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WORKSHOP MANUAL — T815 CRAWLER
Troglotech T815 Crawler Workshop Manual
Troglotech Ltd
Unit 1, 3 Penns Road
Petersfield
Hampshire
GU32 2EW
Page 1
Phone +44(0)1730 711240
Phone +44(0)1730 711240
Fax +44 (0)1730 711240
Email info@troglotech.com
Web www.troglotech.com
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Summary of Contents for Troglotech T815
- Page 1 Troglotech Ltd Phone +44(0)1730 711240 Unit 1, 3 Penns Road Phone +44(0)1730 711240 Petersfield Fax +44 (0)1730 711240 Hampshire Email info@troglotech.com GU32 2EW Web www.troglotech.com WORKSHOP MANUAL — T815 CRAWLER Troglotech T815 Crawler Workshop Manual Page 1...
- Page 2 T815 CRAWLER - OVERVIEW T815 Crawler Overview—Motor Drives MECHANICS: The mechanical construction of the T815 crawler enables quick disassembly and is simple to repair and maintain. NOTE: See https://youtu.be/H5bHqfwd2yg for video of assembly instructions The diagram above shows the plain chassis and the two motor/gearbox drive units.
- Page 3 NOTE: Add a small amount of silicon grease between the motor drive PCB and the pocket in which it is housed to conduct heat away from the driver whenever a motor drive PCB is replaced Troglotech T815 Crawler Workshop Manual Page 3...
- Page 4 NOTE: Add a small amount of silicon grease between the motor drive PCB and the pocket in which it is housed to conduct heat away from the driver whenever a motor drive PCB is replaced Troglotech T815 Crawler Workshop Manual Page 4...
- Page 5 NOTE: Add a small amount of silicon grease between the motor drive PCB and the pocket in which it is housed to conduct heat away from the driver whenever a motor drive PCB is replaced Troglotech T815 Crawler Workshop Manual Page 5...
- Page 6 T815 Crawler Overview—Drivetrain and External Parts DRIVETRAIN: The picture below shows the T815 drivetrain and external parts. The drivetrain consists of six individual axles with integral gears and two Idler Gears. These parts are attached to, or held in place by the Tractor Sides which are secured by 12...
- Page 7 Processor to start and hold ‘KEEP AWAKE’ high whilst the cameras produce video and TTDS communications are established to ensure that the power remains ON. Once the 5V supply is operational Video+ve will drop in DC voltage as the video signal is transmitted. Troglotech T815 Crawler Workshop Manual Page 7...
- Page 8 Motor+ve supply is used as a raw supply for the Motor Drives and additional lighting (large lighthead and reversing lights). The voltage from the battery can drop below 13V which is unsuitable for the T815 camera head which is why a separate 15V supply is available.
- Page 9 Video+ve is present but TTDS data is incorrect or missing. This behaviour will be seen if the software for the Display Unit (both MAIN and COMMS) has not been updated; pre-T815 software does not include the ’KEEP_ALIVE_BIT’ bit on TTDS data.
- Page 10 Calculate crawler orientation for auto-steering Determine maximum motor speed from voltage data T815 Crawler Integration with AUTO DRUM: The T850 Auto Drum system is designed to be a transparent addition to a standard crawler system. However, the crawler changes its behaviour if the Auto Drum is set to ‘AUTO’...
- Page 11 T815 CRAWLER– FAULT FINDING T815 Crawler—Fault Finding—appears completely dead Fault finding of the crawler can be simplified by understanding the behaviour at start-up. If a crawler does not respond when connected to the cable: Check that there is 5V available between the inner and outer sliprings on the cable.
- Page 12 T815 CRAWLER - FAULT FINDING T815 Crawler—Fault Finding—appears completely dead—continued If the battery has a good charge, the cable has 5V available, all connections are clean and the battery is pushed fully home, then the crawler will need dismantling to find the cause.
- Page 13 T815 CRAWLER– FAULT FINDING T815 Crawler—Fault Finding—appears completely dead—continued If no moisture is found on the Processor PCB try pushing the Crawler again with the battery fitted and watch the two LED’s on the Processor: If the two small LED’s D5 and D6 start flashing that indicates that the 5V supply is operational and the processor PCB has started initialising.
- Page 14 T815 CRAWLER - FAULT FINDING T815 Crawler—Fault Finding—appears completely dead—continued The next tests need to be performed on the Power Control PCB—disassemble in the correct order as shown below: If there is no visible damage to any of the PCB’s then check the voltage at the battery connector from the upper connection block on the crawler.
- Page 15 T815 CRAWLER– FAULT FINDING T815 Crawler—Fault Finding—One Drive fails to operate Where one motor drive fails to operate it is most likely that the connection to the motor driver has failed rather than the Motor Driver itself being at fault.
- Page 16 T815 CRAWLER - FAULT FINDING T815 Crawler—Fault Finding—Other Problems Crawler switches ON but T812 head does not initialise, no control over motors. This indicates an IIC problem—and this can either be a connection problem between PCB’s or damage to PCB’s that use IIC to communicate. Sometimes this...
- Page 17 0V, the resistance should be over 10,000 Ohms. If there is a short, remove the Processor PCB and perform the same test—if the resistance increases the problem is elsewhere in the PCB set Troglotech T815 Crawler Workshop Manual Page 17...
- Page 18 T815 CRAWLER - FAULT FINDING T815 Crawler—Fault Finding—Other Problems Crawler switches ON but as soon as the T812 camera head has centralised the power switches back OFF again. The crawler will continue this behaviour until the Display Unit is switched OFF (VIDEO PICTURE PRESENT): This indicates that TTDS data is not being received by the Processor PCB (possibly main cable damage) or the Processor PCB is not responding to the data.
- Page 19 PCB. Repeat this for all 6 grub screws and then go around all 6 fully tightening each grub screw. Refit the Sonde connector. Grease the large o-ring liberally before refitting the rear cover. Troglotech T815 Crawler Workshop Manual Page 19...
- Page 20 Take care assembling the rear cover—there are delicate mating connections and there is wiring to the sonde that can be damaged Have an idea what you want to reach—often removal of one cover is all that is required Troglotech T815 Crawler Workshop Manual Page 20...
- Page 21 Also, rotate one axle and ensure that all three axles rotate ensuring that the gears are correctly meshed and the motor/gearbox is free to rotate. Fit the crawler side screws in the order specified overleaf ensuring the large o-ring is correctly seated: Troglotech T815 Crawler Workshop Manual Page 21...
- Page 22 The Battery Packs are fully sealed and manufactured such that any failure of the internal cells does not cause a source of ignition. Unless strictly authorised by Troglotech in writing they must not, under any circumstances be dismantled as this may affect the safety of the crawler.
- Page 23 T815 CRAWLER - PCB REMOVAL TABLE Table for Removal of Single PCB’s: PCB Description Number on Diagram Order of Removal Power Control PCB 4, 1 Motor Drive PCB (F) 4,1,2 Interconnect 1 PCB 8,7,3 Interconnect 3 PCB Interconnect 2 PCB...
- Page 24 T815 CRAWLER - PCB REPLACEMENT Table for Removal of Single PCB’s: The drawing above shows the order in which the PCB’s are replaced. This allows the crawler body to be handled safely during re-construction: Rest the crawler body on the front face and replace the rear Motor Drive PCB (1) and the ZIF motor connector.
- Page 25 T815 CRAWLER - TIPS Tips when working on T815 Crawler: After any work pressurise the crawler with the pump to 50psi. Keep the pump connected and watch the pressure—ensure it does not drop after stabilising for 5 minutes. If pressure IS lost then re-pressurise to 50psi and immerse the crawler in a tank of water to find the leak.
- Page 26 T815 CRAWLER - TIPS Tips when working on T815 Crawler: When performing any repair make sure to inspect and clean the pogo’s at the rear swivel and the cable termination, the battery and connector block. If the T812 camera is removed inspect and clean the sliprings on the camera and the pogo’s on the crawler.
- Page 27 For clarification: When the Crawler is in Calibration Mode: If the Crawler is moving pressing Iris Close sets the steering offset. If the Crawler is stationary pressing Iris Close sets the Inclinometer offset. Troglotech T815 Crawler Workshop Manual Page 27...
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