nifty HYBRID DC HR15N Series Service Manual
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nifty HYBRID DC HR15N Series Service Manual

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Heightrider
Service Manual
MODEL HR15N/17N SERIES
MkIII
Manufactured by:
Niftylift Limited
Chalkdell Drive
Shenley Wood
Milton Keynes
MK5 6GF
England
www.niftylift.com
e-mail: info@niftylift.com
Tel: +44 (0)1908 223456
Fax: +44 (0)1908 312733
M50602/02

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Summary of Contents for nifty HYBRID DC HR15N Series

  • Page 1 Heightrider Service Manual MODEL HR15N/17N SERIES MkIII Manufactured by: Niftylift Limited Chalkdell Drive Shenley Wood Milton Keynes MK5 6GF England www.niftylift.com e-mail: info@niftylift.com Tel: +44 (0)1908 223456 Fax: +44 (0)1908 312733 M50602/02...

  • Page 3: Table Of Contents

    HR15/17N HYBRID DC Service Manual 1 INTRODUCTION AND GENERAL INFORMATION ................1 1.1 Foreword ..............................1 1.1.1 Defined Maintenance Terms......................1 1.2 Warranty...............................2 1.3 Scope..............................2 1.4 General Maintenance Information ......................3 1.4.1 Pre-Maintenance Checks ......................3 1.4.2 Maintenance Information.......................3 1.4.3 Frequent Inspection........................4 1.5 Maintenance Safety Information ......................5 1.5.1 Personal Injury Prevention......................5 1.5.2 Machine Damage Prevention......................5 1.5.3 Diesel System Safety ........................5...
  • Page 4 HR15/17N HYBRID DC Service Manual 3.3 Batteries............................. 26 3.3.1 Condition Check (Daily) ......................26 3.3.2 Condition Check (Weekly) - Excludes AGM Batteries ..............26 3.4 Hydraulic Oil............................27 3.4.1 Level Check (Weekly) ......................... 27 3.4.2 Return Filter Check (Monthly) ..................... 27 3.4.3 Pressure Filter Check (Weekly) ....................
  • Page 5 HR15/17N HYBRID DC Service Manual 5.11 Steering ............................48 5.12 Boom Control Valve ..........................49 5.13 Electrical Control System Overview ....................50 5.14 Control Logic ............................50 5.15 Motor Generator..........................50 5.16 Controller............................51 5.17 Niftylift Diagnostic Unit ........................52 6 TROUBLESHOOTING GUIDE......................54 6.1 Trouble Shooting Information ......................54 6.2 Platform Function Fault Finding......................54 6.3 Engine Fault Finding ..........................55 6.4 Gearbox Fault Finding..........................57...
  • Page 6 HR15/17N HYBRID DC Service Manual Notes English 07/16...

  • Page 7: Introduction And General Information

    HR15/17N HYBRID DC Service Manual Introduction and General Information Foreword The purpose of this manual is to provide the owner, service engineer or technician with information to service and maintain the Niftylift. Prior to carrying out any maintenance or operating the Niftylift the operator's manual should be read and fully understood.

  • Page 8: Warranty

    HR15/17N HYBRID DC Service Manual Table 1: Defined Maintenance Terms Term Action Remove Disconnect and take off component Install Place component in position ready for use Replace Remove and discard the original component and put a new component in its place Secure Install or attach locking device Reinstall...

  • Page 9: General Maintenance Information

    HR15/17N HYBRID DC Service Manual Nifty Pty Ltd, 11 Kennington Dr, Tomago NSW 2322, Australia Tel: +61 (0) 2 4964 9765 Fax: +61 (0) 2 4964 9714 General Maintenance Information Any repair or maintenance work on a Niftylift must be undertaken by a competent person with sufficient training and experience to perform the activity.

  • Page 10: Frequent Inspection

    M50460 Engine Operator’s Manual M50291 For easy access to any of the above documents go to www.niftylift.com, register in the 'My Nifty Registration' section, then navigate to the 'My Nifty' section and enter the Niftylift Serial Number. 1.4.3 Frequent Inspection The owner of the Niftylift shall make sure that a frequent inspection is carried out in accordance with the manufacturer’s instructions, on a Niftylift:...

  • Page 11: Maintenance Safety Information

    HR15/17N HYBRID DC Service Manual (6) Visual inspection of structural components and other critical components such as fasteners, pins, shafts, and locking devices. (7) Placards, warnings and control markings. (8) Items specified by the manufacturer. (9) Emergency lowering means. Maintenance Safety Information 1.5.1 Personal Injury Prevention CORRECT PPE (PERSONAL PROTECTION EQUIPMENT) MUST BE WORN FOR...

  • Page 12: Electrical Safety

    HR15/17N HYBRID DC Service Manual 1.5.4 Electrical Safety During maintenance of the electrical system, disconnect the start battery negative (-) terminal. To isolate the 48V battery system depress the isolation switch on Hybrid machines (See upper diagram). Pull the battery-disconnect handle (Anderson) for DC Electric machines.

  • Page 13: Hydraulic Safety

    HR15/17N HYBRID DC Service Manual 1.5.5 Hydraulic Safety Hydraulic oil escaping under pressure can penetrate the skin and cause serious injury. Do not allow hydraulic oil to squirt or spray. Seek immediate medical attention in the event of hydraulic oil penetrating the skin. Wear chemical-resistant protective gloves and suitable eye protection when handling hydraulic oil.

  • Page 14: Specifications

    HR15/17N HYBRID DC Service Manual Specifications Information correct at time of print, refer to serial number of the Niftylift. Engine Specifications Hybrid Feature Kubota D722 Type Water cooled 4-cycle, 3 cylinder diesel engine Fuel Diesel fuel No. 2-D Engine oil See section 2.4.2 Mass (Dry weight) 63.1kg (139 lbs)

  • Page 15: Function Times

    HR15/17N HYBRID DC Service Manual Function Times Function Up/Right/Out Down/Left/In Time, (Seconds) Hybrid HR15 HR17 HR15 HR17 Slew (180°) Tele in 40±5 40±5 Slew (180°) Tele out 47±5 47±5 Links 18±2 26±5 20±4 26±5 Luffing (Boom rest to full height) 24±5 24±5 Tele in...

  • Page 16: Fluid Properties

    HR15/17N HYBRID DC Service Manual Fluid Properties 2.4.1 Fluid Volumes Fluid Volumes Hydraulic oil tank 35 L (7.7 gal) Fuel tank 20 L (4.4 gal) Engine oil 3.8 L (0.84 gal) Coolant 3.1 L (0.68 gal) 2.4.2 Engine Oil Specifications Ambient temperature Oil type ABOVE 0°C (32°F)

  • Page 17: Engine Coolant Specifications

    HR15/17N HYBRID DC Service Manual 2.4.5 Engine Coolant Specifications Use permanent type (PT) for the Kubota D722 engine. When anti-freeze is mixed with water, the ratio must be less than 50%, see table below. Freezing Point Boiling Point Volume % Anti-freeze °C °F °C...

  • Page 18: Torque Settings

    HR15/17N HYBRID DC Service Manual Torque Settings Bolt quality/size Tightening torque in Nm (ft-lbs) Plated Unplated Grade 10.9 12.9 10.9 12.9 7 (5) 10 (8) 12 (9) 8 (6) 11 (8) 13 (10) 17 (13) 25 (18) 29 (22) 19 (14) 27 (20) 32 (23) 34 (25)

  • Page 19: Hydraulic Hose And Fitting Torque Specifications

    HR15/17N HYBRID DC Service Manual Hydraulic Hose And Fitting Torque Specifications BSP (Solid Black Nut) Soft Seal Positional/Banjo/Block Fittings O-Ring Seal Female (ISO 8434) (ISO 6149 & 1179) Size Thread Torque Nm (ft-lbs) Size Thread Torque Nm (ft-lbs) 1/4” - 19 25 (18) 1/4”...
  • Page 20 HR15/17N HYBRID DC Service Manual Metric (S-Series) Soft Seal Positional/Banjo/Block Elastomeric Seal Male (9974/3869) Fittings (ISO 6149 & 1179) Torque Nm (ft-lbs) Thread Torque Nm (ft-lbs) Thread Steel Aluminium M12 X 1.5 35 (26) M12 X 1.5 40 (30) 20 (15) M14 X 1.5 45 (33) M14 X 1.5...

  • Page 21: Preventative Maintenance

    HR15/17N HYBRID DC Service Manual Preventative Maintenance Maintenance Schedules 3.1.1 Maintenance Procedures and Intervals Operation • Engine Oil Engine Oil Filter • Air Filter @ ▲ ◊ ▲ • Engine Coolant @ • Coolant Hoses and Clamp Bands ▲ • •...
  • Page 22 HR15/17N HYBRID DC Service Manual Maintenance procedures and intervals - continued Operation • • Gearbox Oil Battery condition ▲ ▲ Hydraulic oil level ▲ Return filter ▲ • Pressure filter ▲ • •◊ Hydraulic oil and filters Telescopic boom wear ▲...

  • Page 23: Engine Oil Level Check

    HR15/17N HYBRID DC Service Manual 3.1.2 Engine Oil Level Check 1) Check with the Niftylift on level surface before starting or more than 5 minutes after stopping the engine. 2) Remove oil level dipstick (2) and wipe clean. 3) Insert dipstick and remove to check oil level. 4) If low, add correct specification oil to the oil filling port (1) until the upper limit of the dipstick is reached.

  • Page 24: Engine Oil Replace

    HR15/17N HYBRID DC Service Manual 3.1.3 Engine Oil Replace ENSURE ENGINE IS OFF BEFORE DRAINING THE ENGINE OIL. WHEN DRAINING ENGINE OIL, PLACE A CONTAINER UNDERNEATH THE ENGINE AND DISPOSE ACCORDING TO LOCAL REGULATIONS. DO NOT DRAIN OIL AFTER RUNNING THE ENGINE, ALLOW ENGINE TO COOL DOWN SUFFICIENTLY.

  • Page 25: Engine Coolant Level Check

    HR15/17N HYBRID DC Service Manual 3.1.5 Engine Coolant Level Check DO NOT STOP ENGINE SUDDENLY, IDLE ENGINE FOR 5 MINUTES BEFORE STOPPING. WORK SHOULD BE CARRIED OUT AFTER LETTING THE ENGINE AND RADIATOR COOL OFF COMPLETELY (A MINIMUM OF 30 MINUTES AFTER STOPPING ENGINE).

  • Page 26: Coolant Replace

    HR15/17N HYBRID DC Service Manual 3.1.6 Coolant Replace DO NOT STOP ENGINE SUDDENLY, IDLE ENGINE FOR 5 MINUTES BEFORE STOPPING. WORK SHOULD BE CARRIED OUT AFTER LETTING THE ENGINE AND RADIATOR COOL OFF COMPLETELY (A MINIMUM OF 30 MINUTES AFTER STOPPING ENGINE).

  • Page 27: Air Filter Element Maintenance

    HR15/17N HYBRID DC Service Manual 3.1.8 Air Filter Element Maintenance DO NOT APPLY OIL TO THE AIR FILTER; YOUR NIFTYLIFT IS FITTED WITH A DRY TYPE AIR FILTER. AVOID TOUCHING THE ELEMENT EXCEPT WHEN CLEANING. 1) Open the evacuator valve once a week under ordinary conditions, daily when used in a dust rich environment.

  • Page 28: 3.1.10 In-Line Fuel Filter Replace

    HR15/17N HYBRID DC Service Manual 3.1.10 In-line Fuel Filter Replace FUEL ESCAPE - PLACE A SUITABLE CONTAINER UNDERNEATH THE WORK AREA AND DISPOSE FUEL ACCORDING TO LOCAL REGULATIONS. 1) Locate fuel filter and clamp the feed pipe from tank. 2) Loosen jubilee clips and remove fuel pipes. 3) Replace fuel filter ensuring the arrow on the filter points in the direction of fuel flow (tank to engine).

  • Page 29: 3.1.12 Bleeding Air From The Fuel System

    HR15/17N HYBRID DC Service Manual 3.1.12 Bleeding Air From The Fuel System DO NOT BLEED A HOT ENGINE. FUEL COULD SPILL ON TO THE EXHAUST MANIFOLD CREATING A FIRE RISK. MAKE SURE SUITABLE EYE PROTECTION AND CLOTHING ARE WORN WHEN BLEEDING THE FUEL SYSTEM.

  • Page 30: 3.1.13 Exhaust System Inspect

    HR15/17N HYBRID DC Service Manual 3.1.13 Exhaust System Inspect DO NOT CARRY OUT THIS PROCEDURE WHILST THE ENGINE IS RUNNING. BEWARE OF HOT ENGINE COMPONENTS. 1) Open the Engine canopy. 2) Inspect the exhaust components for signs of cracks and leaks; e.g. carbon build up around joints and seams.

  • Page 31: Drive Hub Gearbox

    HR15/17N HYBRID DC Service Manual Drive Hub Gearbox 3.2.1 Oil Replace 1) Manufacturer’s specifications require this procedure to be carried out after the first 50 to 100 hours, then every 2500 hours or once a year. Depending on the operating cycle this frequency may vary.

  • Page 32: Batteries

    HR15/17N HYBRID DC Service Manual Batteries MAKE SURE SUITABLE EYE PROTECTION AND CLOTHING ARE WORN WHEN MAINTAINING THE BATTERIES. MAKE SURE THERE IS ADEQUATE VENTILATION WHEN CARRYING OUT MAINTENANCE ON THE BATTERIES. CONTACT WITH CONCENTRATED SULFURIC ACID RESULTS IN RAPID DESTRUCTION OF BODY TISSUE VIA BURNS.

  • Page 33: Hydraulic Oil

    HR15/17N HYBRID DC Service Manual 3) Using a hydrometer, check the specific gravity of the battery fluid in each cell in each battery (Target 1.26-1.27 for DYNO Batteries when fully charged). If the specific gravity is not within the serviceable range, battery de-sulphate fluid may be used to restore batteries.
  • Page 34 HR15/17N HYBRID DC Service Manual Suction Strainer SUCTION PIPE 6) Disconnect the suction strainer pipe from the tank. Remove strainer and clean with mild solvent or replace if necessary. SUCTION STRAINER 7) Connect suction pipe and tighten. See section 2.7 for torque value.

  • Page 35: Telescopic Boom

    HR15/17N HYBRID DC Service Manual Telescopic Boom 3.5.1 Wear Pad Check (Monthly) 1) With the links and luffing boom down and the telescope boom fully retracted, check that there are no loose, missing, or defective components in the superstructure end of the telescope boom. This includes wear pads, shims, spacers and fasteners.

  • Page 36: Lubricate Boom Pivot Bushes (Yearly)

    HR15/17N HYBRID DC Service Manual 3.5.3 Lubricate Boom Pivot Bushes (Yearly) At yearly intervals lubricate all DU pivot bushes on the Flyboom, Links and Telescope assemblies. TELESCOPE BOOM LINKS LUBRICATION LUBRICATION POINTS POINTS FLYBOOM LUBRICATION POINTS Use a dry PTFE aerosol lubricant spray such as WD40 W/D44394 or equivalent. Apply lubricant spray and allow to penetrate at each of the pivot bush joints identified in the diagram above.

  • Page 37: Slew Ring Lubrication (Monthly)

    HR15/17N HYBRID DC Service Manual 3.6.2 Slew Ring Lubrication (Monthly) DO NOT CARRY OUT THIS PROCEDURE WHILST THE ENGINE IS RUNNING. 1) Open the control (left hand) canopy. 2) Two grease nipples (1) are located on the side of the superstructure. 3) Pump the grease gun two to three times as required.

  • Page 38: Slew Ring Bolts Check (Yearly)

    HR15/17N HYBRID DC Service Manual 3.6.3 Slew Ring Bolts Check (Yearly) Access the slew ring bolts via the aperture in the superstructure. See section 2.6 for torque settings. Front Axle 3.7.1 Steer Pin Lubrication (Daily) 1) Two grease nipples (1) are located on either side of the front axle.

  • Page 39: Repair Procedures

    HR15/17N HYBRID DC Service Manual Repair Procedures General 4.1.1 Fuses There are 2 main replaceable fuses on the Niftylift: • 325A - Battery Power Circuit (Hybrid and DC Electric), • 125A - Diesel Engine Starter Motor and Alternator (Hybrid). In addition to the 2 main fuses, blade fuses can be found in the following locations: •...
  • Page 40 HR15/17N HYBRID DC Service Manual DC Electric - main fuse location 325A Note; for clarity diagram shows battery tray removed. English 07/16...

  • Page 41: Platform/Cage

    HR15/17N HYBRID DC Service Manual Platform/Cage 4.2.1 Footswitch - Contact Switch replace The footswitch is used to provide power to the Niftylift controls. Remove 1) Isolate the power supply (See section 1.5.4). 2) Remove bolts (1) and (2) and remove the footswitch cover and rubber gasket.

  • Page 42: Booms

    HR15/17N HYBRID DC Service Manual Booms Booms are safety critical components, contact a Niftylift approved dealer for further information. 4.3.1 Energy Chain Link Remove 1) Operate telescopic boom to access the worn or damaged link. 2) Insert a small flat screwdriver into chain bridge (1).

  • Page 43: Power Tray

    HR15/17N HYBRID DC Service Manual Power Tray 4.4.1 Exhaust DO NOT CARRY OUT THIS PROCEDURE WHILST THE ENGINE IS RUNNING. BEWARE OF HOT ENGINE COMPONENTS. Exhaust silencer Remove 1) Open the engine canopy. 2) Remove the exhaust clamp (1) from the exhaust silencer.

  • Page 44: Fan Belt

    HR15/17N HYBRID DC Service Manual 4.4.2 Fan Belt DO NOT CARRY OUT THIS PROCEDURE WHILST THE ENGINE IS RUNNING. BEWARE OF HOT ENGINE COMPONENTS. Remove 1) Open the engine canopy. 2) Remove 4 bolts (1) and remove fan guard. 3) Loosen the alternator mounting bolts and remove the fan belt.

  • Page 45: Base Assembly

    HR15/17N HYBRID DC Service Manual Base Assembly 4.5.1 Steer Cylinder MAKE SURE SUITABLE EYE PROTECTION AND CLOTHING ARE WORN WHEN OPENING THE HYDRAULIC CIRCUIT. PLACE A SUITABLE CONTAINER UNDERNEATH THE WORK AREA AND DISPOSE OIL ACCORDING TO LOCAL REGULATIONS. Remove Steer arm RH 1) Ensure the Niftylift is in its stowed Roll pin 2...
  • Page 46 HR15/17N HYBRID DC Service Manual 19) Check hydraulic oil level and top up with appropriate grade of oil if necessary (See section 2.4.4). 20) Reinstall cover to front axle and tighten 4 bolts. See section 2.6 for torque settings. English 07/16...

  • Page 47: System Overview

    HR15/17N HYBRID DC Service Manual System Overview Introduction 5.1.1 Hybrid System The main hardware for this system consists of the following: (1) 14 kW Diesel engine (2) Centrifugal clutch (3) Motor/generator (4) Motor controller (5) 280 bar (4061 psi) 10.5cc variable displacement pump. The hybrid system is self-contained and can run in either electric or hybrid mode.

  • Page 48: Dc Electric System

    HR15/17N HYBRID DC Service Manual 5.1.2 DC Electric System The main hardware for this system consists of the following: (1) 28VAC 3 phase electric 8kW motor (2) Motor controller (3) 250 bar (3626 psi) 8cc variable displacement pump. Battery Management Battery condition is permanently monitored by the control circuit, such that when available power has decreased to 20% of full charge, the battery status circuit begins to restrict the power to the hydraulic motors.

  • Page 49: Hybrid Operation

    HR15/17N HYBRID DC Service Manual Hybrid Operation In hybrid mode the system operates around two preset RPM values (called upper limit and lower limit). If the RPM is above the upper limit, the engine will charge the batteries (regen) while performing the required function.

  • Page 50: Boom System

    HR15/17N HYBRID DC Service Manual Boom System The boom system uses a maximum of 25L/min from the pump. Functions can be operated proportionally and simultaneously until the demand reaches 25L/min. If the demand exceeds 25L/min then the flow is shared between the functions with priority given to the function with the lowest operating pressure. DC Only Mode The electric motor is set to run at 2200RPM during booms operation.

  • Page 51: Dc Electric

    HR15/17N HYBRID DC Service Manual 5.4.2 DC Electric The drive system uses 60L/min maximum flow from the pump. The table below describes the available driving modes. Driving Mode Speed HR15/HR17 Gradeablity % Hare 3.3 km/h (2.1 mph) Tortoise 1.0 km/h (0.6 mph) Off road 1.2 km/h (0.7 mph) Charging System And Batteries...

  • Page 52: Charging System - Dc Electric

    HR15/17N HYBRID DC Service Manual Absorbent Glass Mat (AGM) Batteries As an alternative to the standard 350 Ah DYNO batteries, the Niftylift may be fitted with 350 Ah Absorbent Glass Mat (AGM) batteries. These batteries are maintenance free, therefore DO NOT REFILL with distilled (deionised) water.

  • Page 53: Hydraulic System Overview

    HR15/17N HYBRID DC Service Manual Hydraulic System Overview A simplified version of the hydraulic system is shown below in block diagram format. Brief descriptions of the operation of individual blocks are given below. Component details, valve arrangement and connections are shown in the hydraulic schematics D81900 (Hybrid) and D81500 (DC Electric). Please refer to D81900/D81500 in conjunction with the electric schematic D81619 for in-depth understanding of the complete system.

  • Page 54: Valve Block Assembly

    HR15/17N HYBRID DC Service Manual Valve Block Assembly The valve block assembly is made up of two components, the Drive Control Valve (DCV) and the Flow Control valve blocks. Together these form the distribution hub of the hydraulic system. The table below describes the main functions.

  • Page 55: Boom Control Valve

    HR15/17N HYBRID DC Service Manual 5.12 Boom Control Valve Boom Control Valve This is a proportional load sensing valve designed to operate all boom functions simultaneously. Flow to each function is compensated and metered by the spool. Where necessary, anti-shock valves are fitted to the work ports.

  • Page 56: Electrical Control System Overview

    HR15/17N HYBRID DC Service Manual 5.13 Electrical Control System Overview CAGE USER INPUTS CAGE CAGE CONTROL SiOPS WEIGH SUPPLY SAFETY INPUTS MOTOR MOTOR CONTROLLER BASE BASE USER CONTROL INPUTS ENGINE SUPPLY OUTPUTS VALVES 5.14 Control Logic Component level details and connections are provided in the Electric Schematic D81619 5.15 Motor Generator...

  • Page 57: Controller

    HR15/17N HYBRID DC Service Manual (DC Electric), 9 kW output (Hybrid) for 20 minutes continuously. If the motor overheats the controller will reduce the current supply and operate in a low power mode. Using the full available 275A line current, the motor can provide 60Nm torque and 8/9 kW shaft power.

  • Page 58: Niftylift Diagnostic Unit

    HR15/17N HYBRID DC Service Manual 5.17 Niftylift Diagnostic Unit This unit can be used to monitor the operation of the control system and for troubleshooting. The monitor menu provides useful information for troubleshooting. The diagram on page 53 shows the layout of the menus.
  • Page 59 HR15/17N HYBRID DC Service Manual Diagnostic Menu English 07/16...

  • Page 60: Troubleshooting Guide

    HR15/17N HYBRID DC Service Manual Troubleshooting guide Trouble Shooting Information This guide is designed to help identify and rectify faults more easily. Known faults are listed below. Your specific Niftylift fault may not be listed here, if not please contact your local Niftylift dealer in order for the guide to be continually improved and updated.

  • Page 61: Engine Fault Finding

    HR15/17N HYBRID DC Service Manual Engine Fault Finding Problem Solution Cause / Test Check the fuel tank and fuel filter. Remove water, dirt and other impurities Fuel is thick and doesn't flow As all fuel will be filtered by the filter, if there should be water or other foreign matters on the filter, clean the filter with diesel If air is in the fuel filter or injection lines, the fuel pump will not work properly.
  • Page 62 HR15/17N HYBRID DC Service Manual Problem Solution Cause / Test Clean orifice and needle valve, being careful not to damage the Carbon stuck around orifice nozzle orifice of injection nozzle piece Check nozzle for condition. Replace if necessary Bad valve or excessive wear of rings, pistons and liners cause Inadequate compression.

  • Page 63: Gearbox Fault Finding

    HR15/17N HYBRID DC Service Manual Gearbox Fault Finding Problem Solution Cause / Test Hardening of the seals due to Clean area and check for leakage after a few days prolonged storage Oil leakage from seals Seals damaged or worn Contact a Niftylift approved service centre Too much lubricant Check oil level (See section 3.2.1) Wheel gear is not correctly...

  • Page 64: Fault Code Display

    HR15/17N HYBRID DC Service Manual Fault Code Display Code Fault Action Description Open circuit or short circuit of Check wiring to the base Sounder Error the base sounder sounder Check bulb is fitted. Open circuit or short circuit of Base Green Button, Bulb Error Check wiring to the base green the base green button bulb button bulb...
  • Page 65 HR15/17N HYBRID DC Service Manual Code Fault Action Description Check wiring from the booms Error of the corresponding down switch (Normally Booms Down Switch Error analogue input during PLC start Closed). up check - Reset power Check wiring from the machine Error of the corresponding enable relay1 (normally closed Machine Enable OK1 Error...
  • Page 66 HR15/17N HYBRID DC Service Manual Code Fault Action Description Check the power supply to the chassis node The base PLC is not receiving Check the CANBus Chassis Node off the CANBus the chassis node's 'present' connections from the base box (Hybrid only) signal to the chassis node...
  • Page 67 HR15/17N HYBRID DC Service Manual Code Fault Action Description The channel 2 cage weigh Check the module is connected Cage Weigh Channel 2 module is disconnected or Check the wiring from the cage Disconnected faulty panel to the module Check the sensor is connected The tilt sensor is disconnected Tilt Sensor Disconnected Check the wiring from the base...
  • Page 68 HR15/17N HYBRID DC Service Manual Code Fault Action Description Check paddle analogue Paddle analogue outputs are voltages Slew Paddle Error not within spec of each other Use another paddle to check inputs to control system Check paddle analogue Paddle analogue outputs are voltages Telescope Paddle Error not within spec of each other...

  • Page 69: Motor Controller Fault Codes

    HR15/17N HYBRID DC Service Manual Motor Controller Fault Codes Programmer LCD Display Code Set/Clear Conditions Possible Cause Effect of fault Controller Overcurrent 1. External short of phase U,V, ShutdownMotor; or W motor connections. Set: Phase current exceeded ShutdownMainContactor; 2. Motor parameters are mis- the current measurement limit.
  • Page 70 HR15/17N HYBRID DC Service Manual Programmer LCD Display Code Set/Clear Conditions Possible Cause Effect of fault 1. Battery Menu parameters are misadjusted. Set: Capacitor bank voltage 2. Non-controller system drain dropped below the Severe on battery. Undervoltage limit with FET 3.
  • Page 71 HR15/17N HYBRID DC Service Manual Programmer LCD Display Code Set/Clear Conditions Possible Cause Effect of fault 1. Normal operation. Fault shows that regen braking currents elevated the battery voltage during regen braking. Controller is performance Set: Capacitor bank voltage limited at this voltage. exceeded the Overvoltage limit Overvoltage Cutback 2.
  • Page 72 HR15/17N HYBRID DC Service Manual Programmer LCD Display Code Set/Clear Conditions Possible Cause Effect of fault 1. Motor temperature is at or above the programmed Temperature Hot setting, and the requested current is being cut back. 2. Motor Temperature Control Set: Motor temperature is at or Menu parameters are mis- above the Temperature Hot...
  • Page 73 HR15/17N HYBRID DC Service Manual Programmer LCD Display Code Set/Clear Conditions Possible Cause Effect of fault Set: Electromagnetic brake driver EM Brake Open/Short (pin 5) is either open or shorted. 1. Open or short on driver load. ShutdownEMBrake; This fault can be set only when 2.
  • Page 74 HR15/17N HYBRID DC Service Manual Programmer LCD Display Code Set/Clear Conditions Possible Cause Effect of fault 1. Main contactor did not close. Main Contactor did not Close 2. Main contactor tips are ShutdownMotor; oxidized, burned or not making Set: With the main contactor ShutdownMainContactor;...
  • Page 75 HR15/17N HYBRID DC Service Manual Programmer LCD Display Code Set/Clear Conditions Possible Cause Effect of fault EEPROM Failure ShutdownMotor; ShutdownMainContactor; 1. Failure to write to EEPROM ShutdownEMBrake; Set: Controller operating system memory. This can be caused ShutdownThrottle; tried to write to EEPROM memory by EEPROM memory writes ShutdownInterlock;...
  • Page 76 HR15/17N HYBRID DC Service Manual Programmer LCD Display Code Set/Clear Conditions Possible Cause Effect of fault VCL Runtime Error ShutdownMainContactor; 1. VCL code encountered a ShutdownMotor; runtime VCL error. Set: Runtime VCL code error ShutdownEMBrake; 2. See Monitor menu» condition. ShutdownThrottle;...
  • Page 77 HR15/17N HYBRID DC Service Manual Programmer LCD Display Code Set/Clear Conditions Possible Cause Effect of fault Set: No motor encoder movement 1. Stalled motor. detected. Stall Detect 2. Motor encoder failure. Clear: Either cycle KSI, or ShutdownEMBrake; 3. Bad crimps or faulty wiring. detect valid motor encoder ShutdownThrottle;...
  • Page 78 HR15/17N HYBRID DC Service Manual Programmer LCD Display Code Set/Clear Conditions Possible Cause Effect of fault VCL/OS Mismatch ShutdownMainContactor; ShutdownMotor; Set: VCL and OS software do ShutdownEMBrake; not match; when KSI cycles, a ShutdownThrottle; check is made to verify that 1.

This manual is also suitable for:

Hybrid dc hr17n series

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