic box at the frequency in question.
When the radio receiver has accepted the coded data telegram of the radio
transmitter, the IRC-system is ready for operation.
4. Safety Regulations
The IRC-system makes it possible to control the loader via radio signals, and
therefore there are certain safety regulations that have to be respected:
• Only personnel, who have been instructed in operating the equipment, must
work with a remote controlled loader.
• The loader operator must read the instruction manuals delivered together
with the loader before starting up loader operation, and follow the instructions
during loader operation.
• When the remote control box is not being used, disconnect it, and pull out
the key from the key switch.
• For safety reasons, keep the remote control box inside the driver’s cab when
not in use.
• Before carrying out mounting, maintenance or repair work, turn off the power
supply to the system
• Do not change or remove anything from the safety devices.
• When cleaning the loader, avoid spraying on water and never use high-
pressure rinsing for cleaning the electronic components.
• that the remote control box belongs to the loader that is to be operated
• whether there are any cracks on or damage to the IRC-system
• that the operating symbols on the remote control box are intact
• that the loader is stopped when pushing the stop button
• that the remote control system functions correctly
• that no other person stays on or near the loader
• that the parking brake of the vehicle has been applied before starting the
engine by means of the remote control box.
• stand in a suitable distance from the hook and the load, have a good
visibility, and see to it that no unauthorised persons enter into the working
area.
• be aware that it is not permitted to move the load over himself or anybody
else
• be ready to let go of the control levers and push the stop button, if he looses
control over the loader movements.
• push the stop button on the remote control box and on the loader.
• put the remote control box in a place inaccessible to others
• report any errors, damage or defects on the equipment to the person
responsible for the loader
Before starting up, the essential safety regulations have to be respected, just as
the general procedure in connection with starting up of the loader has to be
followed.
Please see the Instruction Manual of the loader as well as the RCL Instruction
Manual.
Before loader operation, extend the stabilizer beams and lower the stabilizer
legs to the surface.
When the loader is equipped with an IRC-system, the diodes on the RCL
indicator panel have different indications than a manually operated loader
during start up.
Please note: During stabilizer operation, a change of the load moment of the
loader exceeding 10% will entail that the system automatically changes into
loader operation mode.
When the loader is remote controlled, the operator must keep an eye on the
indications of the RCL indicator panel. Please see the RCL Instruction Manual
of the loader.
If the indicator lamp on the remote control box turns off and the loader cannot
be remote controlled, it may be due to radio interference or system errors.
Please see chapter on troubleshooting.
When the stop button is pushed on the remote control box, the RCL controller
registers this as an error. The RUN and FUNC diodes start flashing.
Start up the IRC-system again according to the procedure and continue loader
operation.
Please note! Every time the IRC-system is started up, always test the
functioning of the stop button. When pushing the stop button, it must not be
possible to remote control the loader.
• On the RCL indicator panel, hold down the yellow press button while pushing
the red press button
• The RUN and FUNC diodes on the RCL indicator panel are still flashing
Now emergency operation of the loader is possible by using the control levers
on the valve block of the loader.
To change back into remote control mode, repeat the procedure stated above:
push/hold down the yellow press button and push the red press button.
If the loader is equipped with an HDL system (Heavy Duty Lifting), it offers the
possibility of an increase of the loader’s nominal load by approx. 10 % while the
working speed is reduced.
Example:
A heavy load is extended at max. speed at a longer out-reach by means of the
“extension out”-function.
When the loader has reached 80% of its capacity limit, the HDL is automatically
activated independent of the operator’s doings.
Now the speed of the “extension out” movement is reduced proportionally down
to 20% of the nominal working speed.
The example describes how the HDL-system works in connection with the
extension-function. The proportional HDL-activation functions in the same way
in connection with all other loader functions, which increase or reduce the load
moment of the loader.
When the HDL-system is activated, this is indicated on the RCL indicator panel
by the FUNC diode flashing.
Irrespective of the loader’s load moment, the working speed of the loader can
be reduced to approx. 20% by pushing the red press button on the remote
control box, thus activating the HDL.
By pushing the red press button once again, the HDL-system is deactivated
again. However, this implies that all control levers have been into neutral
position at the same time as the load moment is below the loader’s normal
lifting capacity limit.
Troubleshooting
It will now be possible to troubleshoot by pushing and holding down the red
press button on the RCL indicator panel.
Maintenance
It is important to check and maintain the IRC-system both currently and when
the loader has its regular service overhaul at an authorised HMF service point.
• When cleaning the loader, avoid spraying on water and never use high-
pressure rinsing for cleaning the electronic components.
• Before carrying out mounting, maintenance or repair work, turn off the power
supply to the system.
• Check whether there are any cracks on or damage to the IRC-system. If yes,
the equipment must be repaired immediately.
Technical Data
Electronic box
Degree of protection: IP 65
System: Synthesizer technics
Operating voltage: 12 to 24 VDC (-50% - +20%)
Decoding: Multi bit activation and comparison
Fuse: 7,5A / 80V Kfz.
Output: Intrinsically safe emergency stop with two MOS-FET-
transistors
12 digital outputs, potential free 250V/8A,
6 analog outputs,
2 speed ranges
Static current: 260mA, Stand by
Antenna connection: TNC-socket
Dimensions: approx. (LxWxH) 265mm x 161mm x 111mm
Weight 2.5kg
Battery Charger
Operating voltage: 12 / 24VDC
Charging current: Design Nova 6L, 100mA
Open circuit voltage: 15 - 22V