Installation, RCL 5300
Installation
RCL 5300
Rev.: 12-17
HMF Technical Service Department
1
Installation, RCL 5300
Important advice when working with the electronic safety system
Do not connect electric components (spotlights, solenoid
valves or others) to the RCL 5300 controller or any of the
other controllers.
Do not connect electric components to the power supply cable for the controllers.
If electric components are to be fitted on the crane or another place on the vehicle,
these components must be connected to the battery of the vehicle via the EJB5380
connection box.
If cranes are mounted in applications where it is not possible to connect the EJB5380
connection box to a battery, it may be necessary to use an electric transformer (e.g.
230 V ≈ / 24 V =).
The transformer has to be dimensioned with regards to power consumption and
smoothed direct voltage in each single case depending on the equipment fitted.
You must remove the cable for the power supply, if you are to weld on the vehicle.
Otherwise there is a risk of the electronic safety system being overloaded and in
worst case damaged.
You must remove the cable for the power supply, if the battery of the vehicle is
discharged, and a “boost starter” is connected to start the engine. Any kind of too
high charging voltage (power supply) or voltage peaks entail the risk of overloading
and in the worst case damaging the electronic safety system.
Be careful if the crane is being washed in connection with service overhauls. Avoid
spraying on water and never use high-pressure rinsing for cleaning the electronic
components. Also be careful not using noxious chemicals and detergents.
Rev.: 12-17
HMF Technical Service Department
2
Installation, RCL 5300
General installation instructions
This chapter provides instructions for how to handle the RCL 5300 Safety System, when the crane
is to be fitted on a vehicle, during service overhauls and in case of connection of any optional
extras.
To obtain the maximum operational safety possible, it is important to follow the installation
instructions thoroughly.
The RCL 5300 controller
The RCL 5300 controller is hinged to the box, which makes
it easy to access the input and output terminals.
The individual wires are mounted in detachable multi-plugs on
the controller’s printed circuit board.
At the bottom of the box, a plate is fitted with cable lead-ins as
well as a membrane valve, which ventilates the box. The valve
prevents water penetration, but ensures that any condensation
water can flow out of the box.
Because all controllers in the safety system are very tight (IP66),
i.e. water-tight and dust-tight, the input and output terminals are
not greased.
The controllers have “floating” in- and outlets. I.e. one particular
in-/outlet is not dedicated to one particular type of sensor, but it
can be configured to several types of sensors in the safety
system.
There are special requirements to the power supply for the
electronic safety system:
•
The RCL 5300 controller (as well as the radio remote control, if
any) must have its own separate power supply through the
EJB5380 connection box from the battery of the vehicle.
•
All other power-requiring equipment such as oil coolers and
spotlights must have its own separate power supply through
the EJB5380 connection box from the battery.
This separation of the power supplies is necessary to avoid both voltage drops and voltage peaks
getting into the safety system.
The combination of separate power supply and the built-in protection of the electronic components in
the controllers ensures maximum operational safety in the safety system.
When connecting the crane’s electric system to the power supply of the vehicle, the current
instructions from the supplier must be respected.
Please note:
The guarantee on the components in the electronic system is void; if it is determined that
power consuming equipment has been connected to the RCL 5300 or one of the other
controllers.
The power supply to the controllers is being monitored. The highest voltage peak as well as
the number of peaks can be read from the black box-function in the RCL 5300.
Rev.: 12-17
HMF Technical Service Department
3
Installation, RCL 5300
Survey of terminals, RCL 5300
+
IGN
L
H
+
IGN
K111
K212
K313
Analog / Digital in
O4
O3
O2
O1
-
Digital in
Digital Out
Analog / Digital in
+
AD 5
+
AD 6
+
D1
+
D2
+
D3
D4
+
D5
AD 7
-
K121
K222
K323
K424
K525
K141
K242
K343
K444
K545
K646
K747
K131
K232
K333
K434
K535
K636
K737
K360
K359
K258
K157
K356
K255
K154
K353
K252
K151
CAN 2
CAN 1
+
IGN
L
H
Stop
Stop
AD 4
AD 3
+
AD 2
+
AD 1
+
-
Power
+
IGN
L
H
Stop
Stop
RCL 5300
K391
K192
K393
K194
K395
K196
K397
K198
Terminal
K1xx
K2xx
K3xx
K4xx
K5xx
K6xx
K7xx
Signal
Supply ÷
Supply +
Signal
CAN Low
CAN High
Stop (stop button)
Stop (stop button)
Explanation
The first digit in the terminal number
indicates the signal type.
Kx1x
Kx2x
Kx3x
Kx4x
Power
CAN Bus 2
CAN Bus 1
CAN Bus 1
The second digit in the terminal number
indicates the number of the plug.
As to plugs with more than 9 terminals, the
number system continues with the next
number in the sequence of numbers.
Kxx1
Number
The third digit indicates the terminal
number.
As to plugs with more than 9 terminals, the
third digit is increased by the next number
in the sequence of numbers (K170, K271,
K372).
Rev.: 12-17
HMF Technical Service Department
K161
K262
K363
K164
K265
K366
K167
K268
K369
K170
K271
K372
K181
K282
K383
K384
K185
K286
K387
K388
K189
4
Installation, RCL 5300
Survey of terminals, ECT 5320
+
IGN
L
H
+
IGN
L
H
Stop
Stop
+
IGN
L
H
Stop
Stop
K131
K232
K333
K434
K535
K636
K737
+
AD 5
+
AD 6
+
D1
+
D2
CAN 1
K141
K242
K343
K444
K545
K646
K747
ECT 5320
Terminal
K1xx
K2xx
K3xx
K4xx
K5xx
K6xx
K7xx
Signal
Supply ÷
Supply +
Signal
CAN Low
CAN High
Stop (stop button)
Stop (stop button)
Explanation
The first digit in the terminal number
indicates the signal type.
Kx3x
Kx4x
CAN Bus 1
CAN Bus 1
The second digit in the terminal number
indicates the number of the plug.
Kxx1
Number
The third digit indicates the terminal
number.
Marks a terminal, which is not connected to the printed circuit board.
Rev.: 12-17
HMF Technical Service Department
5
Installation, RCL 5300
Survey of terminals, FJC 5330
D2
+
D1
+
AD 4
AD 3
+
AD 2
+
AD 1
+
-
O1
O2
Digital Out
Digital in
FJC 5330
Analog / Digital in
CAN 1
H
L
IGN
+
-
H
L
IGN
+
-
K376
K275
K174
K373
K272
K171
K370
K369
K268
K167
K366
K265
K164
K363
K262
K161
K194
K393
K192
K391
FJC 5330
K545
K444
K343
K242
K141
K535
K434
K333
K232
K131
Terminal
K1xx
K2xx
K3xx
K4xx
K5xx
Signal
Supply ÷
Supply +
Ignition
CAN Low
CAN High
Explanation
The first digit in the terminal number indicates the signal type.
Kx1x
Power
The second digit in the terminal number indicates the number
of the plug.
Kxx1
Number
The third digit indicates the terminal number.
Rev.: 12-17
HMF Technical Service Department
6
Installation, RCL 5300
Survey of terminals, WIC 5333
D2
+
D1
+
AD 4
AD 3
+
AD 2
+
AD 1
+
-
O2
O1
Digital Out
Digital in
WIC 5333
Analog / Digital in
H
L
IGN
+
-
H
L
IGN
+
-
K194
K393
K192
K391
WIC 5333
K051
K352
K353
K354
K355
K056
K357
K358
K359
K360
S8
S7
S6
S5
S4
S3
S2
S1
Load cell 1
CAN 1
K376
K275
K174
K373
K272
K171
K370
K369
K268
K167
K366
K265
K164
K363
K262
K161
K545
K444
K343
K242
K141
K535
K434
K333
K232
K131
Load cell 2
Terminal
K1xx
K2xx
K3xx
K4xx
K5xx
Signal
Supply ÷
Supply +
Ignition
CAN Low
CAN High
Explanation
The first digit in the terminal number indicates the signal type.
Kx1x
Power
The second digit in the terminal number indicates the number
of the plug.
Kxx1
Number
The third digit indicates the terminal number.
Rev.: 12-17
HMF Technical Service Department
7
Installation, RCL 5300
Survey of terminals, CIO 5376
D2
+
D1
+
AD 4
AD 3
+
AD 2
+
AD 1
+
-
O1
O2
Digital Out
Digital in
CIO 5376
Analog / Digital in
CAN 1
H
L
IGN
+
-
H
L
IGN
+
-
K376
K275
K174
K373
K272
K171
K370
K369
K268
K167
K366
K265
K164
K363
K262
K161
K194
K393
K192
K391
CIO 5376
K545
K444
K343
K242
K141
K535
K434
K333
K232
K131
Terminal
K1xx
K2xx
K3xx
K4xx
K5xx
Signal
Supply ÷
Supply +
Ignition
CAN Low
CAN High
Explanation
The first digit in the terminal number indicates the signal type.
Kx1x
Power
The second digit in the terminal number indicates the number
of the plug.
Kxx1
Number
The third digit indicates the terminal number.
Rev.: 12-17
HMF Technical Service Department
8
Installation, RCL 5300
Survey of terminals, ECT 5310
K636
K535
K434
K333
K232
K131
K737
K391
K392
K393
K394
K195
SLC
5363
Stop
O1
O2
O3
O4
-
ECT
5310
Stop
H
L
IGN
+
-
ECT
5310
D4
+
D3 IGN
D2
L
D1
H
Stop Stop
Signal
Supply ÷
Supply +
Ignition
CAN Low
CAN High
Stop (signal)
Stop (signal)
K141
K242
K343
K444
K545
K646
Terminal
K131
K232
K333
K434
K535
K636
K737
K581
K483
K383
K283
K183
K747
Signal
Supply ÷
Supply +
Ignition
CAN Low
CAN High
Stop (signal)
Stop (signal)
K581 K483 +
K383 IGN
K283 L
K183 H
Stop Stop
Terminal
K141
K242
K343
K444
K545
K646
K747
Survey of terminals, SLC 5363
Dig. Out 1
Dig. Out 1
Dig. Out 1
Dig. Out 1
Supply ÷
CIO
5374
K737
K391
K392
K393
K394
K195
K391
K392
K393
K394
K195
K636
K535
K434
K333
K232
K131
Dig. in 1
Dig. in 2
Dig. in 3
Dig. in 4
Supply ÷
Stop
O1
O2
O3
O4
-
K381
K382
K383
K384
K185
SLC
5363
Stop
H
L
IGN
+
-
Signal
Supply ÷
Supply +
Ignition
CAN Low
CAN High
Stop (signal)
Stop (signal)
D4
+
D3 IGN
D2
L
D1
H
Stop Stop
Terminal
K131
K232
K333
K434
K535
K636
K737
K141
K242
K343
K444
K545
K646
Signal
Supply ÷
Supply +
Ignition
CAN Low
CAN High
Stop (signal)
Stop (signal)
K185
K384
K383
K382
K381
K747
Terminal
K141
K242
K343
K444
K545
K646
K747
Survey of terminals, CIO 5374
K391
K392
K393
K394
K195
Dig. Out 1
Dig. Out 1
Dig. Out 1
Dig. Out 1
Supply ÷
Rev.: 12-17
HMF Technical Service Department
K737
K391
K392
K393
K394
K195
Dig. in 1
Dig. in 2
Dig. in 3
Dig. in 4
Supply ÷
K636
K535
K434
K333
K232
K131
K381
K382
K383
K384
K185
CIO
5374
Stop
O1
O2
O3
O4
-
Signal
Supply ÷
Supply +
Ignition
CAN Low
CAN High
Stop (signal)
Stop (signal)
Stop
H
L
IGN
+
-
Terminal
K131
K232
K333
K434
K535
K636
K737
K141
K242
K343
K444
K545
K646
Signal
Supply ÷
Supply +
Ignition
CAN Low
CAN High
Stop (signal)
Stop (signal)
K185
K384
K383
K382
K381
K747
Terminal
K141
K242
K343
K444
K545
K646
K747
9
Installation, RCL 5300
Survey of terminals, CR 2033
Terminal
01
02
03
04
05
Signal
Supply +
Ana. in
Supply ÷
Dig. in
Shield
Terminal
01
02
03
04
05
Signal
Supply +
Ana. in
Supply ÷
Dig. out
Shield
Terminal
01
02
03
04
05
Signal
Supply +
Ana. in
Supply ÷
Dig. in
Shield
Terminal
01
02
03
04
05
Signal
Supply +
Ana. in
Supply ÷
Dig. out
Shield
Terminal
01
02
03
04
05
Signal
Supply +
Ana. in
Supply ÷
Dig. in
Shield
Terminal
01
02
03
04
05
Signal
Supply +
Ana. in
Supply ÷
Dig. out
Shield
Terminal
01
02
03
04
05
Signal
Supply +
Ana. in
Supply ÷
Dig. in
Shield
Terminal
01
02
03
04
05
Signal
Supply +
Ana. in
Supply ÷
Dig. out
Shield
Terminal
01
02
03
04
05
Signal
Chassis
Supply +
Supply ÷
CAN High
CAN Low
Terminal
01
02
03
04
05
Signal
Chassis
Supply +
Supply ÷
CAN High
CAN Low
Rev.: 12-17
HMF Technical Service Department
10
Installation, RCL 5300
Survey of terminals, EJB 5380
J3
+
J3-2
Power RCL
Stab
Boom
Safe
PTO
-
J3-1
F2
15A
F3
10A
K2A
K1A
J4
F1
10A
24V
0V
J7-1
J7-2
J7-3
J7-4
0V
12V
Terminal
J1-x
Signal
Signal
J2-x
Signal
J3-x
J4-x
J5-x
J6-x
J7-x
J8-x
Rev.: 12-17
J8
Extra
Oil
+
-
J4-1
Lignt
- RCL J8-1
+ RCL J8-2
Ignition J8-3
- Extra J8-4
+ Extra J8-5
- Oil J8-6
+ Oil J8-7
- J8-8
Light 1 J8-9
- J8-10
Light 2 J8-11
- J8-12
Light 3 J8-13
On J8-14
+ J8-15
RCL
Converter
J6
- J6-1
+ J6-2
Stab L J6-3
- J6A-1
+ J6A-2
Stab R J6A-3
- J6B-1
+ J6B-2
Boom J6B-3
Safety
J2
Safety
J2-4
J2-3
J2-2
J2-1
2A
J4-2
J1
Auto
Start
Stop
RPM +
RPM -
Power Oil/Light
Engine
J1-5
J1-4
J1-3
J1-2
J1-1
Engine
Auto J5-1
Start J5-2
Stop J5-3
RPM + J5A-1
RPM - J5A-2
J5
F4
Supply +
Supply Supply +
Supply Signal
Supply +
Supply Signal
Supply +
Supply +
Supply Signal
Explanation
Output signals for truck, for engine control
Signal from PTO.
Output signals for truck, for transport
alarm.
Power supply from truck, for the RCL.
Power supply from truck, for oil cooler and
spotlight.
Input signals from RC, for engine control.
Power supply for and input signals from
sensors for transport alarm.
Connection of 12/24 volt converter.
Power supply from EJB5380 for RCL/RC
as well as oil cooler and spotlight.
Signal from RCL for activation of work
light.
HMF Technical Service Department
11
Installation, RCL 5300
Survey of terminals, PVEO-DI
The electric activation PVEO-DI on the
PVSK-change-over valve is activated
ON/OFF from the RCL 5300 and has built-in
spool sensors (DI).
The PVEO-DI has two power supplies:
•
UDC (A and B) for ON/OFF activation of PVSK.
•
UDC2 for spool sensors DI-A and DI-B.
Survey of terminals, PVED-CC
The PVED-CC activations on the PVG 32
control valve are connected in series (Serial
CAN) and have power supply (Vbat+ and
Vbat−) and CAN bus (CAN-L and CAN-H)
connection for the RCL 5300 controller.
The CAN bus is terminated
before the first component and
after the last component in the
serial connection.
The termination is carried out by
connecting a 120 Ω resistance
between the CAN-L and CAN-H.
In systems where the CAN bus is not led on
from the PVED group, the last PVED-CC in the
series connection must be terminated by a plug
that has a built-in 120 Ω resistance.
Rev.: 12-17
HMF Technical Service Department
12
Installation, RCL 5300
Block diagram, RCL 5300
Out1
K636
K397
K646
Out2
Stop termination
K747
K737
Out3
K222,K232,K242
Power
Out4
K212
K313,K323,
K333,K343
K395
Int. Stop
switch
K393
K391
Ign
CPU A
K525
K424
K434,K444
L2
H1 CAN1
PSU
L1
Power supply
K535,K545
H2 CAN2
CPU B
Buzzer
7 Seg & dots
Folie
LEDs & Buttons
Max
30V
K111
Rev.: 12-17
Gnd
Sensor supply
Gnd
HMF Technical Service Department
K286,K282,K271,
K268,K265,K262,
K258,K255,K252
K111,K121,K131,
K141,K151,K154,
K157,K161,K164,
K167,K170,K181,
K185,K189,K192,
K194,K196,K198
13
Installation, RCL 5300
Block diagram, CR 2033
Rev.: 12-17
HMF Technical Service Department
14
Installation, RCL 5300
Programming of spool data for PVED-CC electric activation
When mounting a new PVED electric activation, the spool data, corresponding to
the crane function in question, must be programmed by means of the CGW5355
service terminal.
In the table below spool data are stated according to which crane model/function the electric
activation is to be used for.
Please note. In originally fitted electric activations, it may in certain cases be possible to read
another spool no. (for example 11076314). When replacing these electric activations, also
use the spool data stated in the below table.
Crane type 400 - 735
Crane type 760 - 1230
Crane type 1244Z /
1444Z / 2243Z
Function
Spool data
Function
Spool data
Function
Spool data
Slew
Boom
Jib
Extension
Rotator
Grab
157B7115
157B7030
157B7001
157B7102
157B7001
157B7002
Slew
Boom
Jib
Extension
Rotator
Grab
157B7130
157B7072
157B7042
157B7102
157B7020
157B7022
Slew
Boom
Jib
Extension
Rotator
Grab
157B7131
157B7062
157B7072
157B7122
157B7020
157B7022
Crane type 1560 - 2220 ”Old
middle range”
Function
Slew
Boom
Jib
Extension
Rotator
Grab
Winch
Fly-Jib
Fly-jib Ext.
Function
Spool data
Slew
Boom
Jib
Extension
Rotator
Grab
Winch
Fly-Jib
Fly-jib Ext.
157B7121
157B7073
157B7063
157B7103
157B7020
157B7022
157B7123
157B7021
157B7121
Spool data
157B7130
157B7072
157B7042
157B7103
157B7020
157B7022
157B7123
157B7021
157B7121
Crane type 3450 - 4220
Function
Spool data
Slew
Boom
Jib
Extension
Rotator
Grab
Winch
Fly-Jib
Fly-jib Ext.
157B7030
157B7073
157B7063
157B7123
157B7020
157B7022
157B7123
157B7021
157B7122
Rev.: 12-17
Crane type 2500 - 3000
Crane type 300 - 2620
”New middle range”
Function
Spool data
Slew
Boom
Jib
Extension
Rotator
Grab
Winch
Fly-Jib
Fly-jib Ext.
157B7030
157B7072
157B7062
157B7123
157B7020
157B7022
157B7123
157B7021
157B7121
Crane type 3220 - 8520
Function
Spool data
PVSK
Slew
Boom
Jib
Extension
Rotator
Grab
Winch
Fly-Jib
Fly-jib Ext.
157Bpvsk
157B7123
157B7073
157B7073
157B7123
157B7122
157B7022
157B7123
157B7022
157B7122
HMF Technical Service Department
15