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Hinowa LightLift 20.10 3S Manual

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TECHNICAL COURSE
BOOKLET
LightLift 17.75 3S
LightLift 20.10 3S
PERFORMANCE
TTPE1720021602
1

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  • Page 1 TECHNICAL COURSE BOOKLET LightLift 17.75 3S LightLift 20.10 3S PERFORMANCE TTPE1720021602...

  • Page 2: Table Of Contents

    COURSE CONTENTS INTRODUCTION ..............4 PERFORMANCE DATAS ............5 PERFORMANCE TECHINCAL SPECIFICATIONS: ......5 2.2.1 LL17.75 3S DIMENSIONS ............6 2.2.2 LL17.75 3S WORKING AREA - 230 KG CAPACITY ....7 2.3.1 LL20.10 3S DIMENSIONS ............8 2.3.2 LL20.10 3S WORKING AREA - 230 KG CAPACITY ....9 SERIAL NUMBER LOCATION ..........
  • Page 3 ELECTRONIC BOARDS LIGHT MEANINGS ....... 63 8.5.1 ECM1 (MASTER BOARD FRONT MODULE) LED CODE ....63 8.5.2 ECM2 (MASTER BOARD BACK MODULE) LED CODE ....64 8.5.3 ECM3 (LOAD CELL BOARD) LED CODE ........64 8.5.4 110÷230V BOARD LED COD ..........65 8.5.5 MODEM LED COD ..............

  • Page 4: Introduction

    INTRODUCTION This booklet describes the technical and safety features, the electrical system and the hydraulic system of the Hinowa LightLift 17.75 3S and 20.10 3S Performance. It does not include how to operate the machine, for this purpose see the Operation and Maintenance Manual.

  • Page 5: Performance Datas

    LL17.75 3S AND 20.10 3S PERFORMANCE DATAS LL17.75 20.10 PERFORMANCE TECHINCAL SPECIFICATIONS LL1775 LL2010 Platform capacity 230 Kg 230 Kg Max height (basket floor level) 14,96m 18.05m Max working height 17,06m 20.15m Basket dimensions (standard 2 persons basket) 1335x690mm 134x69 Max working horizontal extension 7,00m 9,20m...

  • Page 6: Ll17.75 3S Dimensions

    2.2.1 LL17.75 3S PERFORMANCE DIMENSIONS NOTE : standard version with 2 persons basket...

  • Page 7: Ll17.75 3S Working Area - 230 Kg Capacity

    2.2.2 LL17.75 3S PERFORMANCE WORKING AREA - 230 KG CAPACITY...

  • Page 8: Ll20.10 3S Dimensions

    2.3.1 LL20.10 3S PERFORMANCE DIMENSIONS NOTE : standard version with 2 persons basket...

  • Page 9: Ll20.10 3S Working Area - 230 Kg Capacity

    2.3.2 LL20.10 3S PERFORMANCE WORKING AREA - 230 KG CAPACITY...

  • Page 10: Serial Number Location

    SERIAL NUMBER LOCATION A serial number plate is affixed on to the frame of the machine. The following illustrations showing its location. SERIAL NUMBER PLATE LOCATION...

  • Page 11: Summary Of Remote Control Functions

    3. SUMMARY OF REMOTE CONTROL FUNCTIONS The remote control functions (commands and signals) of the LightLift 17.75 3S and 20.10 3S Performance are briefly summarized below. Gravity Turret Basket rotation 1-2 arms emergency rotation Main boom Right track descent Left track...

  • Page 12: Machine Ignition

    The remote control is critical for the machine: it displays all the information on the platform status and any error message in case of incorrect use of the controls. It is also possible to access the SERVICE menu, which indicates any anomalies or malfunctioning of machine components.

  • Page 13: Gasoline Engine Pre-Heating

    start. The display shows always in position 3 the motor selected, in case this motor has been stopped the icon will be marked with an “X”. ERROR If the operator tries to start up the machine with a stop button pressed, the "ERROR STOP" message will appear as illustrated here on side.

  • Page 14: Operation And Safety Features Of The Machine

    5. OPERATION AND SAFETY FEATURES OF THE MACHINE The LL 17.75 3S and 20.10 3S Performance aerial platform are divided into two main parts: 1. Ground part or undercarriage part 2. Aerial part Operating in travel or stabilization mode, we are controlling the ground part; on the other hand, moving the booms or the turret rotation we are controlling the aerial part.

  • Page 15: Functioning Of The Ground Part

    5.1 FUNCTIONING OF THE GROUND PART 5.1.1 TRACKS OPERATION To allow tracks movement all the outriggers must be lifted from the ground. When the operator is at the ground it is enough to act on the 2 outer red joysticks to move the tracks. If the remote control is on the basket, it is necessary to press the pedal (if pedal option is active) and act on the joystick at the same time.
  • Page 16 MOVEMENT SPEED SELECTION FOR THE GROUND PART Button 5 on remote control allows the operator to select the speed of the ground part movement. To modify the movement speed, the machine changes the rpm of the engine (electronically controlled). On the machine equipped with the double speed drive gear motors, it is available one speed more (HARE) acting on the chamber of the drive gear motors (slow gear- fast gear).
  • Page 17 The consequence of a stability emergency is, with increasing severity: a) Tracks speed reduction b) Tracks movement stopped, display icon  Moreover the buzzer on the remote control could be activated. WARNING: To move the tracks when the machine is stopped by those conditions it’s necessary to press button 8 on remote control, a counter-down of 10 seconds will be activate on the display and in the meantime tracks movement is allowed in turtle speed with beeper ON.
  • Page 18 X or Y >8° TURTLE TURTLE + Y>10° BUZZER BUZZER + MOVEMENT Weight inside Y>16° STOPPED + basket <=40kg ALARM ICON BUZZER + Weight inside MOVEMENT basket Y>13° STOPPED + >40kg<=120Kg ALARM Weight inside ICON basket <=120Kg TURTLE + X>6° Possible to BUZZER select HARE...
  • Page 19 SPEED CONTROL POSSIBLE CONDITIONS ON THE LL20.10 X or Y >6° TURTLE TURTLE + Y>13° BEEPER BEEPER + Y>20° BASKET DOWNSTREAM MOVEMENT STOPPED+ Y>16° BASKET UPSTREAM ALARM ICON Not possible TURTLE + to select X>8° BEEPER OPEN HARE BEEPER + UNDERCARRIAGE MOVEMENT CLOSED...
  • Page 20 X or Y >6° TURTLE TURTLE Y>13° +BEEPER BEEPER + Y>20° BASKET DOWNSTREAM MOVEMENT STOPPED + Y>16° BASKET UPSTREAM ALARM ICON TURTLE + Weight inside X>8° BEEPER basket BEEPER + <=120Kg UNDERCARRIAGE MOVEMENT Possible to CLOSED X>10° STOPPED + select HARE ALARM ICON TURTLE +...

  • Page 21: Outrigger Movement

    5.1.2 OUTRIGGER MOVEMENT It is possible to move the outriggers only when the machine is closed and aligned, or when the photocells receive the signal reflected in the reflector installed on the jib arm of the machine (see figure below). When the machine is aligned, the alignment symbol appears in position 6 of the display.
  • Page 22 ERROR SELF STABILIZATION SELF STABILIZATION PROCEDURE NOT IMPOSSIBLE BECAUSE THE COMPLETED PROPERLY OR BUTTON MACHINE IS NOT PERFECTLY RELEASED UNTIL THE “OK”. IT IS CLOSED AND ALIGNED NECESSARY TO DO IT AGAIN WAITING FOR THE “OK” ON THE DISPLAY. SELF DESTABILIZATION To proceed with the self destabilization it is necessary that the aerial part is perfectly closed and aligned and that the relevant icon is visualized in position 6 of the remote control.
  • Page 23 MANUAL STABILIZATION It is possible to move one outrigger at time using the remote control; this operation may be very useful in case it is necessary to place one outrigger in a particularly narrow zone. To proceed with the manual operation of the outriggers it is necessary that the aerial part is perfectly closed and aligned.

  • Page 24: Functioning Of The Aerial Part

    5.2 FUNCTIONING OF THE AERIAL PART The movement of the aerial part is possible only when the machine has been stabilized, i.e. when the stabilized machine icon is present in position 5 of the display. To move the aerial part with the remote control, it must be positioned in its support in the cage, a magnet placed in the support excites a sensor located in the remote control.
  • Page 25  ST1-ST2-ST3-ST4 indicate micro switches on the outriggers, so the display will visualize OK when the outrigger is properly on the ground, while NO will be visualized when the outrigger is not resting on the ground.  INCL indicates inclination machine.

  • Page 26: Stop Buttons

    If the operator, using the remote control, rotates the aerial part with the first arm not raised enough to avoid contact between the first arm and the engine’s carter, before the contact the rotation movement is disabled. If the rotation joystick is released and activated again to try to impact the lower part of the first arm against the engine’s carter, the movement is automatically disabled and the remote control will show the operator the icon to the side, indicating that the...

  • Page 27: Pedal (Optional)

    5.4 PEDAL (OPTIONAL) On some markets is required the presence of the pedal, to move the aerial part; this function guaranty a double control on the movements, preventing unintentional movements and it is available as option also for the markets where it is not explicitly required.
  • Page 28 EMERGENCY TOOLS LOCATION In order to fulfill the following emergency operations, machine is equipped with emergency tools, that should be founded in the main carter as indicated by the picture below. MAIN CARTER ON THE MAIN CARTER ON THE LEFT SIDE OF THE RIGHT SIDE OF THE PLATFORM 17.75 PLATFORM 20.10...

  • Page 29: Emergency Operations Of The Aerial Part

    6.1 EMERGENCY OPERATIONS OF THE AERIAL PART The main goal of the emergency procedure for the aerial part is to take to the ground the operator staying in the basket. 6.1.1 GRAVITY EMERGENCY DESCENT SITUATIONS FOR USE IT:  Engine and/or electric motor not working: The hydraulic system is not under pressure because the engine is not working.

  • Page 30: Operations From Ground Control Position

    6.1.2 OPERATIONS FROM GROUND CONTROL POSITION SITUATIONS FOR USE IT:  Operator illness  Remote control breakdown CONDITIONS REQUIRED:  Engine and/or electric motor working properly  Electrical system functioning properly  Machine stabilized (machine stabilized icon active) The main purpose of using the ground control position is to rescue the operator in the basket or to move the aerial part without an operator in the basket and in any case without remote control at the ground.

  • Page 31: Emergency Descent With Safeties By-Pass

    6.1.3 EMERGENCY DESCENT WITH SAFETIES BY-PASS In particular cases of need, the Hinowa LL17.75 and 20.10 are equipped with a safeties by-pass allowing the aerial part movement even if there is no consent by all the safety devices. SITUATIONS FOR USE IT: Gravity emergency descent is not possible due to the presence of obstacles.

  • Page 32: Emergency Descent With Hand Pump

    6.1.4 EMERGENCY DESCENT FROM THE GROUND WITH HAND PUMP (FROM LL17.75/4 and LL20.10/3 read APPENDIX 9) SITUATIONS FOR USE IT:  Engine and/or electric motor not working (for engine emergency start see chapter “6.3 - Engines emergency start”)  Electrical system out of order The only reason why to use of the emergency descent from the ground is a machine breakdown.
  • Page 33 PROCEDURE “A” FOR AERIAL PART SCREW TYPE PROPORTIONAL VALVE ON 17.75/100 a) Turn OFF the ignition switch . b) Take the regulation knob of the proportional valve from the main carter and insert it in the specific adjustment screw of the proportional valve. c) Screw in the knob completely.
  • Page 34 e) Use the ON-OFF levers inside the ground control box, following the indications on the label near the ON-OFF LEVERS controls; at the same time, use the hand pump to send oil to the movement. sequence movements is: - extension arm closure –...

  • Page 35: Emergency Movements Of The Ground Part

    c) Push the button on the proportional valve keeping it pressed while attempting the required movement as indicated at point d). BUTTON PROPORTIONAL VALVE ON-OFF LEVERS d) Use the ON-OFF levers inside the ground control box, following the indications on the label near the controls, while the proportional valve button is pressed;...

  • Page 36: Outriggers Movement With The Manual Pump

    The control module records time, date and all the operations carried out during the by-pass; Hinowa personnel could visualize the complete list and movements carried out during the safeties by-pass. The safeties by-pass is an extremely dangerous operation, normal conditions have to be restored as soon as a safe position has been reached.
  • Page 37 SCREW TYPE BUTTON TYPE PROPORTIONAL PROPORTIONAL VALVE FOR VALVE FOR GROUND PART GROUND PART PROCEDURE “C” GROUND PART SCREW TYPE PROPORTIONAL VALVE ON 17.75 UNTILL SERIAL NUMBER 012L7 a) Check that the platform is completely closed and aligned. b) Fully but delicately tighten the black handles of the proportional valves located on the two valve blocks of the undercarriage.
  • Page 38 c) In order to move the right side of the undercarriage, move the deviator of the hand pump in the corresponding position; than manually screw the aerial part/undercarriage right part deviator using the black cap in the picture below, in order to send oil to the right ground part. ON 17.75 AERIAL PART/UNDERCARRIAGE HAND PUMP...
  • Page 39 e) To move the left undercarriage, move the deviator on the manual hydraulic pump into the corresponding position. HAND PUMP DEVIATOR ON 17.75 ON 20.10 f) Use the levers of the left undercarriage valve block to activate the desired movement while using the hand pump to send oil to the movement (see picture below).
  • Page 40 ON 17.75 AERIAL PART/UNDERCARRIAGE HAND PUMP RIGHT PART DEVIATOR DEVIATOR ON 20.10 c) Push the button on the proportional valve keeping it pressed while activating the required movement as indicated at point d). Push button on the left side to move outrigger 1 and 2, Push button on the right side to move outrigger 3 and 4.
  • Page 41 ON 17.75 ON 20.10 e) To move the left undercarriage, move the deviator on the manual hydraulic pump into the corresponding position. HAND PUMP DEVIATOR ON 17.75 ON 20.10 f) Use the levers of the left undercarriage valve block to activate the desired movement while the proportional valve button is pressed;...

  • Page 42: Engines Emergency Start Procedures

    g) When emergency operation finished unscrew aerial part/undercarriage right part deviator. 6.3 ENGINES EMERGENCY START PROCEDURES The following procedure shows how to separate engine from the platform system. It could be useful in the followings cases:  To verify if the engine is out of order ...
  • Page 43 HATZ 1B40 EMERGENCY START (FOR 17.75 DIESEL)
  • Page 44 PERKINS 402.05 EMERGENCY START (FOR 20.10 DIESEL)

  • Page 45: Hydraulic System

    7. HYDRAULIC SYSTEM LL 17.75 3S AND 20.10 3S PERFORMANCE (FROM LL17.75/4 and LL20.10/3 read APPENDIX 9) HYDRAULIC 7.1 COMPONENTS LOCATION COLLECTOR ON 17.75 HYDRAULIC COLLECTOR ON 20.10 AERIAL PART VALVE BLOCK GROUND PART VALVE BLOCKS...
  • Page 46 Please see appendix 1 for a description of the hydraulic system. The numbers in brackets identify the components of the hydraulic circuit. The Light Lift 17.75 3S and 20.10 3S Performance platform hydraulic system are powered through three pump units: 1.
  • Page 47 Deviator valve normally (when not fed) send oil to aerial part valveblock, so that it feeds right side ground valveblock only when its coil is energized. Its coil is energized (oil to the right side ground part) when machine is ON but not stabilized (or not respecting all the conditions to allow aerial part movements) and with engine/electric motor running.

  • Page 48: Ground Part Functioning

    If the platform is equipped with the double speed drive gear motors, manifold (5) will contain also the system that activates the second translation speed. Selecting the second speed from the remote control (HARE icon), the control module will send an electrical signal to energize the coil of the second speed solenoid valve.
  • Page 49 The ground part is controlled by 2 valve blocks (right side and left side), both equipped with a maximum pressure valve, a proportional valve and the elements for moving each one movement. PROPORTIONAL PRESSURE VALVE VALVE ON-OFF SOLENOID VALVES Oil from line “B” is sent to the left-side ground part valve block (8). Here, through a proportional valve managed by the control module and the ON-OFF solenoid valves (one per movement), it commands the two left-side outriggers, the hydraulic drive gear motor for left track and the cylinders for widening the...
  • Page 50 During the intermediate steps of auto-stabilization and auto-destabilization, so when two or three outriggers are touching the ground, the engine automatically works at minimum speed (even if we set “HARE” or “N”) to avoid sudden movements of the machine in the stabilizing phase. BOTTOM BLOCKING VALVES...

  • Page 51: Aerial Part Functioning

    If the pressure in the line increases because a greater driving force is required (ex. uphill or tracks rotation), the maximum pressure valve calibrated at 26 bar allows the automatic reduction of the gear and then of the tracks speed. This system is called Auto2speed and it allows to manage automatically the power required, providing on demand a greater force with a slower speed.
  • Page 52 Oil in the aerial part valve block controls, the rotation motor for the aerial part rotation (17) the cylinder for moving 1 and 2 arm (23), the cylinder for moving the 3 arm (24), the extension arm cylinder (25), the jib cylinder (26), the basket rotation motor (27) and the basket leveling circuit (28-29) through a compensated proportional valve installed and the ON-OFF solenoid valves (one per movement) in the aerial part valve block.
  • Page 53 It allows the opening of a calibrated passage that connect the bottom of the cylinder to the tank, passing through the ON-OFF solenoid valves, if these valves are energized through the joysticks on the remote control, oil can flow and return to the tank. This is possible because in this way the seal on the cylinder is by-passed.
  • Page 54 stem chamber section along the extension arm cylinder could cause unbalanced oil flows. To maintain balanced speeds the extension arm is equipped with a regenerator valve that carries out the recycling of one part of oil flow while the extension arm is commanded to open, therefore it compensates oil flows and balances the speeds.

  • Page 55: Electrical System

    BASKET ROTATION FUNCTIONING Basket rotation occurs through a rotation motor equipped with two double piloted balance valves (one per chamber). The maximum rotation possible is 62° in both directions for a total of 124°. The engine is always set at minimum rpm. AERIAL PART ROTATION FUNCTIONING The movement occurs through a rotation motor connected directly to the ball- bearing ring.
  • Page 56 When no signal is being sent both wires float around 2,5V. Any electrical noise can affect the high or the low wire but never both, so communication could not be corrupted. The electrical system boards are designed and constructed according to specific standards for automotive components and are therefore equipped with self-protection systems.
  • Page 57 Only for 17.75 /100, the 3 arm cylinder position sensor communicates with the ECM1-2 though the schedule located in the box on the connecting arm between the 2 and 3 arms (2nd ARM BOX SCHEDULE). 2nd ARM BOX SCHEDULE (ONLY FOR 17.75 /100) Only for 17.75 /100, inside the jib arm box, where is installed the ECM3, is also located the JIB CONNECTOR SCHEDULE, as indicated in the picture below.

  • Page 58: Can Bus Devices Connection Scheme

    8.2 CAN BUS DEVICES CONNECTION SCHEME (ONLY FOR 17.75 /100) 3rd ARM CYLINDER SENSOR MODEM CONNECTOR SCHEDULE MASTER BOARD (ECM1-2) 2nd ARM BOX SCHEDULE REMOTE CONTROL LOAD CELL BOARD (ECM3) CAN BUS system connections...

  • Page 59: Safety Devices Not In Can-Bus

    (FOR 17.75 FROM /200 AND 20.10) 3rd ARM CYLINDER SENSOR MODEM MASTER BOARD ENGINE (ECM1-2) REVOLUTION SCHEDULE REMOTE CONTROL LOAD CELL BOARD (ECM3) CAN BUS system connections 8.3 SAFETY DEVICES NOT IN CAN-BUS The machine has also safety devices that are not part of the CAN line and that communicate with the ECM1-2, or directly or through ECM3.
  • Page 60 c) Outrigger ground switch: these are 4 switches (one each outrigger) that detect if the outrigger is touching the ground or not. d) Jib arm switch: it detects if the jib arm is perfectly closed or opened. It has a double control line normally closed.
  • Page 61 Load sensor: it’s an extensimeter sensor that gives a double electric signal to the ECM3. These signals are compared and communicated using CAN BUS to the ECM1-2. j) Emergency button remote control: when the remote control is connected basket cable, emergency button double signal is linked to the ECM3.

  • Page 62: Safety Devices Not In Can-Bus Connection Scheme

    8.4 SAFETY DEVICES NOT IN CAN-BUS CONNECTION SCHEME ECM1-2 ONLY ON 20.10 ECM3...

  • Page 63: Electronic Boards Light Meanings

    8.5 ELECTRONIC BOARDS LIGHT MEANINGS The master board (ECM1-2) is composed by two modules, the front module called ECM2 and the back module called ECM1. 8.5.1 ECM2 (MASTER BOARD FRONT MODULE) LED CODE : With LED steady ON DL1 green LED ON: Power +5V to MASTER BOARD FRONT MODULE CPU DL2 yellow LED ON: All the outriggers are lifted from the ground or machine is closed and aligned (photocells signal) DL3 yellow LED ON: All the outriggers are touching the ground or all the...

  • Page 64: Ecm2 (Master Board Back Module) Led Code

    8.5.2 ECM1 (MASTER BOARD BACK MODULE) LED CODE : With LED steady ON DL1 green LED ON: power +5V to safety channel “A” CPU DL2 yellow LED ON: safety relay for tracks functions channel “A” CPU closed DL3 yellow LED ON: safety relay for aerial functions channel “A” CPU closed DL4 green LED ON: power +5V to safety channel “B”...

  • Page 65: 110÷230V Board Led Cod

    8.5.4 110÷230V BOARD LED CODE (FROM LL17.75/4 and LL20.10/3 read APPENDIX 9): DL1 red LED steady ON: electric motor ON DL2 yellow LED permanently OFF or blinking: Charging completed, battery in maintaining DL3 green LED steady ON: 12V feeding from the electronic transformer (switching) ON DL3 green LED flashing : current required is too high (it could be due to battery level too low)

  • Page 66: Electronic Boards Replacement And Setting

    9 ELECTRONIC BOARDS REPLACEMENT AND SETTING The following electronic boards need to be programmed once they are replaced:  ECM1-2 - Master board  ECM3 - Load cell board  Modem 9.1 ELECTRONIC BOARDS SOFTWARE UPLOADER The software for all the above mentioned electronic boards is normally uploaded on the master board (ECM1-2).

  • Page 67: Electronic Boards Software Installation

    CONNECTING THE CABLES AND ACTIVATING THE SYSTEM At the base of the platform, without opening the main carter, just open the slot and connect the plug to the appropriate connector. SLOT CONNECTION KIT: 17162500 26582800 Activate the system connecting the battery cutter and turn ON the ignition switch .

  • Page 68: Electronic Boards Software Updating

    To install the software, it’s necessary to enter into the menu FIRMWARE and so following the here below reported menu path through the remote control SERVICE menu 6-SERVICE / 7-SETUP / 5-PASSWORD / 1883 / 9-ESC / 3-EXTRA / 2- FIRMWARE Please note that as indicated it be necessary to introduce the password 1883.

  • Page 69: Master Board (Ecm1-2) Parameters Setting

    From the remote control will be possible to install the electronic boards software as described here above on chapter 9.2. 9.4 MASTER BOARD (ECM1-2) PARAMETERS SETTING After the software installation it’s necessary to set all the parameters in the master board (ECM1-2), following the dedicate procedure. The parameters that must be settled are listed below.

  • Page 70: Battery Charge System

    ÷ The output Voltage from the electronic transformer doesn’t depend on the electric network Voltage or frequency, output is calibrated by Hinowa at 12,7 V DC. On the lower side of the electronic transformer there’s a green LED that is lighted when the electronic transformer is active.

  • Page 71: Remote Control

    In case of need the Voltage output can be regulated by the trimmer screw indicated in the picture here below. OUTPUT VOLTAGE REGOLATION TRIMMER If the recharging current required by the battery is too high, the electronic transformer interrupts the charge process for a while, when the absorption will be decreased it will start again the charge, then on the 110÷230V board green LED will be flashing.

  • Page 72: Error Messages - Self Diagnosis

    Press pedal Battery Select a Gravity (option) voltage low control emergency descent Overload in Weigh in basket Engine Lift 1 and 2 basket too low arms preheating active Inclination too Safety by- Software Cables sensor high to stabilize pass active updates anomaly machine...

  • Page 73: Diagnostics On The Display

    Below are the possible alarm messages: Close and Inclination too ERROR ERROR ERROR Error in sensor on allign the high to move 3 arm cylinder machine tracks. Overload in Movement not ERROR ERROR It is basket allowed by necessary to gravity lift 1-2 arms emergency...
  • Page 74 1. INPUT MENU In this menu it is possible to visualize the status (or changes of status) of all the devices that give an input signal to the ECM1-2. In this way it is possible to identify, in case of machine malfunction, which device is not sending correctly its status and so check it directly to fix the malfunction.
  • Page 75 Outrigger n.4 on the ground – the switch is released and A line is closed ST4 GND A Outrigger n.4 lifted – the switch is pressed and A line is opened Outrigger n.4 on the ground – the switch is released and B line is closed ST4 GND B Outrigger n.4 lifted –...
  • Page 76 TEMP ALRM A The temperature external probe reached the maximum value – “A” line of the temperature Option probe is closed reserved for The temperature external probe hasn’t reached the maximum value – “A” line of the some markets temperature probe is open TEMP ALRM B The temperature external probe reached the maximum value –...
  • Page 77 The stop button on remote control in basket is released – “A” line is closed EM.BASK.A The stop button on remote control in basket is pressed or the ground remote control is disconnected – “A” line is open The stop button on remote control in basket is released – “B” line is closed EM.BASK.
  • Page 78 TEMPERAT. 37,6 Indicates the temperature of the ECM1-2 in °C SUPPLY (V) 12,1 Indicates the batteries voltage, or the output voltage from the battery charger BATTERY % Only for Lithium version: indicates the % level of charge of the pack. 2.
  • Page 79 Below all the pages of the errors menu are listed with the meanings of the different voices. PAGE 1 ST1 GND Control switch if outrigger n. 1 is on the ground ERRORS FREE DO NOT CONSIDER ST2 GND Control switch if outrigger n. 2 is on the ground ST1 GND FREE DO NOT CONSIDER...
  • Page 80 Average voltage of the cells 1 PREV 2 NEXT 9 ESC 4. RAMPS This menu is restricted to Hinowa staff. 5. CURRENTS This menu is restricted to Hinowa staff. 6. WORKING HOURS WORK. HOURS This menu allows entering in the display to the side which ENGINE indicates the working hours of the machine.

  • Page 81: Functioning Of The Remote Control On The Ground

    3 4 5 6 7 8 11.4 FUNCTIONING OF THE REMOTE CONTROL ON THE GROUND In case of exhibitions or demonstrations or in case of particular emergency situations, it is possible to move the aerial part connecting the remote control on the ground.

  • Page 82: Load Cell

    4. Turn the control position selector key SLOT located under emergency button following the indications of the sticker, in order to select the ground control position. CONTROL POSITION KEY SELECTOR 5. Turn ignition switch ON, so the machine is ready to be used. From this position at the ground it’s possible to move both the aerial part and the undercarriage part.

  • Page 83: Gasoline Engine Honda Igx440

    Hinowa ECM1-2 communicates with the Honda electronic unit controlling two contacts through which predetermined rpm are set. In the specific instance,...
  • Page 84 TEC1 = GREY ENGINE CONNECTOR The configuration of the rpm is calibrated through a special program directly in Hinowa. If the carburetor is replaced, a new parameterization of the electronic unit of the motor is required. Below we list the different rpm regime considering the different movement...
  • Page 85 1500 1500 Auto stabilization with 2 or 3 outriggers at the ground 2200 2200 Auto stabilization with all outriggers at the ground 3600 3600 Auto destabilization with all outrigger lifted from the ground 1500 1500 Auto destabilization with at least 1 outrigger at the ground (*) The setting indicated here above is indicatory NOTE: the electric motor works always at minimum speed (1500 rpm).
  • Page 86 The LED for a failure flashes periodically, as shown in the following figure. Example: in the case of "2 flashes” the sequence of 0.3 sec. ON > 0.3 sec. OFF > 0.3 sec. ON > 1.5 sec. OFF is repeated as a cycle. HONDA IGX 440 QUICK TROUBLESHOOTING LED Status •...
  • Page 87 (*3): If the faulty engine temperature sensor is detected while engine is running, the engine does not stop and the LED does not flash. After the engine is stopped, the engine does not start until the faulty engine temperature sensor is solved. FIRST OPERATION Check fueling from fuel tank to carburetor.
  • Page 88 SECOND OPERATION IF PROBLEM IS ON ENGINE Spark checking Changing the engine control unit Changing the ECU.

  • Page 89: Diesel Engine Hatz 1B40 (For 17.75 Diesel)

    12.2 DIESEL ENGINE HATZ 1B40 (FOR 17.75 DIESEL) Design 4 stroke Injection Direct Number of cylinders Displacement 462 cm³ Bore/Stroke 88/76 mm Fuel tank capacity Cooling system Lubricating oil pressure (oil temperature 100C) 2,5 bars at 3000 rpm Lubricating oil capacity (with oil sump) 3,2 l 1% of fuel consumption Max lubricating oil consumption (after running in)
  • Page 90 A sensor located in the Hatz engine detects the rpm and communicates them to the ECM1-2. The ECM1-2, according to the rpm information received from the sensor and according to the movement selected by the operator, controls a solenoid that regulates the rpm. SOLENOIDE FOR RPM CONTROL RPM SENSOR...
  • Page 91 The configuration of the rpm is calibrated through the engine revolution schedule. Below we list the different rpm regime considering the different movement selected by the operator: HATZ 1B40 RPM SETTING NORMAL/ TURTLE MOVEMENT (*) HARE 1850 3600 1st and 2nd arm UP 1850 2200 1st and 2nd arm DOWN...

  • Page 92: Diesel Engine Perkins 402.05 (For 20.10 Diesel)

    12.3 DIESEL ENGINE PERKINS 402.05 (FOR 20.10 DIESEL) Design 4 stroke, naturally aspired Injection Indirect Cylinders and arrangement In-Line two cylinder Displacement 507 cm³ Bore/Stroke 67/72 mm Fuel tank capacity 10 l Compression Ratio 23,5:1 Rotation that is viewed from the flywheel Counterclockwise Maximum Operating speed (rpm) 3600 rpm...
  • Page 95 The configuration of the rpm is calibrated through the engine revolution schedule. Below we list the different rpm regime considering the different movement selected by the operator: PERKINS 402.05 RPM SETTING NORMAL/ TURTLE MOVEMENT (*) HARE 1500 3600 1st and 2nd arm UP 1500 2200 1st and 2nd arm DOWN...

  • Page 96: Lithium Version (48V For 17.75, 72V For 20.10)

    12.4 LITHIUM VERSION – ELECTRIC MOTOR FOR BATTERY PACK LL17.75 fit a 48V battery pack, LL20.10 fit a 72V battery pack Number of cells in the battery pack: 15 cells for 48V, 22 cells for 72V Rated voltage of each cell: 3,2 Volt Max cell voltage: 3,65 Volt...
  • Page 97 DIAGNOSTICS AND FAULT CODES The main devices forming the lithium batteries power system are equipped with self-diagnosis with fault codes which indicate to the operator which is the possible anomaly on the machine. The devices with self-diagnosis are:  Inverter ...
  • Page 98 Hinowa ECM1-2 communicates with the inverter controlling three contacts through which predetermined rpm are set. In the specific instance the contacts are the followings: FOR 48 V BATTERY PACK (LL17.75) FOR 72 V BATTERY PACK (LL20.10)
  • Page 99 Below we list the different rpm regime considering the different movement selected by the operator 48V Lithium system. LITHIUM 48V RPM SETTING (LL17.75) ENERGY TURTLE NORMAL/HARE MOVEMENT (*) SAVING 2250 1st and 2nd arm UP 1350 1st and 2nd arm DOWN 2100 3rs and 4th arm UP 1350...
  • Page 100 Below we list the different rpm regime considering the different movement selected by the operator 72V Lithium system. LITHIUM 72V RPM SETTING (LL20.10) ENERGY TURTLE NORMAL/HARE MOVEMENT (*) SAVING 1200 2550 1st and 2nd arm UP 1500 1st and 2nd arm DOWN 1800 3rs and 4th arm UP 1200...

  • Page 101: Appendix 1 - Hydraulic System

    APPENDIX 1 HYDRAULIC SYSTEM (1 part – GROUND PART)
  • Page 102 HYDRAULIC SYSTEM (2 part- AERIAL PART)
  • Page 103 HYDRAULIC SYSTEM LIGHTLIFT (CAPTION) GROUND PART AERIAL PART...

  • Page 104: Appendix 2 - Remote Control Joystick Replacement

    APPENDIX 2 REMOTE CONTROL JOYSTICK REPLACEMENT Teach In: must be carried out when one of the joystick is replaced. Switch OFF the system. Now keep pressed the two outermost buttons on the right side of the keyboard together with the top outermost button on the left for 7 seconds.

  • Page 105: Appendix 3 - Can-Bus Diagnostics And Troubleshooting

    Electronic board or software wrong: check if the platform’s devices are compatibles with installed software, if necessary contact Hinowa with the serial number and the release number of the installed software CAN BUS signal missing: check the connection as indicated at...
  • Page 106 Only ff the problems occurred after a software updating, check if the platform’s devices are compatibles with the new software, in this case, if necessary contact Hinowa with the serial number and the release number of the software install. 4 CAN BUS DEVICES AND CONNECTIONS CHECK If you didn’t fix the problem it’s requires going on with CAN BUS devices...
  • Page 107 CAN BUS contacts on the devices, consult the relative page on the electric wiring diagrams Anytime that you have replaced a connection, connecting the battery cutter and turning ON ignition switch , check if CAN BUS error disappear. This operation is necessary to check not only the continuity of the wires but also the status, because it could happen that a wire is scratched so even maintaining the continuity it introduces a disturb into the signal...
  • Page 108 CAN BUS DEVICES CONNECTIONS (BLUE LINES) (ONLY FOR 17.75 /100) 3rd ARM CYLINDER SENSOR MODEM CONNECTOR SCHEDULE MASTER BOARD (ECM1-2) 2nd ARM BOX SCHEDULE REMOTE CONTROL LOAD CELL BOARD (ECM3) CAN BUS system connections...
  • Page 109 (FOR 17.75 FROM /200 AND 20.10) 3rd ARM CYLINDER SENSOR MODEM MASTER BOARD ENGINE (ECM1-2) REVOLUTION SCHEDULE SCHEDULE REMOTE CONTROL LOAD CELL BOARD (ECM3) CAN BUS system connections...
  • Page 110 CAN BUS DEVICES POSITIONS ONLY FOR 17.75 /100 ONLY FOR 17.75 /100 FOR 17.75 FROM /200 AND 20.10 After checking, if the problem comes out from the device it’s required to change the device, if the problem comes out from the connection it’s required to change the wires.
  • Page 111 5 RESISTENCES CHECK WITHOUT FEEDING THE SYSTEM, looking into the electric diagram of your platform (as the example here below), check the remote control/receiver and ECM1-2 CAN BUS resistances (in the red round) on page CAN NETWORK (page “E”), i.e. test the resistance measured within the cable H and L that should be about 120 Ohm with the device disconnected from the other and 60 Ohm with the device connected each other, (always with FEED OFF)

  • Page 112: Appendix 4 - Currents And Ramps Setting

    To set the current have to be followed the procedure “Performance parameters setting” In case of need ask Hinowa with the platform serial number to be informed about the specific parameters setting originally settled on your platform. CURRENTS ARE DEFINED BY HINOWA AND CANNOT BE CUSTOMIZED.
  • Page 113 To set the ramp have to be followed the procedure, “Performance parameters setting”. In case of need ask Hinowa with the platform serial number to be informed about the specific parameters setting originally settled on your platform.

  • Page 114: Appendix 5 - Load Cell System Calibration Procedure

    JOYSTICK VALUE JOYSTICK = 127 JOYSTICK = 50 TIME LINE TA2 - DEC ELERATION RAMP 2 TA2 - TA1 - TA1 - ACC ELERATION ACC ELERATION DEC ELERATION RAMP 2 – 3.9“ RAMP 1 – 10“ RAMP 1 From the graph above we can see that the ramp determinates the curve inclination and therefore the acceleration.
  • Page 115 PROCEED AS FOLLOWS: Power the remote control turning ignition switch ON START CALIBRATION: Take the remote control in hand and take a position on the ground, not in the basket. In this position, press button 9 for SERVICE menu on the remote control and look at the information that appear on the display.

  • Page 116: Appendix 6 - Accelerometers Calibration Procedure

    APPENDIX 6 ACCELEROMETERS CALIBRATION PROCEDURE (TILT SENSOR RESET) This operation is required when the master board (ECM1-2) has lost the references for the accelerometers or the need to replace the master board (ECM1-2) itself. PROCEED AS FOLLOWS: IMPORTANT: to do this operation it’s important that motors are switched OFF, just turn ignition switch ON to feed the ECM1-2.

  • Page 117: Appendix 7 - Light Indication On Electrovalves

    APPENDIX 7 (FROM 17.75/200 AND FOR 20.10) LIGHT INDICATION ON ELECTROVALVES On Light Lift 17.75 from /200 and on Light Lift 20.10 the aerial and ground ON/OFF valves and also the hydraulic deviator valve are equipped with a light to indicate their status. ON-OFF valves are lighted while they are electrically fed, doesn’t matter the correspondent proportional valve or deviator status.

  • Page 118: Appendix 9 - Frequently Issues Solving

    CONTROL POSITION SELECTOR SWITCH AERIAL PART MOVEMENTS INDICATIONS MOTORS INGNITION BUTTONS AERIAL PART MOVEMENTS LEVERS APPENDIX 9 FREQUENTLY ISSUES SOLVING 1) Dead display Turn ignition switch OFF and disconnect the battery cutter. Switch ON them after a few seconds (first battery cutter). Wait 10 seconds for start up and check display.
  • Page 119 If the display doesn’t start up check the remote control connector and remote cable, especially CAN BUS wires 5 and 6 (Page E3 wiring diagram). Check the whole CAN BUS line from ground to platform (Page E3 wiring diagram). Connect remote control at the ground cable and verify its functioning. If it’s working the problem is on the electric lines to platform basket cable or on the control position key selector or switches.
  • Page 120 correct value (less than 10 each one) testing physically the leveling with an external level on the machine base. If values are not correct do accelerometer reset procedure with the correct leveling of the machine (see appendix 6) and then test the system. If it lose the calibration or still not working master board (ECM1-2) possibly needs to be replaced.
  • Page 121 11) Rahm System is not working: Verify serial number and password. Verify to write serial number in capital letter and password in small letters. Ask if possible to put machine outdoor and try again. Ask to check if modem is flashing slowly (see chapter 8.5.5) as it should if there is net signal, otherwise problem is network itself.

  • Page 122: Appendix 10 - Mk2 Pdatings

    APPENDIX 10 MK2 UPDATINGS MK2 updatings have been introduced from LL17.75/4 and from LL20.10/3. MAIN KEY ON GROUND CONTROLS BOX MK2 machines have no key on engine, also MK2 lithium machines have no key on lithium pack, the main key is on ground control box. NEW AERIAL PART HYDRAULIC VALVEBLOCK AND NEW CONTROL POSITION KEY SELECTOR BOX Inside the ground control box, the aerial part hydraulic valveblock has been...
  • Page 123 ELECTRIC MOTOR WITH DISENGAGER AND ACTIVATION RELAY The 110÷230V board is not installed anymore, its function has been replaced by one relay, installed on thermic switch box (circuit breaker box), that controls the electric motor activation/deactivation. Electric motor is equipped with a disengager. NEW CHARGING SYSTEM The electronic transformer has been changed, the new one is installed without box inside the carter aside the 12V battery, so that transformer box is not...
  • Page 124 NEW ELECTRIC PLUG The 110÷230V fixed plug used to connect the machine to the electric network has been replaced by an UNFIX plug. NEW 12V BATTERIES New 12V battery is AGM (Absorbent glass mat) and START&STOP technology, with capacity 60Ah. NEW LOAD CELL SYSTEM Load cell sensor and load cell board (ECM3) are different from the one installed till LL17.75/300 and LL20.10/200.
  • Page 125 NEW HONDA ENGINE ON LL17.75 FROM /400 From LL17.75/400 gasoline version is equipped with Honda engine iGX390 coupled with pumps unit 3,15cc/rev each. Design 4 strokes, overhead camshaft Ignition system variable ignition timing Ignition timing single cylinder inclined by Number of cylinders 25°...
  • Page 126 Below we list the different rpm regime considering the different movement selected by the operator: HONDA IGX 390 RPSM SETTING TURTLE NORMAL/HAR MOVEMENT (*) 1500 1st and 2nd arm UP 1500 2350 1st and 2nd arm DOWN 1500 2350 3rs and 4th arm UP 1500 1500 3rs and 4th arm DOWN...
  • Page 127 NEW OUTRIGGERS LIGHTS New outrigger warning lights are bigger than old version and led. NEW BASKET WITH NEW REMOTE CONTROL SUPPORT AND WHEELS New basket is equipped with a new design remote control support and with four wheels to be better displaced when removed.
  • Page 128 SKYGUARD OPTIONAL New basket, electric installation and software are predisposed for anti- entrapment system, called SKYGUARD. SKYGUARD BAR SKYGUARD ICON When SkyGuard is installed and its function activated by the relevant menu, if its bar is just pressed while making some aerial part movement, all of the aerial part movements will be immediately stopped.
  • Page 129 make it disappear it must be pressed and released the remote control emergency stop. In case of need the SkyGuard function could be bypassed by keeping pressed the button n.8 of the remote control, this operation allows to move the machine only in the case to have the bar always pressed, or stuck, but it will not allow the movements if the bar has been pressed and released.

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