SMARTDRIVE MASTER SYSTEM - Poclain Hydraulics · Block diagram with management of two dual ... enables slow movement independent of the engine ... POCLAIN HYDRAULICS SmartDrive Master

T E C H N I C A L C A T A L O G

SMARTDRIVE MASTER SYSTEMELECTRONIC MANAGEMENT OF HYDROSTATIC TRANSMISSIONS

SmartDrive Master System POCLAIN HYDRAULICS

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Methodology :This document is intended for manufacturers of machines that incorporate Poclain Hydraulics products. It describes the technical characteristics of Poclain Hydraulics products and specifies installation conditions that will ensure optimum operation. This document includes important comments concerning safety. They are indicated in the following way:

This document also includes essential operating instructions for the product and general information. These are indicated in the following way:

The views in this document are created using metric standards. The dimensional data is given in mm and in inches (inches are between brackets and italic)

Safety comment.

Essential instructions.

General information .

Information on the model number.Information on the model code.

Weight of component without oil.

Volume of oil.

Units.

Tightening torque.

Screws.

Information intended for Poclain-Hydraulics personnel.

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CONTENTPOCLAIN HYDRAULICS SmartDrive Master System

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CHARACTERISTICS 4

Foreword 4Operating principles 5Main system characteristics 6Description of functions 7

ACCESSORIES 11

SmartDrive™ ECU 11Input / output characteristics 13Communication connector 14SmartDrive™ communication cable 1556-pin main connector 16SmartDrive™ Master cable 18Identification of the SmartDrive™ Master 19List of SmartDrive™ Master System components 20

INSTALLATION 23

First level diagnostic 27Appendix 28


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FOREWORDPoclain Hydraulics has created and developed SmartDriveTM Master System, a system that simplifies and optimizes the running of hydrostatic transmissions of mobile machinery. It comprises a computer that regulates the running of hydrostatic transmission components (engine, hydraulic ground drive pump, hydraulic motors, and brakes) through sensors and actuators.The on-board software calculates the machine's ground drive speed in accordance with the driver setting and the programmed acceleration and deceleration ramps. These ramps, which are among the many parameters that enable the machine's behavior to be customized, determine the vehicle's responsiveness and aggressiveness.The combination of the flexibility of the electronics and the power of the hydraulics makes this a system which can be adapted and set up for all driving styles.

It consists of the following components:

SA control pump Regulating computer

Hand held terminalSet-up - Calibration - Diagnosis by computer

CHARACTERISTICS

POCLAIN HYDRAULICS SmartDrive Master System

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OPERATING PRINCIPLESThe SD Master System ECU (Electronic Control Unit) regulates the running of the transmission elements (hydraulic pumps, engine, hydraulic motors, and brake) through sensors and actuators. It can therefore manage the whole transmission, offer various driving modes adapted to the vehicle and the driver, control the braking, and can offer multiples control points for the transmission's components.

Block diagram with management of two dual displacement motors

It comprises:

A. A regulation computer specific to the transmission control system;

B. An actuator controlling the engine;

C. One or two pumps with power assisted controls, fitted with a C1displacement control solenoid, a C2 (swashplate position) feedback potentiometer, a speed sensor and 500-bar pressure sensor;

D. A joystick or pedal, mode selection switch, fault light, stop light, speed sensor display, etc.

Auxiliary

Setup

B

A

D

C

C1

C2


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MAIN SYSTEM CHARACTERISTICS

FunctionsAre specific to each application.

In general the system offers:

• Hydrostatic transmission control: automatic displacement shift, management of engine rotation speed, power restriction, anti-stall, etc.• Brake management• Front/rear axle differential lock• Signaling• Speed regulation (cruise control)• Limp mode management

Examples of parametersThe parameters can be set for each application either using the PHASES software or the portable hand held terminal. They may also be subject to special access authorization.

They govern the:

• pump (displacement threshold for shifting from 1st to 2nd displacement; maximum permitted displacement for pump No. 1).• engine (speed, etc.)• hydraulic motor (displacement)• brake valves (dynamic brake pressure at rest)• sensors (emergency brake pressure detection threshold, etc.)• cruise control function• driving modes, (automotive, etc).

Description Characteritics

Supply voltage12 V DC24 V DC

Hydraulic circuit maximum pressure450 bar[6500 PSI]

Intensity of use Medium to high pressure (medium to heavy duty)

Operating temperature- 25 °C à 70 °C[- 13 °F to 158 °F]


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DESCRIPTION OF FUNCTIONSDriving modesWith agricultural machinery, the driver can have two operating configurations as standard:

[ Road Mode ]

This is an automotive type of driving, similar to an automatic transmission. The transmission ratio is established automatically by the load management of the engine, pump displacement and hydraulic motor displacement. The load on the engine is therefore related to the vehicle speed, enabling pollution and fuel consumption to be reduced.

[ Field Mode ]

The load on the engine is constant; the auxiliary tools consume the majority of its power.

Hence these ground drive defining parameters may be different from one [ Field Mode ] to another. The operational design specifications book for the vehicle transmission sets these parameters.

Shifting between modes is done under different safety conditions managed by the SD Master ECU: for example a sprayer can only shift to [ Road Mode ] if the spray bars are folded back.

For a forklift truck type application, we can distinguish other driving modes:

• [ Mode 1 ]: for novice forklift drivers: driving with safety features (limited max speed, lower acceleration rate, etc.)• [ Mode 3 ]: for experienced forklift drivers: driving is more responsive and reactive (rapid acceleration).• [Inching Mode ]: simultaneous application of the brake and accelerator pedals produces an inching effect (hydraulic clutch control that

enables slow movement independent of the engine load).

Machine transmission control

Automatic displacement shift

A SmartDrive™ Master System transmission varies speed continually.Depending on the acceleration or brake settings issued by the driver, hydraulic motor displacement shift is surge-free. This is accomplished by simultaneous pump displacement control and motor displacement shift control.So since everything takes place nearly automatically, the driver can concentrate on more tasks with greater added value, such as the machine's working functions, and particularly tool management.

Rotation speed management of the engine

The SD Master ECU can integrally manage the engine in two ways:• by means of an actuator• by means of a CAN BusThe ECU optimizes the rotation speed of the engine for the requested power level.

Anti-stall function

In [ Field Mode ], this function reduces the pump speed to prevent the engine stalling if the power required by the hydrostatic transmission exceeds the engine's available power.

Limitation of ground drive power

Agricultural machinery has engines which are generally oversize for the ground drive requirements for supplying the power needed for the on-board tools in [ Field Mode ].In [ Road Mode ], there is no protection; the engine's full power is available. Limiting the integrated power in a transmission controlled by a SmartDrive™ Master System therefore protects the hydrostatic transmission from possible excess output, which could cause irreversible damage over time.

Detection of pump fluid contaminationThe SmartDrive™ Master ECU is capable of detecting possible oil contamination by using the pump feedback control and a potentiometer that tells it the position of the pump's cam casing swashplate. This element protects against malfunctions caused by pump displacement shifts.

It is possible to define other modes, depending on the nature of the work to be carried out and the environment.


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Brake management

Service brake (dynamic)

The brake pedal:• activates mechanical braking,• reduces the pump displacement via the SmartDrive™ Master ECU.

The braking system is of the combined type, i.e. the mechanical braking torque combines with the hydrostatic transmission's braking torque (pump speed reduced).The SmartDrive™ Master System manages the pump and hydraulic motor displacement reduction by taking account of the level of mechanical braking, so that the hydrostatic transmission prevents possible wheel lock.

Parking brake

The parking brake is held by the spring force.To deactivate this brake, the driver activates either a switch, a lever or a foot control. These components then transmit pressure to the brake pistons, which overcome the spring force.

Emergency stop

If the parking brake switch is activated for an emergency stop, the mechanical parking brakes and the hydrostatic brake engage by means of a pump displacement ramp managed by the Smart Drive™ Master System.

Front/rear axle differential lockThis function is available for transmissions fitted with four hydraulic motors and a PW tandem pump.

In [ Field Mode ], it isolates the hydraulic circuits of each front and rear axle using an electro-hydraulic valve.

Speed regulation or "Cruise control"When using the machine for field operations, the driver may require a regulated constant ground drive speed. There are two possible arrangements:

1 - The operator depresses a push button that activates the "Cruise Control" function.At that moment, the traveling speed of the machine is taken as a reference. The ECU manipulates the pump speed setting to maintain the desired speed. The "Cruise Control" function can be overridden by depressing either the brake pedal or a button.

2 - The driver programs in the max speed to be reached in this "Cruise Control" function using the push buttons.The rest of the operating principle is the same as the 1st instance.The max programmed speed will then be attained for the joystick entire stroke (the control lever for the pump displacement).


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Constant speed with combined auxiliary control

In [ Field Mode ], the machine's ground drive speed remains constant in spite of the acceleration of the engine required to the auxiliary functions.The operator, now freed from controlling the speed, can concentrate on tasks with higher added value.

Example of driving position and types of information sent to SmartDrive™ Master

SignalingThe ECU manages the signaling (braking, reverse lights, warning beep, etc.) depending on the ground drive condition.

Limp mode managementDepending on possible faults with the transmission, various operations are possible in degraded mode, to enable minimal ground drive.These degraded modes may be defined in certain cases by agreement with the manufacturer.

CAN Bus communicationThe ECU presents a standard 2.0A or the applied 2.0B CAN interface.When connected to the machine's CAN network, the SmartDrive™ Master ECU can therefore:• Receive messages (engine setting, joystick, selectors, etc.)• Send messages (signaling, fault indicator, error message, etc.)

CAN customization requires major configuration in terms of the complexity of the architecture of the CAN for each manufacturer.Please consult your POCLAIN HYDRAULICS sales engineer.

Options

Cruise control

Parking brake

Controls

Engine load

Pumppressure

Pumpspeed

Stop

Default

Emergency stop

Acceleration / Deceleration

Hydraulic braking

Brake

Hydraulic motor speed

Motor displacement shift

Pre

ssur

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Spee

d

Pump displacement control


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SMARTDRIVE™ ECU

Commercial name SD Off-Road box SD Master box SD Premier boxPart number 001142255G 001142254F A11999S

FeaturesMaterial AluminiumMass 1.850 kg [4.07 lb]

Operating temperature -25 °C to 70 °C[-13 °F to 158 °F]

Mounting 4 x Ø 7 mm 4 x [0.28 dia.]

Protection index of ECU with its connectors IP65 (weather proof)Electricity supply 12 V cc - 24 V ccCurrent 8 A 14A 20AElectrical protection Excess voltage, Inverter PolarityMicroprocessor 16 bitsMicroprocessor frequency 20 MHzECU setup with a PC or setup terminal

Electromagnetic compatibility

• CISPR 25 : Measure of electromagnetic and radiated emissions.• NF R 13-004-3 : Susceptibility to the radiations of electric fields.• ISO 7637 : Immunity to transitory overvoltages.• ISO/CD 10605 : Immunity to electrostatic discharges• e marking (Directive 2009/19/EC)

Associated software

The control software is adjusted for each application (see p.18). The software can be customized for each application. Poclain Hydraulics recommends that you consult your sales engineer.Setting parametersYou can set parameters either by a hand held terminal or by an software called PHASESTM . See page 18.

ACCESSORIES


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Layout of SmartDrive™ Premier box

InstallationChassis fixing

Quantity Class N.m [lb.ft] ± 10 %M 6 4 8.8 10±1 [7.37±0.73]

Electrical connectionsWhen wiring, check that the wire can nei-ther be cut off, nor torn off when the ma-chine is working or moving.

Communication connector COM-SD-CONNECTOR-PLUGMain connector KIT-CONNECTOR-MAIN-SD

SmartDriveTM Master cable (1 m) CABLE-SD-MASTER-56-1000SmartDriveTM Master cable (5 m) CABLE-SD-MASTER-56-5000Communication cable (1m) COM-CABLE-SD-1000Communication cable (5m) COM-CABLE-SD-5000


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INPUT / OUTPUT CHARACTERISTICSOn-Off digital inputs (x 11)The sensors read are NPN.Description Min. Max.Maximum current for pressure switch digital input (pin 5, 6, 7 on SmartDrive Master connector) - 54 mA

Maximum current for other digital input - 12 mA

Analog inputs (x 8)Description Min. Max.Measurement range 0 V 5 VAccuracy - 1 %Input impedance 100 k

Frequency inputs (x 1)The sensors read can be NPN and PUSH/PULL.Description Min. Max.Measurement range 0 Hz 1,5 kHzMaximum voltage for a low level - 1,5 VMinimum voltage for a high level 8 V -

Differential frequency inputs (x 1)The sensors read can be PUSH/PULL and variable reluctance.For PUSH/PULL sensor only Freq (+) has to be connected.Description Min. Max.Measurement range 0 Hz 8,5 kHzMaximum voltage for a low level for PUSH/PULL sensor - 1,5 VMinimum voltage for a high level for PUSH/PULL sensor 8V -Minimum peak to peak voltage for variable reluctance sensor 500 mV -

Digital outputs (x 9)Description Min. Max.

Maximum current - 0,5 A under 12 V 0,25 A under 24 V

Output voltage Vbat - 1 V Vbat

PWM outputs dedicated to pumps with SA control (x 2)Description Min. Max.

Maximum current - 2,4 A under 12 V1,2 A under 24 V

Frequency PWM - 10 kHz

H bridge outputs (x 1)Description Min. Max.Maximum current - 3 AMaximum output voltage - VbatFrequency PWM 61 Hz 300 Hz

Sensors power supply 5 VDescription Min. Max.Maximum current - 200 mAOutput voltage 4,90 V 5,10 V

Sensors power supply 12 VDescription Min. Max.Maximum current - 200 mAOutput voltage if Vbat > 13,25 V 11,50 V 12,50 VOutput voltage if Vbat < 13,25 V Vbat - 0,75 V


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COMMUNICATION CONNECTOR

A 120 ohm bus termination resistor can be installed between K and E, or K and F.

Commercial name COM SD LT CONNECTOR KITPart number 007142204Q

Features

ComponantsBayonet connector14 pinsCable diameter: 4.5 - 12 [0.15 - 0.47]

Communication wiringWith PC For Hand Held Terminal

Commercial name SD PC LT CABLE SD HHT LT CABLE

Connector mounting

1. Unscrew the connector sub-assemblies. Passthe cable through the securing elements.

2. Strip the wires to a length of 5 mm [0.19 in]. Solder the wires on to the pins as shown in the table below.

3. Remount the connector by screwing the securing elements to one another.

PIN J1 Function Wire section mm²A NC Not connected

ECU side viewB NC Not connectedC NC Not connectedD NC Not connectedE CANL Low CAN signal 0.22F CANL Low CAN signal 0.22H NC Not connectedJ NC Not connectedK CANH_120 Connexion for CAN bus end 120 Ù 0.22L NC Not connectedM CANH High CAN signal 0.22N CANH High CAN signal 0.22P GND ground 0.22R GND ground 0.22


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SMARTDRIVE™ COMMUNICATION CABLE

Commercial name COM-CABLE-SD-1000 COM-CABLE-SD-5000Part number A20360F A20361GFunction Connect a SmartDriveTM ECU communication elements to the machine wiring.Compatibility Electronic transmission management with SmartDriveTM ECU.FeaturesLenght of cable 1m 5mMaterial PVCNumber of wires 14Sections of wires 0.22mm2

Layout

Electrical wiringPin Wire

A WhiteB BrownC GreenD YellowE GrayF PinkH BlueJ RedK BlackL VioletM Gray/PinkN Red/BlueP White/GreenR Brown/Green

or


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56-PIN MAIN CONNECTOR

Commercial name MAIN SD CONNECTOR KITPart number 007142203P

Features

Components

Connectors: 211PC562S0008Locking cam: 211A567007Protective cover: 211A560008Pins: 211CC2S1120 (x60)Stoppers (when a pin is not used): 210A015019 (x60)

Protection index IP 68Cable section 0.35 to 2 mm² [0.0005 to 0.003 in²]

Fitting the main connectorLocking device position

A.Place the black unit on the ECU. Note its position and separate its from the ECU.

B.

Insert the purple locking device into the unit from the botton to the top and push until it clicks. The cable will have to be positioned on the locking device side.

Fitting the connector1. Unclip the 2 yellow supports.2. Remove these supports.

3. Turn the unit over.


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4.Strip the wire over 4 mm. Crimp each conductor on its lug using pliers FCI211S005.

5.

Insert each lug into the connector as shown in the electrical circuit diagram in the appendix. In case of error, use extraction tool 2105048 to remove the lug.

6. Insert the green plugs into the free ports of the connector.

7. Clip on the 2 yellow supports.

8.Position the cover and lower it. The cover tab (A) must be on the right of the unit tab (B).

9. Lock it by pulling on it until there is a click.

10. Secure the cable uising a cable grip.Removing the locking device12. To remove the purple locking device, press as shown.13. Partially pull out the locking device, press as shown.

14.Repeat point 12 on the other side, and completely remove the locking device.

Fitting the main connector


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SMARTDRIVE™ MASTER CABLE

Commercial name CABLE-SD-MASTER-56-1000 CABLE-SD-MASTER-56-5000Part number A20309A A20310BFunction Connect a SmartDriveTM Master ECU or a SmartDriveTM Premier ECU (J1) to the

machine wiring.Compatibility Electronic transmission management with SmartDriveTM Master ECU or

SmartDriveTM Premier ECU.FeaturesLenght of cable 1m 5mMaterial PVCNumber of wires 56Sections of wires 1mm2

Layout

Electrical wiring

The wires of the cable are numbered.Pin Wire

1 12 23 3

55 5556 green/yellow

or

. . .

. . .

. . .

. . .


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IDENTIFICATION OF THE SMARTDRIVE™ MASTER

A : Model code:e.g. SD MASTER BOXB : Code (Part number):e.g. 001142255GD : Number (Chronological number):e.g. 7572

Only the calculator and the valves are identified by this model identification plate.

The part number and the chronological order number must be specified to order spare parts.

The dimensions of the components described in this bro-chure, the operation and the CEM chapter are given in the characteristics brochure.

A

B

D

001

001142255G

7572

SD MASTER BOX


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LIST OF SMARTDRIVE™ MASTER SYSTEM COMPONENTS

ECU and its connections

Setting parameters

SA control pump environment

Auxiliaries

Control elements

Model code Part number

Regulating ECU BOITIER SD Master 001142254F

Main connector KIT CONNECTEUR MAIN SD 007142203P x1

SmartDriveTM Master cable (1 m) CABLE-SD-MASTER-56-1000 A20309A

SmartDriveTM Master cable (5 m) CABLE-SD-MASTER-56-5000 A20310B

Communication connector KIT CONNECTEUR COM SD LT 007142204Q x1

Communication cable (1 m) COM-CABLE-SD-1000 A20360F

Communication cable (5 m) COM-CABLE-SD-5000 A20361G

SmartDriveTM Master connectors Kit connecteur SD Master 007142230T

CAN wiring CABLE DE COMMUNICATION Y SD 006142217X


Control software (including SD PC LT wiring) Pack PHASES Master 005142206E

Wiring CABLE SD PC LT 006142212S

Setup terminal TERMINAL EQ. ST2000 005142202A

Wiring CABLE SD HHT LT 006142213T


SA control pump VOIR BROCHURE n°677777500L

Feedback connector KIT CONNECT. CAPT. CDE SA 007142212Z x3

Speed sensor connector KIT CONNECT. CAPT. TACHY 007142215C x1

Solenoid connector KIT CONNECT CDE SA 007142211X x1


600-bar PRESSURE SENSOR - 1/4G connector CAPT PRES 600b MH2 G 1/4’’ 003241171M

160-bar PRESSURE SENSOR - 1/4G connector CAPT PRES 160b MH2 G 1/4’’ 003241164E

600-bar PRESSURE SENSOR - 9/16 connector CAPT PRES 600b MH2 9/16’’ 003241170L

160-bar PRESSURE SENSOR - M10 connector CAPT PRES 160b MH2 M10 003241167H


Suspended pedal ELECTRIC-VERTICAL-PEDAL A13540S

Suspended pedal connector KIT CONNECT CAPT CDE SA 007142212Z

Floor pedal (provided with connector) ELEC-HORIZ-PEDAL-30°-DUAL A50838J

Joystick (provided with connector) JOYSTICK-35°-HANDLE-LOCK 003442799X

Rotary potentiometer ANGULAR-SENSOR-CABLE-MP-WP A13534L

Steering sensor connectorKIT CONNECTEUR CAPTEUR DE VIRAGE 007142222K

Linear potentiometer POTENTIOMETRE LINEAIRE ML10 003241108T


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Engine environment

Hydraulic motor environment

System studyTo simplify the integration of POCLAIN HYDRAULICS components into your system, our sales engineers investigate your specific needs.


12V engine actuator ACTIONNEUR E GAS 12V 005743902W

24V engine actuator ACTIONNEUR E GAS 24V 005743901V

Actuator connector KIT CONNECTEUR ACTIONNEUR 007142219G x1


T4 SENSOR 12-44 A22082C

Speed sensor T4 SENSOR 12-53 A22083D

T4 SENSOR 12-62 A22084E

M12 cable for speed sensor ELEC-CABLE-M12-180°-5000 A07468S x1

ELEC-CABLE-M12-90°-5000 A04999J x1

SmartDriveTM Premier System list of componentsModel code Part number

SmartDriveTM Premier connectors KIT CONNECTEUR SD PREMIER 0071422231U

Commercial codes and item numbers may change during the lifetime of the system. To have the latest update, please contact POCLAIN HYDRAULICS.


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INSTALLATIONMachine safety recommendations

Before installation

Be sure that the hydraulic system power source (engine) is stopped and that the battery is disconnected. • Do not proceed to installation on a hot or pressurized hydraulic system (accumulators must be purged).

During installation• Some hydraulic components are very heavy. Secure them with a lifting device of adequate capacity when installing on the machine frame.• During handling, protect all interface surfaces from shocks (piloting surfaces, studs, ports, connectors, plugs, etc.)• Ensure cleanliness of piloting and thrust surfaces of components and devices on the chassis before reassembly (no paint).• Never heat hydraulic fluid, as it may flame at high temperature. Some solvents are also flammable.• Do not smoke during installation.

Machine wiring recommendations.• All the cables must be encased in flexible metal or plastic sheaths;• All cables or sheaths must be held well in place and locked in to prevent pull-ou;• Bring the sheath supports close together;• The sheaths must be able to slide into the anchoring;• Avoid mechanical stresses in the cables;• Do not place the cables or sheaths close to moving or vibrating parts;• Do not lay the sheaths along sharp angles. Protect them at each bend;• Avoid laying the sheaths too close to high heat sources;• Use wires with abrasion-resistant sheaths;• Use cables that resist temperatures between 85°C and 105°C [ 185°F and 221°F ] close to heat sources;• Separate power cables from control cables;Pass the cables inside the machine, ensuring as much contact as possible with metal surfaces (steel). This will act as a shield against electromagnetic radiation.

Parking brake wiring recommendations

The machine manufacturer is responsible for safety mea-sures during the installation of our products. They must com-ply with applicable laws in the country or state.

Place the machine on the wheel blocks.Set up a safety area. Observe all personnel safety instructions.

Hot or pressurized hydraulic fluid may cause serious burns & infections to the human body. Consult a doctor in case of ac-cident.

If the box controls also the parking brake, you must IMPERATIVELY wire as shown opposite.

Warning: The switch used must-to be able to carry the current which circulates in the solenoid brake.

1- Exit orders parking brake.2- Entry On/Off sensor.3- Solenoid of parking brake (if supplied = brake).4- Switch of parking brake.5- Solenoid relay.

Is possible to use a switch which can not take the current, but that induces 2 constraints:• The diagram should be carried out as shown opposite (switch placed on the pilot circuit of SmartDrive™ Master and Premier).

• The driver of the machine cannot operate directly the parking brake, he must make sure that this one is well applied before leaving the machine.

INSTALLATION


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setting parametersThe commissioning involves the downloading of the software and parameters defined by the manufacturer and POCLAIN HYDRAULICS.However, a customized parameter setting is possible. To set them, use the PHASES Master software or the manual terminal.

Setting by the PHASES software:Install the PHASES software (see the 801378162C installation guide).Connect the calculator to the PC computer with the CABLE SD PC LT wire by connecting the SUBD9 wire of the PC to the communication connector of the calculator.For more information on the PHASES software, refer to its hot-line.

Setting by the manual terminalThe manual terminal only allows to modify the parameters directly in the calculator. You can't save any configuration under no circumstances.Connect the calculator to the hand handing terminal computer with the CABLE SD HHT LT wire by connecting the RJ11 wire of the HHT to the calculator's communication connector.To parameter the system by the hand held terminal, see the n° A06618T installation guide.

Checking the installation before starting up

Checking of the electrical environmentThe PHASES software enables you to view any anomalies detected by the SD Master ECU, by delivering an error code, a brief explanation and a list of possible causes. In particular, it indicates:• short-circuit type electrical anomalies on the ground, or the 5V,• cabling errors: switch allocated/not allocated to a given part,• input/output malfunctions.The portable HHT can also check these points without help files.

Hydraulic circuitCheck that the connection of the following components is in conformity with the hydraulic circuit diagram and with their respective installation and commissioning manuals.• valves;• hydraulic pump;• hydraulic motors.

Verification of hydraulic pump installation (clockwise rotation PV pump)

For further information, see PHASES™ user guide no. 801378162C and hand held terminal user guide no. A06618T.

The elements to be checked depend on the application of each vehicle. Please remember that each manufacturer is ul-timately responsible for checking their machinery at the end of the line.

The calibration can detect cable configurations (see next chapter).

The pressure drop in the hydraulic motor return circuits must not bring the pilot pressure in the valves below 20 bar [290 PSI].

The valve and motor drain piping must be connected di-rectly to the tank.

Pump 1 C motor (*) 2 C motor AxlePort A Port R Port R Port LPort B Port L Port A Port R* front left wheel of machine


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Electrical connexion: check the solenoid and feedback potentiometer connections to the pump against the electrical circuit diagram in the appendix of this brochure.

Checking of hydraulic pressures Fit the machine temporarily with pressure gauges and check the against the table below.

Pressure gauge Pressure Informationsbar [PSI]

1 0 - 4 [0 - 58] Pump case pressure2 0 - 450 [0 - 6 530] HP (high pressure) pressure supply3 0 - 4 [0 - 58] Motor case pressure4 0 - 450 [0 - 6 530] HP (high pressure) pressure supply5 0 - 40 [0 - 580] Charge pressure

Auxiliaries

Block diagram with dual displacement motors


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Starting up the engine

Put the F/N/R (Forward/Neutral/Reverse) shift lever in the neutral position. Apply the parking brake.Switch on the ECU.Start the engine, and wait until the charge pressure is established.

Start the engine again and then use the PHASES software in the input/output diagnostic module to check that the readings of the various sensors (switch, potentiometer sensors, etc.) are displayed correctly when you actuate them.

Checking the wiring of the engine actuator (option)When you press on the travel pedal, the actuator must rotate:• Clockwise (as seen from shaft end) for a clockwise connection;• counter-clockwise (as seen from shaft end) for a counter-clockwise connection.Check that the feedback signal from the actuator potentiometer sensor is increasing with voltmeter.

This checking can also be made using the HHT, from the calibration menu. The terminal gives a real-time display of the voltage and the actuator excitement sensor percentage.

Calibrating all the partsThis calibration can be carried out using either PHASES or the HHT. See their respective user manuals.

Activating pump displacementRelease the parking brake.Put the F/N/R shift lever (or switch or joystick) in the Forward Drive position.Gently depress the travel pedal; the wheels must turn slowly forward.

Check the pressure levels.

Checking the system’s specific functions on wheel blocks

The forward/reverse ground drive direction using the joystick or switch.

Return to neutral• Put the gear shift in neutral when in ground drive: the machine will decelerate in accordance with the programmed deceleration ramp.

Reversal• Reverse when in ground drive: the wheels of the machine will decelerate then accelerate in the opposite direction depending on the pedal position.

Braking• Test the parking brake: activating it deactivates the travel pedal.• Test the emergency brake by fully depressing the brake pedal.

Checking that the system works on wheelsRepeat the previous tests (except tests of braking).Test the functions that are specific to your application (anti-stall, cruise control, etc)

Place the machine on the wheel blocks.Set up a safety area. Observe all personnel safety instructions.

Press the emergency stop button and check that it stops the engine and cuts off power to the SD MASTER box.

Limit the wheel rotation speed to 10% of their maximum speed when the machine is on wheel blocks.

A functional check of the parking brake must be carried out each time it is used as an auxiliary brake (or emergency brake). For all vehicles capable of speeds over 25 km/hour, please contact your Poclain Hydraulics application engineer.


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FIRST LEVEL DIAGNOSTICFault warning lamp on dashboard:The warning lamp flashes in the event of a fault.Otherwise, it remains unlit.

Indicator lights on the box front face:These indicate the system status in real time.• If the vehicle is fit with a speed sensor, the green indicator lights flash at the wheel rotation frequency, enabling a diagnostic on this motors' speed sensor.• The indicator lights, orange if the vehicle is traveling or red if the vehicle is stationary, indicate a system failure. The malfunction is identified by an error code, represented in the table below.

1 2 3 4 Defaults Error code

No default -

5V supply 4

12V supply 3

Low battery power 2

Battery overpower 1

Warning lamp 15


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APPENDIXExample of electrical wiring

Please ask our technical department for the wiring of on/off sensor.

Engine actuator

Joystic / TP switch

Teach-in switch / Set-dec

Teachin switch / Res-Acc

Accumulator brake pressure

Parking brake switch

Engine RPM -

Engine RPM +

1C/ 2C Front axle

Pump 1

Solénoid 1

Solénoid 2

Feedback

Speed

Solénoid 1

Solénoid 2

FeedbackPump 2

1C/ 2C rear axle

Joystic

Road / Field

Cruise control

Travel pedale

High pressure sensor

Brake pressure sensor

PArking brake status

Cruise control status

Field / Road mode

Reverse lamp

Brake lamp

Battery

Key switch


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Advice concerning the electrical wiringMark out each wire with numbered plastic rings. Each wire must be securely held to the machine with clamps placed every 20 cm [7.87 in].

Sections are in mm² for a wire 10 meters long at operating temperature < 80°C [176 °F].

Key to table below:GND Analog inputs ASupply TOR inputs DSignal Frequency inputs F

Power outputs PH bridge outputs H

PinWire n° Pin

Wire n° Function Type Part

Section mm² [in²]

3 213 A 42 31 GND Battery (-) 1.5 [0.059]

5 301 R 41 32 GND Battery (-) 1.5 [0.059]

6 309 V 14 121 W Supply Battery (+) 1.5 [0.059]

7 304 S 13 122 W Supply Battery (+) 1.5 [0.059]

8 302 B

43

201 N Supply

5V

Pump 1 Feedback Potent 0.5 [0.020]

9 503 L 202 M Supply Pump 2 Feedback Potent. 0.5 [0.020]

10 504 O 203 A Supply Joystick 0.5 [0.020]

12 517 I 206 D Supply Travel pedal 0.5 [0.020]

13 122 W 207 E Supply High Pressure Sensor 0.5 [0.020]

14 121 W 208 F Supply Brake Pressure Sensor 0.5 [0.020]

15

251 N 209 X Supply Engine actuator Feed Back 0.5 [0.020]

252 M 29 509 X Signal H Engine actuator 0.75 [0.030]

253 A 33 211 N Signal A Pump 1 Feedback Potent. 0.5 [0.020]

256 D 34 212 M Signal A Pump 2 Feedback Potent. 0.5 [0.020]

257 E 3 213 A Signal A Joystick 0.5 [0.020]

258 F 17 216 D Signal A Travel pedal 0.5 [0.020]

259 X 31 217 E Signal A High Pressure Sensor 0.5 [0.020]

17 216 D 45 218 F Signal A Brake Pressure Sensor 0.5 [0.020]

18 507 J 32 219 X Signal A Actuator Feed Back 0.5 [0.020]

19 508 K 46 220 M Signal F Pump 2 Speed 0.5 [0.020]

20 303 C 47 221 M Signal F Pump 2 Speed 0.5 [0.020]

21 306 Q

15

251 N GND Pump 1 Feedback Potent. 0.5 [0.020]

22 308 U 252 M GND Pump 2 Feedback Potent. 0.5 [0.020]

23 954 M 253 A GND Joystick 0.5 [0.020]

24 952 N 256 D GND Travel pedal 0.5 [0.020]

25 901 N 257 E GND High Pressure Sensor 0.5 [0.020]

26 903 M 258 F GND Brake Pressure Sensor 0.5 [0.020]

27 904 N 259 X GND Engine actuator Feed Back 0.5 [0.020]

28 902 M 30 539 X GND H Engine actuator 0.75 [0.030]

29 509 X 5 301 R Signal D Parking brake switch 0.5 [0.020]

30 539 X 8 302 B Signal D Road/Field switch 0.5 [0.020]

31 217 E 20 303 C Signal D Cruise control switch 0.5 [0.020]

32 219 X 7 304 S Signal D Brake accumulator pressure 0.75 [0.030]

33 211 N 35 305 P Signall D Engine speed (+) 0.5 [0.020]

34 212 M 21 306 Q Signa D Engine speed (–) 0.5 [0.020]

35 305 P 36 307 T Signal D Cruise control speed increase 0.5 [0.020]

36 307 T 22 308 U Signal D Cruise control speed decrease 0.5 [0.020]

37 407 A 6 309 V Signal D Joystick /pedal switch 0.5 [0.020]


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38 408 A

44

351 R GND Parking brake switch 0.5 [0.020]

39

531 L 352 B GND Road/Field Switch 0.5 [0.020]

532 O 353 C GND Cruise control switch 0.5 [0.020]

533 G 354 S GND Accumulator brake pressure 0.5 [0.020]

535 L 355 P GND Engine speed (+) 0.5 [0.020]

536 O 356 Q GND Engine speed (–) 0.5 [0.020]

537 G 357 T GND Cruise control speed increase 0.5 [0.020]

538 H 358 U GND Cruise control speed decrease 0.5 [0.020]

40

541 I 359 V GND Joystick /pedal switch 0.5 [0.020]

543 J 37 407 A Signal D JoystickRev Switch Joystick 0.5 [0.020]

544 K 38 408 A GND Fwd Switch Joystick 0.5 [0.020]

545 I 44 457 A Signal D Fwd Switch Joystick 0.5 [0.020]

547 J 9 503 L Supply P Rear displacement shift 0.75 [0.030]

548 K 10 504 O Supply P Front displacement shift 0.75 [0.030]

41 31 - 32 54 506 G Supply P Parking Brake Lamp 0.75 [0.030]

42 31 18 507 J Supply P Reverse Lamp 0.75 [0.030]

43

201 N 19 508 K Supply P Stop lights 0.75 [0.030]

202 M 11 516 H Supply P Cruise Control Lamp 0.75 [0.030]

203 A 12 517 I Supply P Road/Field Mode Switch 0.75 [0.030]

206 D

39

531 L GND Rear displacement shift 0.75 [0.030]

207 E 532 O GND Front displacement shift 0.75 [0.030]

208 F 533 G GND Parking Brake Lamp 0.75 [0.030]

209X 535 L GND Reverse Lamp 0.75 [0.030]

44

351 R 536 O GND Brake Lamp 0.75 [0.030]

352 B 537 G GND Cruise Control Lamp 0.75 [0.030]

353 C 538 H GND Road/Field mode switch 0.75 [0.030]

354 S

40

541 I Supply P Road/Field mode lamp 0.75 [0.030]

355 P 543 J Supply P Reverse lamp 0.75 [0.030]

356 Q 544 K Supply P Brake lamp 0.75 [0.030]

357 T 545 I GND Road/Field Mode Switch 0.75 [0.030]

358 U 547 J GND Reverse lamp 0.75 [0.030]

359 V 548 K GND Brake lamp 0.75 [0.030]

457 A 25 901 N Signal Pump 1 S1 (+) 0.75 [0.030]

45 218F 28 902 M Signal Pump 1 S2 (+) 0.75 [0.030]

46 220 M 26 903 M Signal Pump 2 S1 (+) 0.75 [0.030]

47 221 M 27 904 N Signal Pump 2 S2 (+) 0.75 [0.030]

52 516 H 56 951 N Signal Pump 1 S1 (–) 0.75 [0.030]

54 506 G 24 952 N Signal Pump 1 S2 (–) 0.75 [0.030]

55 953 M 55 953 M Signal Pump 2 S1 (–) 0.75 [0.030]

56 951 N 23 954 M Signal Pump 2 S2 (–) 0.75 [0.030]

PinWire n° Pin

Wire n° Function Type Part

Section mm² [in²]


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More information on

Poclain Hydraulics reserves the right to make any modifications it deems necessary to the products described in this document without prior notification.The information contained in this document must be confirmed by Poclain Hydraulics before any order is submitted.Illustrations are not binding.The Poclain Hydraulics brand is the property of Poclain Hydraulics S.A.

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