Service Manual MUCKMASTER LHD Remote Control System

SERVICE MANUAL
MUCKMASTER LHD REMOTE

CONTROL SYSTEM
\\Hlsdow02\e\HLS Manuals\PDF\Service Manual MUCKMASTER LHD Remote Control System.doc

Revision # (3) November/2004
Created by Admin Department
Service Manual MUCKMASTER LHD Remote Control System
TABLE OF CONTENTS
Section One System Information
Warranty
System Specifications
Operators Manual
Commissioning and Diagnostic Procedures
Section Two Bills of Material, Drawings & Schematics

Bill of Material ASLHDS-2
Bill of Material ASLHDM-2
Bill of Material KITLHDDASH1
Bill of Material ASLHDS-2-11
Drawing # 1747
Drawing # LHD DRIVERBOARDdanphoss(LHD)
Drawing # SLAVEWIRING
Drawing # 3098
Drawing # 3081
Drawing # 11(Layout1)
Approved By: Ryan Siggelkow
Printed On: 11/26/04 4:07 PM
SECTION ONE
SYSTEM INFORMATION
Printed On: 11/26/04 4:07 PM
Page 1 of 13
HLS HARD-LINE SOLUTIONS INC.

WARRANTY
HLS HARD-LINE Solutions Inc. warrants its equipment and replacement parts to be free from
defects in material and workmanship for six months from delivery to the first user.
Defective parts returned to HLS during the warranty period will be repaired or replaced in its
discredtion unless exclusions apply. This HLS warranty does not include labour or shipping costs
associated with repair or replacement.
HLS-effected installations of its equipment form part of this warranty, but repair or replacement
will be limited to the individual component proven defective.
This warranty does not apply to equipment or parts found by HLS to have been damaged through
normal wear and tear, misuse, abuse, neglect, accident, or alterations not specifically authorized
by HLS. Wear and tear includes normal deterioration of moving parts, seals, and corrosion of
metal components.
This warranty does not include preventative maintenance, operating services, adjustments, and
inspections, which are the responsibility of the purchaser.
This warranty replaces all statutory and other warranties implied by law. Purchaser has
conducted its due diligence in choosing this HLS equipment and does not rely on any
representation of merchantability or fitness for purpose.
HLS HARD-LINE SOLUTIONS INC. SHALL IN NO EVENT BE LIABLE FOR
CONSEQUENTIAL OR INCIDENTAL DAMAGES ARISING FROM THE USE OF ITS
EQUIPMENT OR PRODUCTS.
Printed On: 11/26/04 4:07 PM
Page 2 of 13
SYSTEM OVERVIEW
Modern mining techniques rely extensively on radio remote control systems. Radio remote
controlled LHDs provide a safe and productive means to move large amounts of ore. The
complete radio remote control system has a Remote Unit and a Vehicle Unit. The control
package should be modular, compact, easy to work with, and adaptable to all types of
equipment, regardless of manufacturer. HARD-LINE Solutions MUCKMASTER control
package provides this solution.
FEATURES
MUCKMASTER control systems can be configured On/Off, proportional, or a combination
on any manufacturer's LHD, regardless of machine configuration. MUCKMASTER control
systems enhance safety and operating features by the use of a Microprocessor.
PROGRAMMABLE FEATURES
Operators are forced to follow set procedures when operating the radio remote controlled
LHD. The LHD will shutdown if the correct steps are not followed. MUCKMASTER control
systems force the operator to use safe operating procedures.
SYSTEM COMPONENTS
This system is made of four basic blocks:
1.
2.
3.
4.
Master Unit
Slave Unit
Hydraulic Interface
Electric Interface
1. Master Unit
Master Unit contains:
-
One Microprocessor
One 900 MHz Radio
One Enclosure
Master Unit LED Board
Mounting Plate
900 MHz Whip Antenna
One Driver Board
One Master Unit 10 Socket Connector Wiring Harness
One Master Unit 19 Socket Connector Wiring Harness
Connector(s) with LED
Printed On: 11/26/04 4:07 PM
Page 3 of 13
The components specifications following:

900 MHz Radio
Wireless Medium:
Operating Frequency Range:
Approvals:
Radio Data Rate:
Maximum Radio Data Rate:
Frequency Resolution:
Frequency Stability:
Chipping Rate:
Spread Ratio (Min / Max):
Processing Gain (Min / Max):
Output Power:
Sensitivity (@10-5 bit error rate):

Adjacent Channel Rejection:
Receive / Transmit Turnaround Time:
Modulation:
Direct Sequence Spread Spectrum Radio

902 - 928 MHz
US: FCC 15.247
up to 860 KBPS (FCC, CANADA)
1.35 MBPS (not FCC approved)
300 kHz
+/- 5 kHz
selectable up to 9.457 Mcps
5:1 / 50:1
11 dB / 17 dB
+26.5 dBm
450 mW
-95 dBm @ 215 KBPS, -87dBm @ 860 KBPS
23 dBc
1 ms
BPSK
Enclosure
Built with Aluminum die-cast

Captive stainless steel lid screws
Recessed neoprene gasket with tongue and groove construction is oil and petroleum
resistant Provide outstanding protection against dust, oil and pressurized water
Corrosion resistant
Temperature range of material in continuous use: -40C to +80C
Dimensions 5 x 8 x 3 inch ( 127 x 223 x 83 mm )
Mounting Plates with shock absorbers
DIN 40050 Standards
ISO 9001 Specifications
2. Slave Unit
Slave Unit contains:
-
One Microcontroller
Two Joysticks
One 900 MHz Radio
One auxiliary Board
One Antenna Board
Four On/Off Switches
Three Momentary On Switches
One Mushroom Switch
One Enclosure
One Skid Plate
Slave Unit LED Board
Printed On: 11/26/04 4:07 PM
Page 4 of 13
The components specifications following:

900 MHz Radio
Wireless Medium:
Operating Frequency Range:
Approvals:
Radio Data Rate:
Maximum Radio Data Rate:
Frequency Resolution:
Frequency Stability:
Chipping Rate:
Spread Ratio (Min / Max):
Processing Gain (Min / Max):
Output Power:
Sensitivity (@10-5 bit error rate):

Adjacent Channel Rejection:
Receive / Transmit Turnaround Time:
Modulation:
Direct Sequence Spread Spectrum Radio

902 - 928 MHz
US: FCC 15.247
up to 860 KBPS (FCC, CANADA)
1.35 MBPS (not FCC approved)
300 kHz
+/- 5 kHz
selectable up to 9.457 Mcps
5:1 / 50:1
11 dB / 17 dB
+26.5 dBm
450 mW
-95 dBm @ 215 KBPS, -87dBm @ 860 KBPS
23 dBc
1 ms
BPSK
Enclosure
Built with Polyester

The foamed gasket are bound to the groove and have an exceptionally low compression set,
The gasket is resistant to chemicals and a wide temperature range.
Excellent Impact Resistance
Excellent Corrosion Resistance
Dimensions 13.4 x 6.3 x 3.9 inch (340 x 160 x 100 mm)
Aluminum Skid Plate
VO Flammability Rating
ISO 9001 Specifications
3. Hydraulic Interface
-
Hydraulic Manifold(s)
On/Off Cartridge(s)
Proportional Cartridge(s)
Slave Cylinders (if necessary)
4. Electric Interface
-
One Selector Switch c/w contact blocks

Relay(s) 12Vdc or 24Vdc
Throttle interface 12 or 24Vdc PWM input to 5Vdc output or 10Vdc output (optical isolation)
Printed On: 11/26/04 4:07 PM
Page 5 of 13
INTRODUCTION:
Modern mining techniques rely extensively on radio remote control systems. Radio
remote controlled LHDs provide a safe and productive means to move large amounts
of ore. The complete radio remote control system consists of a Joystick Unit and a
Vehicle Unit. Both the Joystick Unit and the Vehicle Unit are in constant 2-way
communication. The control package should be compact, modular, easy to work with,
and adaptable to all types of equipment, regardless of manufacturer. HARD-LINE
Solutions MUCKMASTER control package provides this solution.
FEATURES:
MUCKMASTER control systems can be configured as On/Off, proportional, or a

combination of both on any manufacturer's LHD, regardless of machine configuration.
MUCKMASTER control systems enhance safety and operating features by the use of
a Microprocessor.
PROGRAMMABLE FEATURES:
Operators are forced to follow set procedures when operating the radio remote
controlled LHD. The LHD will shutdown if the correct steps are not followed.
MUCKMASTER control systems force the operator to use safe operating procedures.
INSTALLATION:
The MUCKMASTER is modular and designed for quick installation. A modular

interconnecting system is incorporated to simplify electrical and hydraulic solenoid
connections.
DIAGNOSTIC INDICATORS:
There are indicators at critical points in the system, including inside the radio and in
the MUCKMASTER control package. Indicators on the MUCKMASTER control box
provide status on the machine operating mode, the engine, and the brake systems.
With minimum training, operators or maintenance personnel can use the indicators
to quickly find the source of a malfunction and provide reliable information to
management.
PROGRAMMED SAFETY FEATURES:
Listed below are the main features that are programmed as standard operating
procedures in MUCKMASTER control systems.
Printed On: 11/26/04 4:07 PM
Page 6 of 13
OPERATING PROCEDURES:
MANUAL TO REMOTE MODE:
Drive the LHD to the draw point.

Bring the LHD to a complete stop near remote operators station.
Put the LHD manual gear selector into NEUTRAL position.
Apply the LHD park brake.
Switch MANUAL / REMOTE SELECTOR to REMOTE position. *Note: The LHD
will continue to run for 60 seconds. The LHD is now under automatic control and
special attention must be given to safe operating procedures.
Leave the LHD and proceed to remote operators station.
Turn the Joystick Unit SYSTEM POWER switch to ON position. *Note: Ensure
the EMERGENCY STOP mushroom switch is in the UP position and the park
brake switch is in the applied or on position.
The LHD is now in radio remote control mode. Proceed with mucking operation.
The LHD will shut down if:

The LHD manual gear selector is not in NEUTRAL and the MANUAL / REMOTE
SELECTOR is switched to REMOTE.
The LHD park brake is not applied and the MANUAL / REMOTE SELECTOR is
switched to REMOTE.
The Joystick Unit SYSTEM POWER switch is ON when the MANUAL / REMOTE
SELECTOR is switched to REMOTE.
The Joystick Unit SYSTEM POWER switch is not turned to ON within 60
seconds.
The Joystick Unit SYSTEM POWER switch is turned ON and the Joystick Unit
PARK BRAKE switch is OFF (released).
RADIO TO MANUAL MODE:
Bring the LHD to a complete stop near remote operators station.

Put the Joystick Unit FORWARD / REVERSE joystick into neutral position.
Switch the Joystick Unit PARK BRAKE switch to the Applied or ON position.
Toggle the Joystick Unit DELAYED SHUTDOWN switch.
Switch the Joystick Unit SYSTEM POWER switch to OFF position. *Note: The
LHD will continue to run for 60 seconds. The LHD is now under automatic control
and special attention must be given to safe operating procedures.
Leave remote operators station and proceed to the LHD.
Switch the MANUAL / REMOTE SELECTOR to MANUAL position.
The LHD is now in manual control mode. Proceed with haul dump operation.
The LHD will shut down if:

The Joystick Unit EMERG. STOP mushroom switch is depressed.
The Joystick Unit SYSTEM POWER is turned OFF without toggling the
DELAYED SHUTDOWN switch.
The Joystick Unit PARK BRAKE is not applied (ON) before toggling the DELAYED
SHUTDOWN switch.
The Joystick Unit FIRE SUPPRESS switch is activated.
The MANUAL / REMOTE SELECTOR switch is not turned to MANUAL position
within 60 seconds.
Printed On: 11/26/04 4:07 PM
Page 7 of 13
REMOTE CONTROL MODE FUNCTIONS:
While in remote mode the following functions are available to the operator: Remote
start function with park brake interlock - The park brake toggle on the Joystick Unit
must be in ON position to start the machine.
E-Stop function Shuts down the engine, stops the machine and applies the
brakes when the E-stop function is activated.
Delayed shutdown - Allows the machine to run for a predetermined time (60
seconds) before the engine is shutdown. This feature is used when changing from
remote to manual mode.
Service brake application - They are applied automatically after half a second delay
when the left hand joystick is in NEUTRAL position.
Service brake application - They can be applied as required using the toggle switch
on top of the right hand joystick.
Forward/Reverse park brake interlock - The control system will not allow the
transmission to go into forward or reverse with the park brake switch on the
Joystick Unit in the Applied or ON position.
Engine Start - apply the park brake and press the start button until engine is
running.
The front and rear lights on the LHD can be turned on or off from the light switch on
the Joystick Unit.
Engine throttle - The engine throttle can be controlled proportionally from the
Joystick Unit. The engine speed increases as the left-hand joystick is moved from
the NEUTRAL position. Applying the Park Brake and moving the left-hand joystick
to the top or bottom can activate engine throttle proportionally while maintaining a
parked LHD.
Forward/Reverse - The directions are obtained by moving the left-hand joystick in
the direction as indicated.
Steering - The steering functions are activated by moving the left-hand joystick left
to right.
Boom and bucket functions are activated using the right hand joystick.
Fire suppression - The fire suppression is activated by the toggle switch on the
Joystick Unit. When the fire suppression switch is activated and maintained for
three seconds the park brake and service brakes are applied, the engine is shut off
with the transmission in neutral. The switch must be held for 3 seconds to activate
the fire suppression output.
Printed On: 11/26/04 4:07 PM
Page 8 of 13
EMERGENCY STOP:
Press down on the Joystick Unit EMERG. STOP switch. * Note: The LHD
will shift into NEUTRAL, park and service brake will activate, and engine
will shut down immediately.
SYSTEM POWER SWITCH SHUTDOWN:
Switch the Joystick Unit SYSTEM POWER switch to OFF position.

* Note: The LHD will shift into NEUTRAL, park and service brake will
activate, and engine will shut down immediately.
JOYSTICK UNIT TILT SHUTDOWN:
If the Joystick Unit is tilted over for one-quarter of a second. * Note: The
LHD will shift into NEUTRAL, park and service brake will activate, and
engine will shut down immediately.
FIRE SUPPRESSION SHUTDOWN:
Pull pin and hold the Joystick Unit FIRE SUPPRESS switch for 3 seconds.
* Note: The LHD will shift into NEUTRAL, park and service brake will
activate, engine will shut down immediately, and fire suppression will
activate.
To reset system, the Joystick Unit system power has to be switched off and
then on.
DUAL VALVE BRAKE SYSTEM:
The MUCKMASTER LHD Radio Remote Control System uses a Dual

Valve Brake system. This means that there are two brake valves that work
independently of each other. In the even that one brake fails, the other
brake can be used to safely stop the LHD.
PARK BRAKE VALVE:
The Park Brake Switch activates the Park Brake Valve to release the Park
Brakes when the switch is in the OFF position. When the Park Brake switch
is moved to the ON position, the Park Brake Valve applies the brakes.
SERVICE BRAKE VALVE:
The Service Brakes can be applied by using the Service Brake Switch on
top of the right hand joystick or by allowing the left hand joystick go to the
neutral position. The brakes will apply after a half second delay when the
joystick is in neutral or immediately when pressing the switch. This valve is
the Service Brake Valve.
OPERATOR TRAINING:
The operating procedures, as outlined by the manufacturers of the RRC

and LHD control package, and the mine site, must be completely
understood by the operator. Machine downtimes can be minimized if both
operator and service personnel have had the proper training on the
complete remote control system. Training services are available from
HARD-LINE Solutions Inc.
Printed On: 11/26/04 4:07 PM
Page 9 of 13
INDICATOR LIGHTS FOR THE MASTER UNIT (VEHICLE UNIT):

Power on - Indicates that the voltage is sufficient.
Ready - Indicates that the LHD park brake is applied, that the transmission is in
neutral and the selector switch is selected remote
Link - Indicates that Vehicle Unit and Joystick Unit are communicating
Diagnostics Light will turn on when:
a) The LHD Park Brake has not been applied.
b) The LHD transmission is not in Neutral before switching from Manual to
Remote
c) The Manual/Remote switch is defective.
Correct any of the above conditions and reselect Remote
INDICATOR LIGHTS FOR THE SLAVE UNIT (JOYSTICK UNIT):
Power on - Indicates that the voltage is sufficient. Flashing or cycling lights
indicates insufficient supplied voltage.
Link - Indicates that Slave Unit and Master Unit are communicating
Diagnostics Light will turn on when:
a) The Delayed Shutdown feature is activated.
b) The Joystick unit is tilted over for more than one-quarter of a second while
in Link.
c) The switch closure test is performed.
d) The Joystick Unit is powered up before switching from Manual to Remote.
e) The LHD Park Brake is not applied and or the transmission is not in
Neutral before switching from Manual to Remote.
f) The switches on the Joystick Unit are not in their safe power up positions
when turning Joystick Unit on.
Correct any of the above conditions and reapply power to the Slave unit.
Printed On: 11/26/04 4:07 PM
Page 10 of 13
GUIDELINES TO FOLLOW FOR REMOTE CONTROL SAFETY:

a) Always work with SAFETY FIRST in mind at all times.
b) Always do a pre-check of the LHD for proper operation in Manual and also in Remote. Be
sure of proper brake application in Manual and that the service brakes work properly in
Remote. NOTE: If a problem exists in Manual control it will also exist in Remote control. If
any problems exist in manual, especially brakes, LHD must be serviced before operating in
remote control.
c) Never turn your attention away from a remote operated machine unless it is stopped and the
brakes are applied.
d) Never operate remote control equipment if you are not trained. Advise the training
department that you need training and this can be set up with HLS.
GUIDELINES TO FOLLOW FOR REMOTE CONTROL CARE:
a)
b)
c)
d)
e)
Never carry Slave unit by the joysticks. They are not built for such a purpose.
Do not wash the Slave unit or Master unit when washing the LHD.
Never boost or weld on LHD without disconnecting the Vehicle Unit.
Do not carry any HLS RRC equipment in the bucket of the LHD.
Do not continue to use RRC package if in ill repair and/or the RRC Slave or Master unit is not
functioning properly. Advise any maintenance staff and the equipment will be repaired.
f) Be sure to use the proper antennas for each application, 900MHz whip for Master and if
Slave unit is modified for external antenna. Use 2.4GHz antenna for the video unit only.
g) Check to verify that all antenna connections are solid, center pin is not pulled back, and that
cables are in good order.
h) If using batteries to power Slave unit, be sure to use a fully charged battery before each shift.
If using power brick adapters, make sure power cables are in safe condition and have not
been modified in any way. The Slave unit operates on 5vdc only.
Printed On: 11/26/04 4:07 PM
Page 11 of 13
MUCKMASTER OPERATOR TRAINING

TEST - A
1. As part of the required pre-operation check, the operator should always make sure that:
A) All remote control components are secure
B) There are no oil leaks at any hoses or hydraulic manifolds
C) All functions on Joystick Unit are operational
D) All the above
2. Guidelines for safe operation of the remote control unit are established by:
A) The safest way possible
B) The fastest way possible
C) The safety standards establish at the mine site
D) As the operator sees fit
3. Before leaving the machine to operate in remote, the operator should always:
A) Place wheel chocks under the wheel
B) Apply park brake; engage transmission in first gear and shutdown LHD
C) Apply park brake, place transmission in neutral, and turn the selector switch to
the remote position
D) Apply the park brakes, turn the LHD off and change the selector switch to the
remote position
4. When the green indicating lights on the master unit and dash are illuminated this means that.
A) The Joystick and Vehicle Units are operating correctly
B) The batteries in the Vehicle Unit need changing
C) The LHD is functioning properly
D) There is a fault with one of the components
5. The unattended Joystick unit feature means that: When the Joystick unit is left on, and the
selector switch is turned from the manual to the remote position:
A) The Vehicle Unit will only shut off the engine
B) The Vehicle Unit will apply the brakes and then shut engine off
C) The Vehicle Unit will apply the brakes until the operator releases them with
the Joystick Unit
D) The Joystick Unit is lost and a warning lamp will flash
6. The main purpose of the master unit is to:
A) Monitor the brakes
B) Verify that the LHD is running
C) Aid the troubleshooting process in case of remote breakdown
D) Control front and rear lights
7. The service brake is activated automatically by:
A) Moving the direction joystick back to the center position
B) Using the park brake switch on the slave unit
C) Pressing down the emergency stop button
D) Using the toggle switch on the top of the joystick
Printed On: 11/26/04 4:07 PM
Page 12 of 13
8. When welding or boosting on the LHD, you should always:

A) Disconnect the battery
B) Turn the Joystick Unit off
C) Turn the remote switch to manual
D) Disconnect the dash cable (and DDEC if applies)
9. During a delayed shutdown how much time is the operator permitted to return the LHD to
manual mode.
A) 10 seconds
B) 10 minutes
C) 60 seconds
D) 30 seconds
10. The LHD will start only in remote if:
A) The Joystick Unit power is on, the emergency stop button is in the down
position, the park brake switch is in the on position, and the LHD is in neutral
B) The Joystick Unit power is on, the emergency stop button is in the up position,
the park brake switch is in the on position, and the LHD is in neutral
C) The joystick unit's power is on, the emergency stop button is in the up
position, the park brake switch is in the off position, and the LHD is in neutral.
D) The Joystick Unit power is off, the emergency stop button is in the up position,
the park brake switch is in the on position, and the LHD is in neutral
11. The fire suppression system can be activated remotely by:
A) Voice
B) Running to the machine and activating the manual actuator
C) Removing the fire suppression retaining pin and activating the toggle switch
on the Joystick Unit for three (3) seconds
D) All the above
12. When remote mucking is performed the operator is allowed to:
A) Work from the LHDs bucket
B) Stand beside the LHD
C) Follow the LHD so you can see better
D) None of the above
Printed On: 11/26/04 4:07 PM
Page 13 of 13
MUCKMASTER OPERATOR TRAINING

TEST - B
1. The operator must be trained to understand the basic principles of the remote control
package.
TRUE
FALSE
2. The remote system has only one way to apply brakes.

TRUE
FALSE
3. When the selector switch is moved to the remote position, the operator has 60 seconds to turn
the Joystick Unit on.
TRUE
FALSE
4. If the park brake switch on the Joystick Unit is in the on position (i.e. brakes applied), the
transmission will not engage in forward or reverse.
TRUE
FALSE
5. If the park brake switch on the Joystick Unit is in the off position (i.e. brakes released), the LHD
will not start in remote mode.
TRUE
FALSE
6. Remote mucking is done in the second gear.

TRUE
FALSE
7. The remote control unit has no distance limitations.

TRUE
FALSE
8. Before any welding or boosting is done on a machine, the dash cable must be disconnected
from the machine control unit (Vehicle unit).
TRUE
FALSE
9. The green light on the dash is used to verify proper communication between the Joystick Unit
and Vehicle unit.
TRUE
FALSE
Printed On: 11/26/04 4:07 PM
1 LHD Radio Remote Control Commissioning and Troubleshooting
Page 1 of 35
HLS HARD-LINE Solutions Inc.

LHD Radio Control System
Commissioning and Diagnostics Procedures
1998 HLS HARD-LINE Solutions Inc.
Revised 2001-04-04
CONTENTS:
Safety considerations when commissioning / troubleshooting.
Terminology
Description of remote control interlocks and timeouts
Radio control overview
Commissioning procedures
Troubleshooting guide
APPENDICES:
Vehicle Unit connector pin-outs
Joystick Unit controls
Joystick Unit control SAFE positions
Proportional output scaling table
Proportional control output measurements
Commissioning checklist
Problem report form
Revision history
Revised 2001-04-04
Printed 2001-04-04 at 4:20PM
Page 2 of 35
Safety considerations when commissioning / troubleshooting.

The following safety considerations are presented in no particular order. These considerations
are in addition to any government regulations and/or company policies regarding the safe
operation of radio controlled vehicles.
NEVER OPERATE A RADIO CONTROL VEHICLE WITHIN A SERVICE BAY OR GARAGE.

Radio Control commissioning checks should be conducted in a reasonably level, open area.
No other Radio Control vehicles should be in operation near the LHD during commissioning.
The operator conducting commissioning tests should be qualified to operate the LHD and
understand the principles & safety considerations regarding Radio Remote Control vehicle
operation.
The operator should conduct commissioning tests while in the operators cab in order to take
manual control in case of an emergency.
Observers should maintain a safe distance from the LHD.
Fire suppression squib should be disconnected to safely perform the fire suppression
commissioning tests.
Verify that wheel chocks are in place
Terminology
LHD - Load Haul Dump (LHD)
Vehicle Unit the MUCKMASTER control box which plugs into the LHD via 10- and 19-pin
CANON bayonet connectors.
Joystick Unit the radio control box, which the operator uses to control the LHD when it is in
radio remote control.
Radio Control System the Vehicle and Joystick Unit pair.
Radio Control Link the two-way communication link which is maintained between the Vehicle
and Joystick Units.
HIGH Input any input voltage levels above 5 volts.
LOW input any input voltage level below 2 volt.
Continuity resistance measurement under 2 ohms.
Open Circuit any resistance measurement over one Megaohms.
D/H Indicates boom up, down & bucket roll, dump functions
Revised 2001-04-04
Printed 2001-04-04 at 4:20PM
Page 3 of 35
Description of remote control interlocks and timeouts

Engine Start interlock
Start switch will only be processed when the Joystick Unit controls are in their SAFE RESTART
positions.
Delayed Shutdown interlock
Delayed shutdown switch will only be processed when the Joystick Unit controls are in their
SAFE SHUTDOWN positions. When the Delayed shutdown switch is released, the operator has
three (3) seconds to turn off the Joystick Unit. When the Joystick Unit is turned off within this time,
only the RUN output (CANON-19 pin E) is held high. If the Joystick Unit is still on after three (3)
seconds, the delayed shutdown request is cancelled. Turning off the Joystick Unit after canceling
the delayed shutdown request will shut the LHD down as if the emergency stop was pressed.
Unattended Vehicle Timer
When the Delayed shutdown switch is processed, the operator has 60 seconds to board the LHD
and switch from REMOTE to MANUAL control. The Vehicle Unit will hold the RUN output
(CANON-19 pin E) high for this time. When the 60 seconds has elapsed, the LHD will shut down.
Unattended Remote Timer
When the MANUAL/REMOTE switch is turned from the MANUAL to the REMOTE position, the
RUN output (CANON-19 pin E) is held HIGH to keep the engine running. The operator then has
60 seconds to turn on the Joystick Unit and establish a control link. If a control link is not
established in this time, the engine will shut down. After this time, control can still be established,
but it will be necessary to restart the LHD.
Unattended Remote Standby Timer
When the radio control link is broken, the Vehicle Unit will stay in its ACTIVE STATE and attempt
to reestablish the control link for 90 seconds. After 90 seconds, the Vehicle Unit will enter a
SLEEP state. Turning on the Joystick unit will restore the Vehicle Unit to the ACTIVE STATE.
Forward/Reverse Park Brake interlock
The LHD will only go into forward and reverse when the park brake is released.
Neutral Service Brake interlock
The LHD service brake is only released when its transmission is set to forward or reverse. When
the direction is returned to neutral, the service brake will be applied after one half second delay.
Manual to remote interlock
When the operator is ready to remotely operate the LHD, he MUST first apply parking brake
and place transmission to neutral position before selecting remote. If the operator does not
the LHD will shutdown automatically. The operator will not be able to continue until fault
conditions are cleared.
Revised 2001-04-04
Printed 2001-04-04 at 4:20PM
Page 4 of 35
Commissioning procedures
Perform each test in the Commissioning Checklist in order.
Place a check in the PASS or FAIL column when each test is completed.
When performing a test, follow the steps in the order indicated.
Example
*** COMMISSIONING EXAMPLE ***
One or more items from the checklist which are tested during this procedure.
Name of Test Procedure
Description of test.
ACTION
1
Action to be taken in step 1
OBSERVATION
Output is HIGH
2
;

*** COMMISSIONING EXAMPLE completed ***
Check the PASS column of this item before proceeding to do the next step
Step 1
Step 2
Output is LOW
Troubleshooting
When a problem occurs in step 1, this box lists possible causes and tests to perform:
Output is LOW: The voltage measured between the output and chassis ground is
below 6 volts.
Output is HIGH: The voltage measured between the output and chassis ground is
within 2 volts of the input voltage.
Revised 2001-04-04
Printed 2001-04-04 at 4:20PM
Page 5 of 35
*** REMOTE SELECT SWITCH FUNCTION TEST ***

Remote Select Switch Function Test Procedure
This test verifies that the remote select switch functions properly.
High remote select input places the LHD in remote control mode.
Low remote select input places the LHD in manual control.
ACTION
Switch MANUAL / REMOTE SELECTOR to MANUAL position.
1
2
3
4
;
5
OBSERVATION
READY light OFF
DIAG. light OFF
Apply LHD manual park brake.
READY light OFF
DIAG. light OFF
Put LHD manual gear selector into NEUTRAL position.
READY light OFF
DIAG. light OFF
Switch MANUAL / REMOTE SELECTOR to REMOTE position.
READY light ON
DIAG. light OFF
*** REMOTE SELECT SWITCH FUNCTION TEST completed ***
Step 1
Step 2
Step 3
Troubleshooting
READY light ON: Check that the Remote Select input (CANON-19 pin S; Blue wire) is
LOW when MANUAL / REMOTE SELECTOR is in MANUAL position.
READY light ON: Verify that the Park Brake Confirm input (CANON-19 pin U - Orange
wire) is HIGH when LHD park brake is applied.
READY light ON: Verify that the Neutral input (CANON-19 pin T; Black/White wire) is
HIGH when MANUAL / REMOTE SELECTOR is in REMOTE position.
Revised 2001-04-04
Printed 2001-04-04 at 4:20PM
Page 6 of 35
*** PARK BRAKE STATUS INPUT TEST ***

Park Brake Status Input Test Procedure
This test verifies that the park brake status input functions properly.
High park brake status input indicates that the LHDs manual park brake is applied.
Low park brake status input indicates that the LHDs manual park brake is released.
The radio control link requires the manual park brake be applied when the LHD is switched from
manual to remote control.
ACTION
OBSERVATION
1
2
3
4
Release LHD park brake.
READY light OFF
DIAG. light OFF
5
READY light OFF
DIAG. light ON
6
READY light ON
DIAG. light OFF
;
*** PARK BRAKE STATUS INPUT TEST completed ***
7
Step 5
Step 6
Troubleshooting
READY light ON:
1) Verify that the Park Brake Confirm (CANON-19 pin U; Orange wire) is LOW
when LHD park brake is released.
2) Perform the Neutral Status Input Test.(Pg. 7)
DIAG. light ON:
1) Perform the Remote Select Switch Function Test.(Pg. 5)
Revised 2001-04-04
Printed 2001-04-04 at 4:20PM
Page 7 of 35
*** NEUTRAL STATUS INPUT TEST ***

Neutral Status Input Test Procedure
This test verifies that the neutral status input functions properly.
High neutral status input indicates that the LHDs manual gear selector is in neutral.
Low neutral status input indicates that the LHDs manual gear selector is not in neutral.
The radio control link requires the manual gear selector be in neutral when the LHD is switched
from manual to remote control.
ACTION
OBSERVATION
1
2
3
4
Put LHD manual gear selector into FORWARD position.
READY light OFF
DIAG. light OFF
5
READY light OFF
DIAG. light ON
6
READY light ON
DIAG. light OFF
7
READY light OFF
DIAG. light OFF
8
Put LHD manual gear selector into REVERSE position.
READY light OFF
DIAG. light OFF
9
READY light OFF
DIAG. light ON
10 Put LHD manual gear selector into NEUTRAL position.
READY light ON
DIAG. light OFF
;
*** NEUTRAL STATUS INPUT TEST completed ***
11 Switch MANUAL / REMOTE SELECTOR to MANUAL position.
READY light OFF
DIAG. light OFF
Step 5
Step 6
Step 9
Step
10
Troubleshooting
READY light ON:
1) Verify that the Neutral Confirm (CANON-19 pin T; Black/White wire) is LOW when
manual gear selector is set to FORWARD position.
2) Perform the Park Brake Status Input Test.(Pg. 6)
DIAG. light ON:
3) Verify that the Neutral Confirm (CANON-19 pin T - Black/White wire) is HIGH when
manual gear selector is set to NEUTRAL position.
READY light ON:
1) Verify that the Neutral Confirm (CANON-19 pin T; Black/White wire) is LOW when
manual gear selector is set to REVERSE position.
2) Perform the Park Brake Input Test.(Pg. 6)
DIAG. light ON:
3) Verify that the Neutral Confirm (CANON-19 pin T; Black/White wire) is HIGH when
manual gear selector is set to NEUTRAL position.
Revised 2001-04-04
Printed 2001-04-04 at 4:20PM
Page 8 of 35
*** UNATTENDED VEHICLE TIMEOUT TEST ***

Unattended Vehicle Timeout Test Procedure
This test verifies that the LHD will shut down if the Joystick Unit does not establish a radio
control link within the 60-second timeout.
ACTION
OBSERVATION
1
2
3
Manually start the LHD.
Set MANUAL / REMOTE SELECTOR to REMOTE position.
4
READY light ON
Engine continues
to run.
5
Wait for 60-second control link timeout to expire.
Engine shuts
down.
;
*** UNATTENDED VEHICLE TIMEOUT TEST completed ***
Set MANUAL / REMOTE SELECTOR to MANUAL position.
6
Step 4
Step 5
Troubleshooting
Engine shuts down:
1) Check that the Run output (CANON-19 pin E; Blue/Red wire) has not been tied
LOW or disconnected.
2) Perform the Park Status Input Test.(Pg. 6)
4) Verify if the Joystick unit is powered up before the Manual/Remote Selector is
switched to the Remote position.
Engine does not shut down:
1) Check that the Run output (CANON-19 pin E; Blue/Red wire) has not been tied
HIGH between the Normally Open switch (Manual/Remote Selector) and the
Engine Shutdown Solenoid or DDEC Shutdown Input.
2) Check that the Normally Open switch (Manual/Remote Selector) opens the
Shutdown circuit between the Key Switch and the Engine Shutdown Solenoid or
DDEC Shutdown Input.
Revised 2001-04-04
Printed 2001-04-04 at 4:20PM
Page 9 of 35
*** JOYSTICK UNIT POWER SWITCH TEST ***

Joystick Unit Power Switch Test Procedure
This test verifies that the Joystick Unit power switch is functioning and that it is able to turn on.
ACTION
OBSERVATION
1
Set Joystick Unit PARK BRAKE switch to APPLIED or ON
2
position.
Turn the Joystick Unit POWER switch to ON position.
3
POWER light ON
Turn the Joystick Unit POWER switch to OFF position.
4
POWER light
OFF
;
*** JOYSTICK UNIT POWER SWITCH TEST completed ***
Step 3
Troubleshooting
POWER light is not ON:
1) The EMERGENCY STOP mushroom switch is in the DOWN position.
2) The CAP LAMP battery or POWER SUPPLY is not connected.
3) See the Joystick Unit Wiring schematic for any breaks or shorts in the Power Up
circuit.
Revised 2001-04-04
Printed 2001-04-04 at 4:20PM
Page 10 of 35
*** JOYSTICK UNIT TILT SWITCH TEST ***

Joystick Unit Tilt Switch Test Procedure
This test verifies that the joystick unit recognizes when it has been tilted.
When the joystick unit is tipped over for more than 2 seconds the control link is terminated, the
LHD will shut down and the brakes will apply.
ACTION
OBSERVATION
1
2
3
4
Manually start the LHD.
5
READY light ON
Engine continues
to run.
6
position.
7
POWER light ON
LINK light ON
8
Tip Joystick Unit on its side. Wait for two (2) seconds.
DIAG light ON
Engine shuts
down.
9
Return Joystick Unit to the upright position.
DIAG light ON
;
*** JOYSTICK UNIT TILT SWITCH TEST completed ***
10 Turn the Joystick Unit POWER switch to OFF position.
Step 8
Step 9
Troubleshooting
DIAG light OFF/ Engine continues to run: Return the radio control to the service depot
for servicing.
DIAG light OFF: Return the radio control to the service depot for servicing.
Revised 2001-04-04
Printed 2001-04-04 at 4:20PM
Page 11 of 35
*** JOYSTICK UNIT SWITCH CLOSURE TEST ***

Joystick Unit Switch Closure Test Procedure
This test verifies all switch closures for all the functions on the Joystick Unit.
ACTION
1
2
position.
Set Joystick Unit FRONT LIGHTS switch to OFF position.
3
Set Joystick Unit REAR LIGHTS switch to OFF position.
4
5
Tip Joystick Unit on its side.
Turn the Joystick Unit POWER switch to ON position.(Wait 2 or 3
6
seconds)
7
Return Joystick Unit to the upright position.
Repeat steps 8 to 9 for each of the following control positions:
8
9
;
10
OBSERVATION
DIAG light ON
DIAG light OFF
Set Joystick Unit PARK BRAKE switch to RELEASED or OFF

position.
Hold down Joystick Unit DELAYED SHUTDOWN switch.
Set Joystick Unit FRONT LIGHTS switch to ON position.
Set Joystick Unit REAR LIGHTS switch to ON position.
Hold down Joystick Unit START switch.
Hold down Joystick Unit FIRE switch.
Hold down Joystick Unit left FULL BRAKE switch.
Hold down Joystick Unit right FULL BRAKE switch.
Move Joystick Unit right joystick to BOOM DOWN position.
Move Joystick Unit right joystick to BOOM UP position.
Move Joystick Unit right joystick to BUCKET ROLL position.
Move Joystick Unit right joystick to BUCKET DUMP position.
Hold down Joystick Unit FULL THROTTLE switch.
Hold down Joystick Unit HALF THROTTLE switch.
Move Joystick Unit left joystick to FORWARD position.
Move Joystick Unit left joystick to REVERSE position.
Move Joystick Unit left joystick to STEER LEFT position.
Move Joystick Unit left joystick to STEER RIGHT position.
Tip Joystick Unit on its side.
Set the control to the indicated position.
DIAG light ON
Restore the control to its previous position.
DIAG light OFF
*** JOYSTICK UNIT SWITCH CLOSURE TEST completed ***
Step 7
Step 8
Step 9
Troubleshooting
DIAG light ON:
Continue test but look for the control that leaves the DIAG light ON in step 9. If no
control leaves the DIAG light ON, then one of the controls may have been improperly
set at the start of the test. If all controls appear to be set correctly, then one of the
toggle switches may have been spun around 180.
DIAG light OFF:
1) Control that was tested was in its initial control test position.
2) Two or more controls are not in their initial control test position.
3) Check for a break or short in the Joystick Unit for the control being tested.
DIAG light ON:
1) One control is not in its initial test position.
2) If the DIAG light was ON in step 8, check for a break or short in the Joystick Unit
for the control just tested.
Revised 2001-04-04
Printed 2001-04-04 at 4:20PM
Page 12 of 35
*** CONTROL LINK TEST ***

*** JOYSTICK UNIT POWER UP SWITCH TEST ***
Control Link Test Procedure
This test verifies that the radio control link will not be established until all controls are set in their
SAFE POWERUP positions when the Joystick Unit is turned on.
ACTION
OBSERVATION
1
2
3
4
position.
5
READY light ON
6
READY light ON
LINK light ON
;
*** CONTROL LINK TEST completed ***
Repeat Steps 7 to 10 for each of the following control positions:
7
8
9
10
;
11
12

position.
Hold down Joystick Unit DELAYED SHUTDOWN switch.
Hold down Joystick Unit START switch.
DIAG light ON
LINK light OFF
DIAG light OFF
LINK light ON
*** JOYSTICK UNIT POWER UP SWITCH TEST completed ***
Step 6
Step 9
Troubleshooting
LINK light OFF:
Perform the Joystick Unit Switch Closure Test to verify controls are functioning
correctly.(Pg. 11)
LINK light ON:
correctly.(Pg. 11)
Revised 2001-04-04
Printed 2001-04-04 at 4:20PM
Page 13 of 35
*** EMERGENCY STOP TEST ***

Emergency Stop Test Procedure
This test verifies that the emergency stop switch will break a radio control link, shut down the
LHD and apply the brakes.
ACTION
OBSERVATION
1
2
3
Manually start the LHD
Engine starts
4
5
position.
6
READY light ON
7
LINK light ON
Push down the Joystick Unit EMERGENCY STOP mushroom switch.
8
LINK light OFF
Engine off
Pull up the Joystick Unit EMERGENCY STOP mushroom switch.
9
LINK light ON
Engine off
;
*** EMERGENCY STOP TEST completed ***
10 Turn Joystick Unit POWER switch to OFF position.
Step 8
Troubleshooting
LINK light ON / Engine running:
See the Joystick Unit Wiring schematic for any breaks or shorts in the Power Up
circuit.
Revised 2001-04-04
Printed 2001-04-04 at 4:20PM
Page 14 of 35
*** DELAYED SHUTDOWN INTERLOCK TEST ***

Delayed Shutdown Interlock Test Procedure
This test verifies that the LHD will ignore a delayed shutdown request if any of the controls on
the Joystick Unit are not set in their SAFE SHUTDOWN positions.
The operator must turn off the Joystick Unit within three (3) seconds or the delayed shutdown
request will be cancelled.
ACTION
OBSERVATION
1
2
3
4
position.
5
READY light ON
Repeat steps 6 to 11 for each of the following control positions:
6
7
8
9
10
11
;
12

position.
LINK light ON
Engine idling
Set the control to the indicated position
Toggle Joystick Unit DELAYED SHUTDOWN switch.
Engine off
Restore the control to its previous position
*** DELAYED SHUTDOWN INTERLOCK TEST completed ***
Step
10
Troubleshooting
Engine running
correctly.(Pg. 11)
Revised 2001-04-04
Printed 2001-04-04 at 4:20PM
Page 15 of 35
*** DELAYED SHUTDOWN FUNCTION TEST ***

Delayed Shutdown Function Test Procedure
This test verifies that the delayed shutdown function is working properly.
When activated, the delayed shutdown gives the operator 60-seconds to board the LHD and
switch it over to manual control before turning off the engine.
ACTION
OBSERVATION
1
2
3
4
position.
5
READY light ON
6
LINK light ON
7
Engine idling
Toggle Joystick Unit DELAYED SHUTDOWN switch.
8
DIAG light ON for
3 seconds
While the DIAG. light is on, turn the Joystick Unit POWER switch to
9
Engine idling
OFF position.
10 Wait for delayed shutdown timeout period of 60-seconds to expire.
Engine shuts
down
;
*** DELAYED SHUTDOWN FUNCTION TEST completed ***
Step 9
Step
10
Troubleshooting
Engine shuts down:
1) Perform the Joystick Unit Switch Closure Test (Pg. 11) and repeat this test.
2) The 3 second timeout when the Delayed Shutdown switch was activated had
expired before turning off the Joystick Unit.
Engine running:
1) Perform the Joystick Unit Switch Closure Test to verify if the controls are
functioning correctly.(Pg. 11)
2) Wait an additional 30-seconds. If the engine still does not shut down, return the
radio control to the service depot.
Revised 2001-04-04
Printed 2001-04-04 at 4:20PM
Page 16 of 35
*** UNATTENDED REMOTE TEST ***

Unattended Remote Test Procedure
This test verifies that the LHD will shut down if the Joystick unit is turned on BEFORE the LHD is
switched to remote control.
ACTION
OBSERVATION
1
2
3
LINK light OFF
4
5
position.
6
7
8
9
;
10
11

*** UNATTENDED REMOTE TEST completed ***
Step 7
LINK light OFF,

DIAG light ON
LINK light ON
Troubleshooting
LINK light ON :
Return the radio control to the service depot.
Revised 2001-04-04
Printed 2001-04-04 at 4:20PM
Page 17 of 35
*** REMOTE ENGINE START TEST ***

*** REMOTE ENGINE START INTERLOCK TEST ***
Remote Engine Start Test Procedure
This test verifies that the Engine Start Function can only be performed when all of the Joystick
Unit controls are set in their SAFE RESTART positions.
ACTION
OBSERVATION
1
2
3
4
position.
5
READY light ON
6
LINK light ON
Start the LHD using the Joystick Unit START switch.
7
Engine idling.
;
*** REMOTE ENGINE START TEST completed ***
Repeat Steps 8 to 12 for each of the following control positions:
8
9
10
11
12
;
13
14

position.
Engine off
LINK light ON
Engine off
*** REMOTE ENGINE START INTERLOCK TEST completed ***
Step 7
Step
11
Troubleshooting
Engine does not start:
2) Verify that the Start output (CANON-19 pin G; White/Red wire) is HIGH when
the Park Brake button on the Joystick Unit is in the Applied or ON position.
3) See the LHD wiring schematics for any breaks or shorts in the Start circuit.
Engine starts:
2) See the Joystick Unit Wiring schematic for any breaks or shorts in the circuit of the
controlled position, which activates the starter.
3) See the LHD wiring schematics for any breaks or shorts in the Start circuit.
Revised 2001-04-04
Printed 2001-04-04 at 4:20PM
Page 18 of 35
*** FIRE SUPPRESSION FUNCTION TEST ***

****
CAUTION
DISCONNECT THE FIRE SUPPRESSION SQUIB BEFORE PERFORMING THE FIRE
SUPPRESSION FUNCTION TESTS. MEASURE THE FIRE SUPPRESSION OUTPUT BY
PLACING A SPECIAL PURPOSE LAMP OR VOLTMETER ACROSS THE SQUIB CONNECTOR
INPUTS.
****
Fire Suppression Function Test Procedure
This test verifies that the Joystick Unit is able to trigger the on-board fire suppression system.
ACTION
OBSERVATION
1
2
3
4
position.
5
READY light ON
Turn Joystick Unit POWER switch to ON position.
6
LINK light ON
7
Engine starts
Hold down Joystick Unit FIRE SUPPRESSION switch.
8
Engine off
Wait three (3) seconds while holding down Joystick Unit FIRE
FIRE
9
SUPPRESSION switch.
SUPPRESSION
output goes
HIGH
10 Release the Joystick Unit FIRE SUPPRESSION switch.
11 Wait for ten (10) seconds.
FIRE
SUPPRESSION
output goes LOW
;
*** FIRE SUPPRESSION FUNCTION TEST completed ***
12 Turn Joystick Unit POWER switch to OFF position.
Step 8
Step 9
Troubleshooting
Engine continues to run:
1) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Fire Suppression
function.
2) See the Joystick Unit Wiring schematic for any breaks or shorts in the Fire
Suppression circuit.
3) Perform the Unattended Vehicle Timeout Test. (Pg. 8)
Fire Suppression output stays low:
1) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Fire Suppression
function.
2) Verify that the Fire Suppression output (CANON-19 pin F; Orange/Red wire) is
HIGH when the Fire Suppression switch on the Joystick Unit is held for over 3
seconds.
3) See the LHD wiring schematics for any breaks or shorts in the Fire Suppression
circuit.
Revised 2001-04-04
Printed 2001-04-04 at 4:20PM
Page 19 of 35
*** PROPORTIONAL THROTTLE TEST ***

*** PARK BRAKE FORWARD/REVERSE INTERLOCK TEST ***
*** HALF THROTTLE TEST ***
*** FULL THROTTLE TEST ***
Throttle Test Procedure
This test verifies that the throttle power band is set correctly and that the joystick throttle control
is functioning. The test also verifies that the transmission remains in neutral when the Joystick
unit park brake is set to applied or on position.
ACTION
OBSERVATION
1
2
3
4
position.
5
READY light ON
Set Joystick Unit POWER switch to ON position.
6
LINK light ON
7
Ease Joystick Unit left joystick to maximum FORWARD position.
RPM increases
Stop if there is an indication the LHD is moving.
No movement
8
Ease Joystick Unit left joystick to maximum REVERSE position.
RPM increases
Stop if there is an indication the LHD is moving.
No movement
;
*** PROPORTIONAL THROTTLE TEST completed ***
;
*** PARK BRAKE FORWARD/REVERSE INTERLOCK TEST completed ***
Hold down Joystick Unit HALF THROTTLE switch
9
50% max. RPM
10 Release Joystick Unit HALF THROTTLE switch
Idle RPM
;
*** HALF THROTTLE TEST completed ***
11 Hold down Joystick Unit FULL TROTTLE switch.
Max. RPM
12 Release Joystick Unit FULL THROTTLE switch.
Idle RPM
;
*** FULL THROTTLE TEST completed ***
Step 7
&8
Step 7
&8
Step 9
& 11
Troubleshooting
No RPM increase:
1) Verify that the Throttle output (CANON-19 pin L; Blue/Black wire or CANNON-10
pin K) is HIGH when the FWD/REV/STEER Joystick is moved to the up or down
positions.
2) See the LHD wiring schematics for any breaks or shorts in the Throttle circuit.
LHD moves FWD or REV:
1) Verify if the Joystick Unit PARK BRAKE switch is in the APPLIED or ON
position.
2) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Park Brake function.
No RPM increase:
1) Verify that the Throttle output (CANON-19 pin L; Blue/Black wire or CANNON-10
pin K) is HIGH when the Throttle toggle switches on the FWD/REV/STEER joystick
are activated.
2) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Throttle functions.
3) See the LHD wiring schematics for any breaks or shorts in the Throttle circuit.
Revised 2001-04-04
Printed 2001-04-04 at 4:20PM
Page 20 of 35
*** FORWARD/NEUTRAL/REVERSE FUNCTION TEST ***

*** SERVICE BRAKE FUNCTION TEST ***
*** PARK BRAKE FUNCTION TEST ***
Forward/Neutral/Reverse Function Test Procedure
This test verifies that the transmission gear select, proportional throttle control, service brake
and parking brake controls are working.
ACTION
OBSERVATION
1
2
3
4
position.
5
READY light ON
Set Joystick Unit POWER switch to ON position.
6
LINK light ON
7
Engine idling.
8
position.
9
Ease Joystick Unit left joystick to FORWARD position until the LHD
Moves forward
begins moving.
10 Hold down Joystick Unit left FULL BRAKE switch.
Stops moving.
11 Release Joystick Unit left FULL BRAKE switch.
moves forward
12 Hold down Joystick Unit right FULL BRAKE switch.
Stops moving.
13 Release Joystick Unit right FULL BRAKE switch.
moves forward
14 Ease Joystick Unit left joystick to REVERSE position until the LHD
moves backward
begins moving.
15 Hold down Joystick Unit left FULL BRAKE switch.
Stops moving.
16 Release Joystick Unit left FULL BRAKE switch.
moves backward
17 Hold down Joystick Unit right FULL BRAKE switch.
Stops moving.
18 Release Joystick Unit right FULL BRAKE switch.
moves backward
19 Release Joystick Unit left joystick.
Stops moving.
;
*** FORWARD/NEUTRAL/REVERSE FUNCTION TEST completed ***
;
*** SERVICE BRAKE FUNCTION TEST completed ***
;
*** PARK BRAKE FUNCTION TEST completed ***
20 Set Joystick Unit PARK BRAKE switch to APPLIED or ON
position.
Step 9
Troubleshooting
LHD not moving in Forward:
1) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Park Brake and
Forward functions.
2) Verify if the Park Brake output (CANON-19 pin J; Blue/White wire) goes HIGH
when Joystick Unit Park brake is set to RELEASED or OFF position.
3) Verify if the Service Brake output (CANON-19 pin H; Red/White wire) goes HIGH
when left joystick is moved to the FORWARD or REVERSE positions.
4) See the LHD wiring schematics for any breaks or shorts in the Park Brake, Service
Brake Throttle and Forward circuits.
Revised 2001-04-04
Printed 2001-04-04 at 4:20PM
Page 21 of 35
*** FORWARD/NEUTRAL/REVERSE FUNCTION TEST ***

*** SERVICE BRAKE FUNCTION TEST ***
*** PARK BRAKE FUNCTION TEST ***
*** Continued ***
Step
14
Steps
10, 12,
15 &
17
Troubleshooting
LHD not moving in Reverse:
1) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Park Brake and
Reverse functions.
2) Verify if the Park Brake output (CANON-19 pin J; Blue/White wire) goes HIGH
when Joystick Unit Park brake is set to RELEASED or OFF position.
3) Verify if the Service Brake output (CANON-19 pin H; Red/White wire) goes HIGH
when left joystick is moved to the FORWARD or REVERSE positions.
4) See the LHD wiring schematics for any breaks or shorts in the Park Brake, Service
Brake Throttle and Forward circuits.
LHD Service Brakes not Applying:
1) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Service Brake
functions.
2) Verify if the Service Brake output (CANON-19 pin H; Red/White wire) goes LOW
when either toggle on the Right joystick are activated.
3) See the LHD wiring schematics for any breaks or shorts in the Service Brake
circuit.
Revised 2001-04-04
Printed 2001-04-04 at 4:20PM
Page 22 of 35
*** STEER LEFT FUNCTION TEST ***

*** STEER RIGHT FUNCTION TEST ***
Steer Function Test Procedure
This test verifies that the steering power band is set correctly and that the joystick steering
control is functioning.
ACTION
OBSERVATION
1
2
3
4
position.
5
READY light ON
6
LINK light ON
7
Engine idling.
8
LHD slowly turns
Move Joystick Unit left joystick to minimum LEFT position.
to the left.
Hold until the LHD is configured for a tight left turn.
9
LHD slowly turns
Move Joystick Unit left joystick to minimum RIGHT position.
to the right.
Hold until the LHD is configured for a tight right turn.
The turn rate should be about the same as it was for the left.
10 Hold down Joystick Unit HALF THROTTLE switch.
LHD quickly turns
Move Joystick Unit left joystick to maximum LEFT position.
to the left.
Hold until the LHD is configured for a tight left turn.
11 Hold down Joystick Unit HALF THROTTLE switch.
LHD quickly turns
Move Joystick Unit left joystick to maximum RIGHT position.
to the right.
Hold until the LHD is configured for a tight right turn.
The turn rate should be about the same as it was for the left.
12 Straighten the LHD.
;
*** STEER LEFT FUNCTION TEST completed ***
;
*** STEER RIGHT FUNCTION TEST completed ***
Steps 8
& 10
Steps 9
& 11
Troubleshooting
If the LHD does not steer left, verify that:
1) The Steer Left Solenoid on the 6 bank manifold illuminates when the steer left
function is activated.
2) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Steer Left
function.
3) Steer Left Output (CANON-10 pin A) varies between dead band and maximum
RMS voltage for steering function.
If the LHD does not steer right, verify that:
1) The Steer Right Solenoid on the 6 bank manifold illuminates when the steer right
2) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Steer Right
function.
3) Steer Right Output (CANON-10 pin B) varies between dead band and maximum
RMS voltage for steering function.
If the LHD steers fast in one direction; slow in the other direction:
See APENDIX Joystick Potentiometer Calibration Procedures (on page 31 near
the end of this manual.)
Revised 2001-04-04
Printed 2001-04-04 at 4:20PM
Page 23 of 35
*** BOOM UP FUNCTION TEST ***

*** BOOM DOWN FUNCTION TEST ***
Boom Function Test Procedure
This test verifies that the boom function power band is set correctly and that the joystick boom
ACTION
OBSERVATION
1
2
3
4
position.
5
READY light ON
6
LINK light ON
7
Engine idling.
Move Joystick Unit right joystick to minimum RIGHT position.
8
Boom slowly
Hold until the boom is fully raised.
raises.
Move Joystick Unit right joystick to minimum LEFT position.
9
Boom slowly
Hold until the boom is fully lowered.
lowers.
10 Move Joystick Unit right joystick to maximum RIGHT position.
Boom quickly
Hold until the boom is fully raised.
raises.
11 Move Joystick Unit right joystick to maximum LEFT position.
Boom quickly
Hold until the boom is fully lowered.
lowers.
;
*** BOOM UP FUNCTION TEST completed ***
;
*** BOOM DOWN FUNCTION TEST completed ***
Steps 8
& 10
Steps 9
& 11
Troubleshooting
If the boom does not raise verify that:
1) The Boom Up Solenoid on the 6 bank manifold illuminates when the boom up
2) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Boom Up
function.
3) Boom Up Output (CANON-10 pin D) varies between dead band and maximum
RMS voltage for boom function
If the boom does not lower verify that:
1) The Boom Down Solenoid on the 6 bank manifold illuminates when the boom
down function is activated.
2) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Boom Down
function.
3) Boom Down Output (CANON-10 pin F) varies between dead band and maximum
RMS voltage for boom function.
If the LHDs Boom moves fast in one direction; slow in the other direction:
Revised 2001-04-04
Printed 2001-04-04 at 4:20PM
Page 24 of 35
*** BUCKET ROLL FUNCTION TEST ***

*** BUCKET DUMP FUNCTION TEST ***
Bucket Function Test Procedure
This test verifies that the bucket function power band is set correctly and that the joystick boom
ACTION
OBSERVATION
1
2
3
4
position.
5
READY light ON
6
LINK light ON
7
Engine idling.
8
Raise the boom so that the bucket may be moved through its full
range.
Move Joystick Unit right joystick to minimum DOWN position.
9
Bucket slowly rolls.
Hold until the bucket is fully rolled back.
Note: Some RRCs
are configured to roll
the bucket quickly.
10
Move Joystick Unit right joystick to minimum UP position.

Hold until the bucket is fully dumped.
11
Move Joystick Unit right joystick to maximum DOWN position.

Hold until the bucket is fully rolled back.
Move Joystick Unit right joystick to maximum UP position.
Bucket quickly
Hold until the bucket is fully dumped.
dumps.
*** BUCKET ROLL FUNCTION TEST completed ***
*** BUCKET DUMP FUNCTION TEST completed ***
Lower the boom back onto the stop blocks
12
;
;
13
14
15
Steps 9
& 11
Steps 10
& 12
Bucket slowly dumps.

Note: Some RRCs
are configured to roll
the bucket quickly.
Bucket quickly rolls.
Troubleshooting
If the bucket does not roll verify that:
1) The Bucket Roll Solenoid on the 6 bank manifold is illuminated when the bucket
roll function is activated.
2) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Bucket Roll
function.
3) Bucket Roll Output (CANON-10 pin C) varies between dead band and maximum
RMS voltage for bucket function.
If the bucket does not dump verify that:
1) The Bucket Dump Solenoid on the 6 bank manifold is illuminated when the
bucket dump function is activated.
2) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Bucket Dump
function.
3) Bucket Dump Output (CANON-10 Pin E) varies between dead band and
maximum RMS voltage for bucket function.
If the LHDs Bucket moves fast in one direction; slow in the other direction:
Note: Some RRCs are configured to roll and dump the bucket quickly.
Revised 2001-04-04
Printed 2001-04-04 at 4:20PM
Page 25 of 35
*** FRONT LIGHT FUNCTION TEST ***

*** REAR LIGHT FUNCTION TEST ***
Headlight Function Test Procedure
This test verifies that the joystick unit front and rear light controls are functioning.
ACTION
OBSERVATION
1
2
3
4
position.
5
READY light ON
6
LINK light ON
Set Joystick Unit FRONT LIGHTS switch to ON position.
7
Front lights on
Set Joystick Unit FRONT LIGHTS switch to OFF position.
8
Front lights off
;
*** FRONT IGHT FUNCTION TEST completed ***
Set Joystick Unit REAR LIGHTS switch to ON position.
9
Rear lights on
10 Set Joystick Unit REAR LIGHTS switch to OFF position.
Rear lights off
;
*** REAR LIGHT FUNCTION TEST completed ***
Step 7
Step 8
Step 9
Step
10
Troubleshooting
Front lights off:
1) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Front Lights
function.
2) Check that the Front Lights output (CANON-19 pin P) is not shorted to ground or
disconnected.
3) See the LHD wiring schematics for any breaks or shorts in the Front Lights circuit.
Front lights on:
1) Verify if the Front Lights switch in the operators cab is not in the On position.
2) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Front Lights
function.
3) Check that the Front Lights output (CANON-19 pin P) is not tied HIGH.
4) See the LHD wiring schematics for any breaks or shorts in the Front Lights circuit.
Rear lights off:
1) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Rear Lights
function.
2) Check that the Rear Lights output (CANON-19 pin K) is not shorted to ground or
disconnected.
3) See the LHD wiring schematics for any breaks or shorts in the Rear Lights circuit.
Rear lights on:
1) Verify if the Rear Lights switch in the operators cab is not in the On position.
2) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Rear Lights
function.
3) Check that the Rear Lights output (CANON-19 pin K) is not tied HIGH.
4) See the LHD wiring schematics for any breaks or shorts in the Rear Lights circuit.
Revised 2001-04-04
Printed 2001-04-04 at 4:20PM
Page 26 of 35
APPENDIX LHD Vehicle Unit Connector Pin Outs
B A M
C P N L
D R V U K
E S T J
F G H
Pin location
Front view
19-PIN CANON CONNECTOR

#
COLOR
DESCRIPTION
A BLK
Power
Power input to vehicle unit
B GRN/BLK
C GRN/WHT
Ground
Power ground for vehicle unit.
D BLK/RED
Run (Output)
E BLU/RED
High to keep engine running.
Fire Suppression (Output)
F ORN/RED
High to activate onboard fire suppression.
Start (Output)
G WHT/RED
High to activate starter.
Service Brake (Output)
H RED/WHT
High to release service brake.
Park Brake (Output)
J BLU/WHT
High to release the park brake.
Rear Lights (Output)
K RED/BLK
High to turn on rear lights.
Throttle (Output)
100Hz PWM output will vary from dead band duty
L BLU/BLK
cycle to the maximum throttle duty cycle in both the
forward and reverse directions.
Forward (Output)
M ORN/BLK
High to set transmission to FORWARD gear.
Reverse (Output)
N WHT
High to set transmission to REVERSE gear.
Front Lights (Output)
P WHT/BLK
High to turn on front light.
RRC (Output)
R RED
High when radio control link is established.
Remote Select (Input)
S BLU
High input to put LHD in radio remote control.
Neutral Sense (Input)
T BLK/WHT
High to indicate that manual gear select is in neutral.
Park Brake Sense (Input)
U ORN
High indicates manual park brake is applied.
Spare
Note: On other systems, this output is used for the
V GRN
Brake Release Pump (output).
High to turn on pump.
Revised 2001-04-04
Printed 2001-04-04 at 4:20PM
Page 27 of 35
b a h
c j k g
d e f
Pin location
Front view
b a h
c j k g
d e f
Pin location
Front view
10 pin CANON connector

COLOR CODE
# EXT. INT.
PUR
A
BLK
007
PUR
B
GRN/BLK
008
PUR
C
GRN/WHT
005
PUR
D
BLK/RED
003
PUR
E
BLU/RED
006
PUR
F
ORN/RED
004
G
N/C
WHT/RED
H
J
K
BLK
N/C
N/C
RED/WHT
BLU/WHT
RED/BLK
- without BRAD HARRISON Junction Box

DESCRIPTION
Proportional Steer Left (Output)
100 Hz PWM
Proportional Steer Right (Output)
100 Hz PWM
Proportional Bucket Roll (Output)
100 Hz PWM
Proportional Boom Up (Output)
100 Hz PWM
Proportional Bucket Dump (Output)
100 Hz PWM
Proportional Boom Down (Output)
100 Hz PWM
REVERSE (Output)
Ground
Forward (Output)
Throttle (Output)
10 pin CANON connector - Some Early Systems with BRAD

HARRISON Junction Box
COLOR CODE
# EXT. INT.
DESCRIPTION
A WHT BLK
100 Hz PWM
B GRN GRN/BLK
100 Hz PWM
C YEL
GRN/WHT
100 Hz PWM
D GRY BLK/RED
100 Hz PWM
E PNK
BLU/RED
100 Hz PWM
F RED
ORN/RED
100 Hz PWM
RRC (Output)
G BRN
WHT/RED
High when radio control link is established.
H BLU
RED/WHT
Ground
J N/C
BLU/WHT
Spare output 1
K N/C
RED/BLK
Spare output 2
Revised 2001-04-04
Printed 2001-04-04 at 4:20PM
Page 28 of 35
b a h
c j k g
d e f
Pin location
Front view
10 pin CANON connector - 10 AWG Provo Multiconductor

COLOR CODE
# EXT. INT.
DESCRIPTION
A BLK
BLK
100 Hz PWM
B WHT GRN/BLK
100 Hz PWM
C RED
GRN/WHT
100 Hz PWM
D GRN BLK/RED
100 Hz PWM
E BRN
BLU/RED
100 Hz PWM
F BLU
ORN/RED
100 Hz PWM
REVERSE (Output)
G ORN WHT/RED
H
J
K
b a h
c j k g
d e f
Pin location
Front view
YEL
PUR
GRY
RED/WHT
BLU/WHT
RED/BLK
Ground
Forward (Output)
Throttle (Output)
10 pin CANON connector - without BRAD HARRISON Junction Box

COLOR CODE
# EXT.
INT.
DESCRIPTION
A BLK
BLK
100 Hz PWM
B GRN/BLK GRN/BLK
100 Hz PWM
C GRN/WH
GRN/WHT
100 Hz PWM
D BLK/RED
BLK/RED
100 Hz PWM
E BLU/RED
BLU/RED
100 Hz PWM
F ORN/RED ORN/RED
100 Hz PWM
REVERSE (Output)
G WHT/RED WHT/RED
H
J
K
RED/WHT
BLU/WHT
RED/BLK
RED/WHT
BLU/WHT
RED/BLK
Ground
Forward (Output)
Throttle (Output)
Revised 2001-04-04
Printed 2001-04-04 at 4:20PM
Page 29 of 35
APPENDIX LHD Joystick Unit Controls

Joystick Unit Control
POWER
Toggle switch
EMERGENCY STOP
Mushroom pushbutton
DELAYED SHUTDOWN
Momentary toggle
PARK BRAKE
Toggle switch
FRONT LIGHTS
Toggle switch
REAR LIGHTS
Toggle switch
START
Momentary toggle
FIRE SUPPRESSION
Momentary toggle
Left joystick
STEER/THROTTLE
Right joystick
BOOM/BUCKET
Left joystick right Thumb toggle
switch
HALF THROTTLE
Left joystick left Thumb toggle
switch
FULL THROTTLE
Right joystick L/R Thumb toggle
switches
FULL SERVICE BRAKE
Operation
Main power.
Emergency shutdown. Interrupts main power by shutting
the Joystick unit down and terminating the control link.
Pull down before turning off joystick unit and boarding
LHD.
Up to release park brake
Down to apply park brake
Up to turn on front lights
Down to turn off front lights
Up to turn on rear lights
Down to turn off rear lights
Pull down to turn on starter motor.
Remove ring pin and hold down for 3 seconds to activate
the Ansul fire suppression system on the LHD.
Move joystick up for forward movement
Move joystick down for reverse movement
Move joystick left to steer to the left
Move joystick right to steer to the right
Move joystick up for bucket dump
Move joystick down for bucket roll
Move joystick left to lower boom
Move joystick right to raise boom
Press to bring engine to 50% of maximum throttle.
Press to bring engine to maximum throttle.
Press to apply service brake when the LHD is in motion.
Revised 2001-04-04
Printed 2001-04-04 at 4:20PM
Page 30 of 35
APPENDIX LHD Joystick Unit Control SAFE positions

Joystick Unit Control
PARK BRAKE switch
DELAYED SHUTDOWN switch
FRONT LIGHTS switch
REAR LIGHTS switch
START switch
FIRE SUPPRESSION switch
Right joystick
BOOM/BUCKET
Right joystick left thumb switch
Left FULL BRAKE switch
Right joystick right thumb switch
Right FULL BRAKE switch
Left joystick
STEER/THROTTLE
Left joystick left thumb switch
FULL THROTTLE switch
Left joystick right thumb switch
HALF THROTTLE switch
Revised 2001-04-04
SAFE
POWERUP
APPLIED
or ON
Released
Released
Released
Centered
SAFE
RESTART
APPLIED
or ON
Released
Held down
Centered
SAFE
SHUTDOWN
APPLIED
or ON
Held down
Released
Centered
Released
Released
Centered
Centered
Centered
Released
Released
Released
Released
Released
Released
Printed 2001-04-04 at 4:20PM
Page 31 of 35
APPENDIX Joystick Potentiometer Calibration Procedures

1. Open the Joystick Units lid.
2. Disconnect all connectors on the Auxiliary Board (Con 1, Con 2, Con 3, Con 4, Con 5, Con 6
and Con 7).
3. With an Ohmmeter, measure the resistance between the CT pin and pin two (see Fig. 1 at
the bottom of this page for the potentiometer pin-out). The resistance reading should be close
to 0 Ohms (if the reading is not close to 0 Ohms proceed to step 6; If the reading is close to 0
Ohms, proceed to step 4). Note: It is very important that the joystick is resting in its neutral
position; a slight displacement of the joystick will throw off the resistance reading.
4. With an Ohmmeter, measure the resistance between the CCW pin and pin two (see Fig. 1 at
the bottom of this page for the potentiometer pin-out). Write down this reading. Note: It is
very important that the joystick is resting in its neutral position; a slight displacement of the
joystick will throw off the resistance reading.
5. With an Ohmmeter, measure the resistance between pin 3 and pin 2 (see Fig. 1 at the bottom
of this page for the potentiometer pin-out). This reading should be very close to the reading
obtained in step 4 (if the reading is not close to the reading in step 4, proceed to step 6; if the
reading is very close to the reading in step 4, the potentiometer is calibrated and proceed to
step 7). Note: It is very important that the joystick is resting in its neutral position; a slight
displacement of the joystick will throw off the resistance reading.
6. Unscrew both potentiometer-retaining screws (on both sides of the potentiometer). Slightly
turn the potentiometer Clockwise or Counter-Clockwise. Proceed to steps 3,4 and 5. Note: If
while turning the potentiometer slightly and the resistance change is very dramatic or erratic,
send the Remote Control System to Hard-Line Solutions for servicing.
7. Tighten both Potentiometers retaining screws, reconnect all the connectors on the Auxiliary
Board (Con 1, Con 2, Con 3, Con 4, Con 5, Con 6 and Con 7) and close the lid.
Fig. 1
CT
CCW
Revised 2001-04-04
Printed 2001-04-04 at 4:20PM
Page 32 of 35
APPENDIX LHD Proportional Output Scaling Table
BOT.
$3F60 255
$3F68 0
$3F70 0
$3F78 0
$3F80 0
$3F88 0
$3F90 0
$3F98 0
$3FA0 $3FA8 $3FB0 $3FB8 $3FC0 $3FC8 $3FD0 $3FD8 -
Service Brake
Proportional Throttle
Proportional Boom Down
Proportional Boom Up
Proportional Bucket Dump
Proportional Bucket Roll
Proportional Steer Right
Proportional Steer Left
TOP
0
255
255
255
255
255
255
255
-
(in)
20
20
20
20
20
20
20
20
-
MIN
(out)
255
146
128
128
255
255
128
128
-
MID
(in)
(out)
115
255
115
166
86
255
115
255
115
255
115
255
115
255
115
255
-
MAX
(in)
(out)
115
255
115
166
86
255
115
255
115
255
115
255
115
255
115
255
-
Common percentages converted to decimal and hexadecimal notation

Percentage
0%
5%
10%
15%
20%
25%
30%
35%
40%
45%
50%
Decimal
0
13
26
39
51
64
76
89
102
115
128
Hexadecimal
00
0D
1A
27
33
40
4C
59
66
73
80
Percentage
Decimal
Hexadecimal
55%
60%
65%
70%
75%
80%
85%
90%
95%
100%
140
153
166
179
191
204
217
230
242
255
8C
99
A6
B3
BF
CC
D9
E6
F2
FF
Hexadecimal to decimal conversion table

0x
1x
2x
3x
4x
5x
6x
7x
8x
9x
Ax
Bx
Cx
Dx
Ex
Fx
x0
0
16
32
48
64
80
96
112
128
144
160
176
192
208
224
240
x1
1
17
33
49
65
81
97
113
129
145
161
177
193
209
225
241
x2
2
18
34
50
66
82
98
114
130
146
162
178
194
210
226
242
x3
3
19
35
51
67
83
99
115
131
147
163
179
195
211
227
243
x4
4
20
36
52
68
84
100
116
132
148
164
180
196
212
228
244
x5
5
21
37
53
69
85
101
117
133
149
165
181
197
213
229
245
x6
6
22
38
54
70
86
102
118
134
150
166
182
198
214
230
246
x7
7
23
39
55
71
87
103
119
135
151
167
183
199
215
231
247
x8
8
24
40
56
72
88
104
120
136
152
168
184
200
216
232
248
Revised 2001-04-04
x9
9
25
41
57
73
89
105
121
137
153
169
185
201
217
233
249
xA
10
26
42
58
74
90
106
122
138
154
170
186
202
218
234
250
xB
11
27
43
59
75
91
107
123
139
155
171
187
203
219
235
251
xC
12
28
44
60
76
92
108
124
140
156
172
188
204
220
236
252
xD
13
29
45
61
77
93
109
125
141
157
173
189
205
221
237
253
xE
14
30
46
62
78
94
110
126
142
158
174
190
206
222
238
254
xF
15
31
47
63
79
95
111
127
143
159
175
191
207
223
239
255
Printed 2001-04-04 at 4:20PM
Page 33 of 35
APPENDIX LHD Proportional Control Output Measurements

Company:
Mine:
Vehicle ID:
Date:
Input voltage
Forward Throttle Dead Band
Forward Throttle Full
Reverse Throttle Dead Band
Reverse Throttle Full
Full Throttle
Half Throttle
Steer Full Left
Steer Full right
Boom Full Up
Boom Full Down
Bucket Full Roll
Bucket Full Dump
PWM
(%)
N/A
Expected
(RMS)
24VDC
Bench
(RMS)
Field
(RMS)
APPENDIX Revision History

1998-08-21
First printing.
Based upon: Rockbreaker Radio Remote Control Commissioning and
Troubleshooting
1998-09-29
Second printing.
Replaces pages 10, 11, 12, 15, 18, 23, and 24 in previous edition.
Corrected commissioning order p.10 and 11
Replaced references to HOIST with BOOM and TILT with BUCKET (pages 11,
12, 15, and 18)
Added missing commissioning steps for BOOM and BUCKET tests (pages 24
and 24)
1998-10-18
Third printing.
Replaces page 30 in previous edition.
Added Percentage to decimal and hexadecimal conversion table
Added Hexadecimal to decimal conversion table
Revised 2001-04-04
Printed 2001-04-04 at 4:20PM
Page 34 of 35
APPENDIX Problem Report Form

FAX TO:

53 Main Street, Dowling, Ontario, CANADA P0M 1R0
VOICE: (705) 855-1310
FAX: (705) 855-9463
FROM:
Company:
Mine:
Vehicle ID:
Date:
Technician:
Position:
Describe the problem:
Problem resolution:
( ) Radio Being Returned For Service
( ) Requesting a service call
( ) Found a work-around (Please describe below)
Revised 2001-04-04
Printed 2001-04-04 at 4:20PM
Revised 2001-04-04
Page 35 of 35
Printed 2001-04-04 at 4:20PM
SECTION TWO
BILLS OF MATERIAL, DRAWINGS & SCHEMATICS
Printed On: 11/26/04 4:07 PM
Parts List
Assembly Number -- ASLHDS-2 -- MUCKMASTER LHD Slave Unit Standard Assembly Version 2 -- 3098
Item
Part Number
Item
1 ASLHDS-2-04
Part Number
11 ASLHDS-1-03
MUCKMASTER LHD Slave Unit Prepared Fiberglass

Enclosure
MUCKMASTER LHD Slave Unit Wire Harness Power

Switch to E.Stop
Qty: 1 Each
Qty: 1 Each
3781
2 8500K9
8500 Series SPST On-None-Off Switch
Qty: 4 Each
MUCKMASTER LHD Slave Unit Jumpers for all

Switches
1133
3 8500K11
1131
4 8492K1-MOD1
MUCKMASTER LHD Slave Unit Wire Harness 10

Socket AMP from Con 5 to Switches
Qty: 1 Each
2978
Qty: 1 Each
PCB Assembled - Joystick Unit Antenna/LED Board

Sourcing Version with Cable Harness Version B
2016
6 090-008-MOD1
Qty: 1 Each
MS SS Flat Head Phillips Drive 4-40 X 3/4
Qty: 1 Each
Qty: 2 Each
2324
7 10250T5
Washer Flat Nylon #4
1107
8 10250T51
Qty: 2 Each
785
18 NUTSSNYLOC#04
C.H. 1 N/C Contact Block
Nut SS Nylon Insert Locknut (nyloc) 4-40
1108
9 10250TC47-MOD1
Qty: 2 Each
844
19 V10-PRO-T/S-MOD1
C.H. Push/Pull Operator Red Lens modified
V10 Proportional Joystick Throttle/Steering c/w

ASA14A Auxiliary Board
2889
10 ASLHDS-1-02
Qty: 1 Each
5373
20 V10-PRO-D/H
MUCKMASTER LHD Slave Unit Wire Harness 12

Socket AMP Con 3 to Joystick T/S Joystick
Qty: 1 Each
827
17 WFN#04
C.H. Maintained Push/Pull Operator
Qty: 1 Each
2799
16 MSSSFP0440-0.75
Pins Steel Zinc Hitch Clips Double Loop 9/16-13/16,

Modified for Fire Suppression Pin on Slave
Qty: 1 Each
3215
15 ASA10B
Half Toggle Switch Seal
Qty: 1 Each
1707
MUCKMASTER LHD Slave Unit Wire Harness from E

Stop to Battery Cable
5 N1030B
Qty: 7 Each
1709
14 ASLHDS-1-08
Switch Guard for Toggle Switch - Modified
Qty: 1 Each
Qty: 1 Each
13 ASLHDS-1-07
8500 Series SPST Off-None-On Momentary Switch
Qty: 3 Each
1710
12 ASLHDS-1-04
V10 Proportional Joystick Dump/Hoist
1708
Printed on 10/18/2004 at 12:05:05 PM by Master
Qty: 1 Each
repMFBOMCatalog
3026
Page 1 of 2
Item
Part Number
Item
21 ASA01E
PCB Assembled - V10-Joystick Auxiliary Board
Version E
Qty: 1 Each
Skid plate for Rose enclosure 02163609 and wheat

battery c/w screw and new handle holes
3999
22 ASM02D
3997
23 A095-2
5861
Drop Handle Zinc Plated 4 1/8" handle size
Qty: 1 Each
2187
34 MSSSFP10-0.5
900MHZ High Power Radio
MS SS Flat Head Phillips Drive 10-32 X 1/2
Qty: 1 Each
420
24 MSSSPP0256-0.75
Qty: 4 Each
823
35 NUTSSNYLOC#10
MS SS Pan Head Phillips Drive 2-56 X 3/4
Qty: 4 Each
832
25 WLITSS#02
Qty: 4 Each
763
36 SHCS0.25/20x0.75
Lockwasher SS internal tooth no. 2, type A
Qty: 4 Each
Qty: 1 Each
33 099-140
PCB Assembled - Microprocessor Board Version D
Qty: 1 Each
Part Number
32 BR18-MOD2
Socket Head Cap Screws 1/4-20 X 3/4"
1689
26 SRA0256x0.375-0.1875
Qty: 4 Each
797
37 191-400
Spacer Round Aluminum 2-56 Hole, 3/16" Outside

Diameter X 3/8" Long
Joint Connector Nut 1/4-20x12mm for Skid Plate
Qty: 4 Each
Qty: 4 Each
2104
1703
27 762159
Weather Pack Nylon 2 Cavity for Socket Terminals
Qty: 1 Each
194
28 ASLHDS-2-10
MUCKMASTER LHD Slave Unit Electric Accessory
Plug Assembly with Weather Pack Socket Terminal
Qty: 1 Each
5226
29 762162
Weather Pack Wire Seals for 14-16AWG
Qty: 2 Each
197
30 762153
Weather Pack Pin Terminal 14-16AWG
Qty: 2 Each
151
31 762158
Weather Pack Nylon 2 Cavity for Pin Terminals
Qty: 1 Each
193
repMFBOMCatalog
Page 2 of 2
Parts List
Assembly Number -- ASLHDM-2 -- MUCKMASTER LHD Master Unit Standard Assembly Version 2 -3081
Item
Part Number
Item
1 ASLHDM-2-01
Part Number
30 A095-2
MUCKMASTER LHD Master Unit Prepared Enclosure
900MHZ High Power Radio
Qty: 1 Each
Qty: 1 Each
3082
2 ASLHDM-1-02
31 ASLHDM-1-05
MUCKMASTER LHD Master Unit 19 socket panel

mount connector c/w wiring harness
Qty: 1 Each
MUCKMASTER LHD Master Unit Antenna Assembly
2507
3 ASLHDM-1-01
Qty: 1 Each
2505
11 ASD02C
Qty: 4 Each
Qty: 1 Each
Qty: 11 Each
3955
12 ASA02B
MS SS Pan Head Phillips Drive 4-40 X 1/2
Qty: 1 Each
Qty: 8 Each
2565
13 ASM02D
1649
44 MSSSPP1032-1.25
PCB Assembled - Microprocessor Board Version D
3997
20 25.621.1453.0
MS SS Pan Head Phillips Drive 10-32 X 1-1/4
Qty: 4 Each
1870
45 SRA0256x0.375-0.1875
3.81mm Terminal Plug 14 Position PCB C/W Screw

Down and Numbering
3979
21 25.621.1053.0
Spacer Round Aluminum 2-56 Hole, 3/16" Outside

Diameter X 3/8" Long
Qty: 4 Each
2104
46 MSSSCPM68

Down and Numbering
Qty: 1 Each
844
43 MSSSPP0440-0.5
PCB Assembled - Vehicle Unit LED Board Version B
Qty: 3 Each
845
42 NUTSSNYLOC#04
PCB Assembled - Vehicle Unit Driver - Watchdog Run

Monitor on board Version 3
Qty: 1 Each
101
41 NUTSSNYLOC#02
MUCKMASTER LHD Master Unit 10 socket panel

mount connector c/w wiring harness
Qty: 1 Each
420
3978
22 25.621.0753.0
MS SS Raised Cheese Head Phillips Drive M6 X 8mm
Qty: 6 Each
1678
47 WLETSS#06

Down and Numbering
Washer Lock External Tooth SS #6
Qty: 1 Each
Qty: 6 Each
3977
23 25.621.0353.0
3913
48 WFN#04

Down and Numbering
Washer Flat Nylon #4
Qty: 1 Each
Qty: 4 Each
3976
repMFBOMCatalog
785
Page 1 of 2
Item
Part Number
Item
Part Number
50 1.5KE33A
TVS 33V 1500W UNI-DIR TH/H
Qty: 1 Each
345
51 BR22-MOD1
Bracket for Master Unit Enclosure 021222209-00 c/w
Holes
Qty: 1 Each
5135
54 H18-COMM-H45
Teflon Hook Up Wire 1KV 200C 18AWG Blue/Red
Striped
Qty: 0.1 Meter
3423
55 83029-6
Teflon Hook Up Wire 1KV 200C 18AWG Blue
Qty: 0.6 meter
84
56 83029-9
Teflon Hook Up Wire 1KV 200C 18AWG White
Qty: 0.485 meter
87
57 83029-3
Teflon Hook Up Wire 1KV 200C 18AWG Orange
Qty: 0.45 meter
81
58 83029-5
Teflon Hook Up Wire 1KV 200C 18AWG Green
Qty: 0.6 meter
83
59 83029-4
Teflon Hook Up Wire 1KV 200C 18AWG Yellow
Qty: 0.265 meter
82
60 H18-COMM-H82
Teflon Hook Up Wire 1KV 200C 18AWG Black/Red
Striped
Qty: 0.1 Meter
3420
61 HSTT12-48-Q
Heat Shrink Thin Wall 1/8" Black
Qty: 0.03 Meter
108
repMFBOMCatalog
Page 2 of 2
Parts List
Assembly Number -- KITLHDDASH1 -- Kit - LHD Dash Standard -- 1747

Item
Part Number
Item
1 10250T3011
Part Number
11 10250T1
C.H. 2 Position Selector Switch Maintained, Long

Lever
C.H. 1 N/O, 1 N/C Contact Block
Qty: 1 Each
Qty: 1 Each
2025
2 ASCH-02
Assembled Cable Harness 19 Pin Dash Cable
Name Plate Manual Remote MUCKMASTER
Qty: 1 Each
11
3 VF4-15H11
1169
Qty: 4 Each
304
5 26A1348A
Qty: 20 Each
162
6 10250T3
Qty: 0.1 Meter
1398
Qty: 0.3 Meter
1386
1103
7 10250T47
Qty: 0.1 Meter
3127
17 24-6040-0061
C.H. 1 Early Closing N/O, 1 N/C Contact Block
Solder 16 gauge (0.062"/1.5mm) 60/40 "44" Rosin

Core 1Lb.
2927
8 AGC-15
Qty: 0.05 Each
2778
18 BVYR-100707TTT
Fuse AGC-15A Fast Acting 1/4 X 1 1/4 Glass 250V
PMA Connector "Y", IP68 seal, 1 Size 10 Tube, 2 Size

07 "T" Profile Tube
1858
9 HHB
Qty: 1 Each
1265
19 BFAD-P070
Fuse HHB Series In-Line Universal Fuse Holder
PMA Connector Straight, IP67 seal, 7mm to 10mm
1908
10 1N5408
Qty: 2 Each
2632
20 BFN2-07T
Rectifier Axial 1000V 1A TH/H
Qty: 10 Each
16 HSTT75-48-5
C.H. 2 N/C Contact Block
Qty: 1 Each
108
15 HSTT25-48-Q
Relay Terminal Open-Barrel Series 18-20AWG 26A

Crimp On
Qty: 1 Each
Qty: 0.3 Meter
14 HSTT38-48-Q
Relay Socket VF4 quick connector relay with screw

tab,
Qty: 1 Each
2444
4 VCF4-1002
Qty: 2 Each
Qty: 1 Each
13 HSTT12-48-Q
Relay VF4 Auto. 24V Coil 40A cont. quick conn
Qty: 4 Each
1099
12 NP-MR2
PMA Connector Retaining Clip Size 07 "T" Profile

Tube
350
Qty: 7 Each
repMFBOMCatalog
1939
Page 1 of 2
Item
Part Number
Item
21 BFN2-09T
Part Number
32 HSTT19-48-Q
PMA Connector Retaining Clip Size 10 "T" Profile

Tube
Qty: 7 Each
Qty: 0.3 Meter
1940
22 NVN3-07
33 P18-10R
PMA Sealing Caps Size 07
Qty: 7 Each
Terminal Non-Insulation Ring 22-18AWG #10 Stud
1962
23 NVN3-09
Qty: 12 Each
Bracket Shoulder Harness Mounting Bracket Finished
1963
24 BVNL-P07MT
Qty: 1 Each
4694
35 MSSSFP14-1.5
PMA Connector Straight, IP67 seal, PG07 Thread,

Size 07 "T" Profile Tube
MS SS Flat Head Phillips Drive 1/4" NC x 1 1/2"
Qty: 2 Each
Qty: 2 Each
1774
25 GMM-07
3223
36 NUTSSNYLOC0.25/20
PMA Nut PG-07 Thread
Qty: 2 Each
1515
34 BR08-MOD1
PMA Sealing Caps Size 09
Qty: 7 Each
1385
Nut SS Nylon Insert Locknut (nyloc) 1/4-20 N/C
1387
Qty: 2 Each
800
26 SFN4-07
PMA Flat Gasket PG07 Thread
Qty: 2 Each
1773
27 BVYR-101010TTT
PMA Connector "Y", IP68 seal, 3 Size 10 "T" Profile
Tube
Qty: 1 Each
1470
28 BVNL-P090T
PMA Connector Straight, IP67 seal, PG09 Thread,
Size 10 "T" Profile Tube
Qty: 1 Each
279
29 GMM-09
PMA Nut PG-09 Thread
Qty: 1 Each
281
30 SFN4-09
PMA Flat Gasket PG09 Thread
Qty: 1 Each
1325
31 P14-6R
Terminal Non-Insulation Ring 16-14AWG #6
Qty: 10 Each
1478
repMFBOMCatalog
Page 2 of 2
Parts List
Assembly Number -- ASLHDS-2-11 -- MUCKMASTER LHD Slave Unit Weather Pack Electric Accessory
Power\Charger\Battery Cables -- 5247
Item
Part Number
Item
Part Number
1 ASLHDS-2-09
Plug Assembly with Weather Pack PinTerminal
Qty: 3 Each
5225
2 ASLHDS-2-10
Plug Assembly with Weather Pack Socket Terminal
Qty: 3 Each
5226
3 762158
Weather Pack Nylon 2 Cavity for Pin Terminals
Qty: 1 Each
193
4 762162
Weather Pack Wire Seals for 14-16AWG
Qty: 2 Each
197
5 762153
Weather Pack Pin Terminal 14-16AWG
Qty: 2 Each
151
repMFBOMCatalog
Page 1 of 1

Service Manual MUCKMASTER LHD Remote Control System

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Service Manual MUCKMASTER LHD Remote Control System

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