payload monitor system - assets.rct-global.com

PRODUCT MANUAL PAYLOAD MONITOR SYSTEM SERIES 2 WITH LOGGING (470 MHz) Part No. 12082 | 12175

2 | 32 M0868.docx | Rev 1.9 | Modified on 8/08/2018 | © Remote Control Technologies Pty Ltd

DISCLAIMER

© Remote Control Technologies Pty Ltd.

■ No part of this manual may be reproduced, copied, translated, or transmitted in any form or by any means without the written permission of RCT.

■ Information provided in this manual is intended to be accurate and reliable. However, RCT assumes no responsibility for its use or infringements upon the rights of third parties that may result from its use.

■ All examples and diagrams shown in this manual are intended only as an aid to understanding the text, not to guarantee operation. RCT will accept no responsibility for actual use of the product based on these illustrative examples.

■ Please contact your nearest RCT branch for more information concerning applications in life critical situations or high reliability.

■ RCT reserves the right to make changes to any product herein to improve reliability, function or design. All specifications are subject to change without notice.

M0868.docx | Rev 1.9 | Modified on 8/08/2018 | © Remote Control Technologies Pty Ltd 3 | 32

Contents GENERAL SAFETY WARNINGS 4

PRODUCT OVERVIEW 5

OPERATION AND USE 5 TRUCK OPERATOR’S GUIDE 6 LOADER CHANNEL ASSIGNMENT 7 LOADER PAYLOAD DISPLAY 8 - SYSTEM OVERVIEW 8 DISPLAY FUNCTIONS 9 - CHANGING THE BACKLIGHT 9 - LOAD COUNTER 9 RETRIEVING/CLEARING LOGS 10 - USING A USB MEMORY STICK 10 REMOTE PAYLOAD DISPLAY SYSTEMS COMPATIBILITY DIAGRAM 12

INSTALLATION GUIDE 13 ANTENNA INSTALLATION 13 CHANNEL SELECTION 13 PAYLOAD INTERFACE INSTALLATION (LOADER) 13 PAYLOAD INTERFACE INSTALLATION (TRUCK) 13 CHANNEL SELECTOR SWITCH LABELLING 13 DIAGRAMS 14 - TRUCK PAYLOAD INTERFACE EXTERNAL WIRING (477z) 14 - LOADER PAYLOAD INTERFACE EXTERNAL WIRING (524v) 15 - SYSTEM LAYOUT (524u) 16 - TRUCK LOOM CONFIGURATION SELECTION 17 - VIMS LOOM CONFIGURATION (059j) 18 - CATERPILLAR (EARLY) LOOM CONFIGURATION (018k) 19 - KOMATSU LOOM 1 CONFIGURATION (064a) 20 - KOMATSU LOOM 2 CONFIGURATION (268y) 21 - KOMATSU LOOM 3 CONFIGURATION (063ga) 22 - HITACHI LOOM CONFIGURATIONI (513d ) 23 - LOADER LOOM CONFIGURATION (019v) 24 CMP PAYLOAD MONITORING AND CONFIGURATION 25 - CONNECTING TO THE PAYLOAD CONFIGURATION LOOM 25 - MONITOR PAYLOAD STATUS 25 - CONFIGURING THE PAYLOAD INTERFACE 26 USING THE MONITOR AND CONFIGURATION TOOL 27 - READING THE LOG FILES 27

DIAGNOSTICS MODE 28 - DIAGNOSTICS DIGGING LOADER 28 - DIAGNOSTICS LOGGING TRUCK 28 - READING LOG DATA 28

PARTS LIST 29

TROUBLESHOOTING 29

GLOSSARY 30

WARRANTY 30


GENERAL SAFETY WARNINGS

PERSONAL SAFETY

■ Everyone is responsible for safety. ■ The installer/service personnel should be trained and authorized to complete the required work. ■ Ensure that the machine is safely isolated during installation and testing to protect all personnel. ■ Complete all required risk assessments and job safety analysis (JSA) before commencing work. ■ Observe all site specific and machine OEM procedures regarding the following:

– working at heights – working in heat – working in confined spaces – all other site specific occupational health and safety (OH&S) procedures

MACHINE ■ Carry out all prestart operations as per site and machine OEM procedures. ■ Ensure the machine is safely isolated during installation and testing to protect the machine and other

equipment in the area. ■ Do not operate any machine with a known fault and report all findings to the supervisor in writing. ■ Test and operate machine as per machine OEM and site procedures. ■ Read and understand machine and site specific operational and testing instructions. PRODUCT Before applying power to the equipment, the user/repairer/ installer must read all product instructions. If in doubt, seek assistance. ■ Ensure electrical connections are made as per RCT’s recommendations. Test circuits prior to connecting

power to any component. ■ The equipment contains no user serviceable parts inside. Return the unit to RCT for repairs. ■ Retain product and installation instructions for future use. ■ Ensure that RCT’s recommended service procedures are included in the machine’s service routine. ■ Observe all machine, site and RCT product warnings. ■ Follow all machine, site and RCT product operating procedures at all time. The application of safety should not be limited to the above recommendations.


PRODUCT OVERVIEW The EarthTrack® Loader Payload Interface, part number 12082 and 12175, is a production tool designed to display the payload weights being loaded onto a dump truck to a loader operator. This allows the loader operator to optimise the total payload and spread the load evenly. The truck operator selects the loader that they will be serviced by and the trucks weight and strut pressures are transmitted to the loader and displayed on a screen inside the loader's cabin.

The remote payload display has been designed to communicate with many different payload systems, including: ■ Caterpillar TPMS ■ Caterpillar VIMS ■ Komatsu PLM2 ■ Komatsu PLM3 ■ Hitachi

OPERATION AND USE The truck payload interface system communicates with the OEM payload system via a serial RS232 or CAN connection. The interface continually requests the operating mode from the OEM payload system. When a truck enters into a 'Loading' state, the following operations are performed: 1. The payload weight and the four strut pressures are read from the OEM payload system and forwarded

on to the loader’s remote display via the radio channel.

2. Payload weight and strut pressure is displayed remotely on any remote payload displays within range (must be on the same channel). This appears on the connected payload display.

3. Payload weight is displayed locally on up to two large digit displays (if connected).

4. The four strut pressures for front left, front right, rear left and rear right are displayed as bar graphs on the

loader payload display. 5. When the mode received from the OEM payload system changes from ‘loading’, the truck will transmit

higher priority end of load packets for 20 seconds which will confirm to the loader that the load is finished. Some manufacturers’ trucks re-weigh after a short time (2nd gear/ 150 metres travelled for Caterpillar). If this re-weigh weight can be successfully transmitted to the loader, the loader will update its logged data.

If the communications link between the interface and the OEM payload system fails, a series of three horizontal bars will be displayed on the local large digit display only (if fitted).


TRUCK OPERATOR’S GUIDE Each loader is assigned a channel (A/B 1–8); this channel will not change.

If a truck is working with a loader it needs to be on the same channel as the loader. This is selected using the 16-channel selection switch.

LOADER WITH PAYLOAD SYSTEM TRUCK WITH LOADER CHANNEL SELECTED


If a truck changes which loader it is loaded by, the truck operator needs to switch to the correct channel to match the new loader.

LOADER WITH PAYLOAD SYSTEM TRUCK WITH LOADER CHANNEL SELECTED

LOADER WITH PAYLOAD SYSTEM TRUCK WITH WRONG CHANNEL SELECTED

If a truck changes to be loaded by a loader without an EarthTrack® Payload Monitor system, the truck operator must switch to a channel unused by any loader with an EarthTrack® Payload Monitor system installed.

LOADER WITHOUT PAYLOAD SYSTEM TRUCK USES UNUSED CHANNEL

LOADER WITHOUT PAYLOAD SYSTEM TRUCK ON ANOTHER LOADER’S CHANNEL

The operator will have to be aware of which channels each loader is on, and which channels remain unused. In order to inform truck drivers what channel each loader is on, fill out the table on the following page and place copies in all trucks fitted with EarthTrack® Payload systems. LOADER CHANNEL ASSIGNMENT

Fill this table in with the dedicated loader channels. For use in all truck cabins. GROUP A GROUP B CHANNEL LOADER ID CHANNEL LOADER ID

1 1 2 2 3 3 4 4 5 5 6 6 7 7 8 8


LOADER PAYLOAD DISPLAY Loader units use the payload display for user interface. This display has a USB port for reprogramming.

SYSTEM OVERVIEW

No. NAME FUNCTION

1 Selection Dial Used to navigate menus. Rotate the selection dial to navigate the options and depress the selection dial to make a selection.

2 Backlight Used to change the brightness of the backlight on the display. Press once to open the backlight menu box, use the selection dial to make an adjustment, and press once again to close.

3 Reset Count Used to reset the load count. Press once to open the reset the count menu box, and once again to close.

4 Missed Load Used to increment the load count by one. Press once to open the missed load menu box, and once again to close.

5 Logs Used to fetch/clear logs. Press once to open the logs menu box, and once again to close.

6 Status Used to check the status of the unit. Press once to open the status dialog box, and once again to close.

7 Payload Weight Displays the current weight being received from the vehicle.

8 Load Count Displays the current load count of the vehicle.

9 Strut Graphic Display the vehicle strut pressure and payload distribution.


DISPLAY FUNCTIONS CHANGING THE BACKLIGHT

1. To change the brightness of the backlight on the payload display, first locate the backlight button (indicated as “2” on the overview picture), and press it once. A new menu will be displayed:

2. Rotate the selection dial (indicated as “1” on the overview picture) left to dim the screen, and right to increase the brightness. Once the desired level has been reached, press the backlight button once more to close the window.

LOAD COUNTER

1. To reset the load count on the display, first locate the reset count button (indicated as “3” on the overview picture) and press it once.

A new menu will be displayed:

2. Navigate to the OK button on the new menu using the selection dial (indicated as “1” on the overview picture), and press the selection dial to select it. If you no longer wish to clear the load count, you can close the menu by pressing the reset count button again or by navigating to the cancel button and pressing the selection dial.

3. To increment the load count, first locate the missed load button (indicated as “4” on the overview picture) and press it once.

A new menu will be displayed:

4. Navigate to the + button using the selection dial (indicated as “1” on the overview picture) and press the selection dial to select it. After incrementing the load a short lockout period will commence wherein you cannot increment again. If you no longer wish to increment the load count you can close the menu by pressing the missed load button again or by navigating to the cancel button and pressing the selection dial.


RETRIEVING/CLEARING LOGS Logs can be retrieved from a loader unit, it is recommended to download and clear the logs every day to avoid the memory becoming full. Log files are created as a comma separated values (CSV) file type. These files can be opened in Microsoft Excel.

USING A USB MEMORY STICK To retrieve the logs from a loader payload interface using a USB memory stick:

1. Any USB memory stick can be used to retrieve logs; however the user must ensure that the USB memory stick is formatted with a FAT32 file system. The memory stick provided by RCT will be properly formatted before delivery. If another memory stick is used, then follow steps 2 and 3 before proceeding.

2. The next two steps only need to be followed if you are using a USB stick that was not provided by RCT. To confirm that the memory stick has been properly formatted, insert it into a Windows-based computer. Once the drive is properly mounted, it will appear in Windows Explorer.

3. Right-click on the USB drive and select Format. A window will open and display the current file system.


4. Insert the USB drive into the USB port connected to the payload display.

5. Select the Logs button on the payload display and then select Save Logs to USB by pressing the selection dial.

6. If a USB stick is not inserted, the payload display will prompt the user to insert one. Once inserted, the payload display may take a few seconds to properly mount it.

7. Once a memory stick is mounted, select OK by pressing the selection dial. The payload display will confirm if the save is successful. The logs will be saved onto USB drive on the top folder as a comma-separated values file (CSV). This file will be named as follows: ■ Log_[Loader ID]_[YYYYMMDDHHMMSS].

For example: Log_LD1_20141213143612 is a log taken from LD1 at 2:36pm on the 13th of December 2014. This CSV file can be opened using Microsoft Excel software; if the information is not readable try expanding the column width.

8. To clear the logs, press the Logs button, the Logging window will open. Use the selection dial to highlight Clear Logs. Press in the selection dial once. The payload display will show a screen confirming that the logs are cleared.

9. To clear the logs press the Logs button, the Logging window will open. Use the selection dial to highlight Clear Logs. Press in the selection dial once. The payload display will show a screen confirming that the logs are cleared.


REMOTE PAYLOAD DISPLAY SYSTEMS COMPATIBILITY DIAGRAM

STANDARD RECEIVER

NOTE: THIS RECEIVER WILL ACCEPT READINGS FROM ALL THESE

TRUCKS FITTED WITH 470 MHz TRANSMITTERS

RCT APN 12082 KOMATSU PLM II ELECTRIC DRIVE

KOMATSU PLM II MECHANICAL DRIVE

HITACHI

CATERPILLAR TPMS

CATERPILLAR VIMS


INSTALLATION GUIDE ANTENNA INSTALLATION

Mount the antennas away from other radio antennas to avoid interference and inter-modulating signals. Ideally, all antennas should be mounted one metre apart from each other and one metre clear from any other metal structures. Ensure that all corresponding antennas are mounted on the same plane, either vertical or horizontal. For example, if the truck antennas are mounted vertically, then the loader antenna should also be mounted vertically; this will ensure the best performance possible. Note: Always check the frequencies of other radios operating in the vicinity to ensure that they are separated from the frequencies that the remote payload system operates on. CHANNEL SELECTION The remote payload display system can be configured to operate on one of eight available channels. The truck interfaces and the remote receivers must be operating on the same channel to communicate correctly. Channels may be selected in several ways: 1. No link or channel switch will default to ‘Channel 1’. 2. A permanent link between pins as per the following table can be made in an RCT 0073 MS connector to

select a specific channel (pre-made channel selector plugs are also available from RCT (part numbers 10032 – 10039 for channels 1-8 respectively).

3. Fit an RCT 11594 16-channel selector switch. This is the most common system as the operators can

simply select which loading circuit they are operating on.

it is recommended that a permanent link is used for loaders, and a 16-channel selector is installed on every truck.

PAYLOAD INTERFACE INSTALLATION (LOADER) The loader payload interface requires a 24-volt supply connection. The payload weight is displayed on the LCD on the front of the unit; however, it is recommended to attach RCT’s payload display. The payload interface can be installed inside the cabin on a flat surface. The payload LCD display must be mounted in the cabin facing the operator. The payload display unit comes with a RAM mount for adjustable view angles. PAYLOAD INTERFACE INSTALLATION (TRUCK) The truck payload interface requires a 24-volt supply and connection to the manufacturers payload system. The Payload interface can be installed inside or behind the cabin on a flat surface. The channel selector needs to be installed within reach of the truck operator. CHANNEL SELECTOR SWITCH LABELLING

RADIO FREQUENCY

CHANNEL MS CONNECTOR LINKS GROUP A

CHANNEL GROUP B CHANNEL FREQUENCY

1 No Links 1 1 472.025 MHz 2 D + A 2 2 473.100 MHz 3 D + B 3 3 472.300 MHz 4 D + A + B 4 4 473.900 MHz 5 D + C 5 5 472.075 MHz 6 D + A + C 6 6 473.500 MHz 7 D + B + C 7 7 472.700 MHz 8 D + A + B + C 8 8 474.300 MHz


DIAGRAMS TRUCK PAYLOAD INTERFACE EXTERNAL WIRING (477z)

MACHINE MAKE ANDMODEL

PAYLOADSYSTEM

REQUIREDLOOM

CAT EARLY TPMS 8256CAT LATE VIMS 1446KOMATSU 630E PLM2 2061KOMATSU 730E PLM2 2061KOMATSU 830E PLM2 2061KOMATSU 830E PLM3 3789KOMATSU 930E PLM3 3789KOMATSU HD1500-5 PLM2 2061KOMATSU HD1500-7 VHMS 2061KOMATSU HD785-3 PLM3 3276KOMATSU HD785-3 PLM2 3276KOMATSU HD785-5 PLM2 3276KOMATSU HD785-7 VHMS 3276HITACHI EH1100-3 HTMC 12135HITACHI EH1700-3 HTMC 12135

OPTIONAL EXTERNALLARGE DIGIT

DISPLAY BOARDS

POWER AND DATAPORT

PIN FUNCTION

A +VEB RS232 RXC RS232 TXD GNDE CAN HIF CAN LOW

PROGRAMMING PORTSERIAL BAUD RATE 38400

PIN FUNCTION

A RXB 0 VC TX

DISPLAY CONNECTORSSERIAL BAUD RATE 2400

PIN FUNCTION

1 +VE2 -VE3 NOT USED4 TX

(9755)

CHANNELSELECTION

POWER /DATA

PROGRAMMINGPORT

PAYLOADDISPLAY

INTERFACE(12082)

A F

E

DC

B A C

B

1 2

4 3

DISPLAY 2COMMS 2

ANTENNA

1 2

4 3

DISPLAY 1

16 CHANNEL SELECTOR(11594)

1

5

37

8 2

6 4

A

BCHANNELGROUP

87654321

A

B

C

D

E

F

G

H

I

J

K

L

A

B

C

D

E

F

G

H

I

J

K

L

87654321

A4

COPYRIGHT - ALL RIGHTS RESERVEDThis drawing is the property of REMOTECONTROL TECHNOLOGIES PTY LTD (RCT),and is not to be copied or used in whole or inpart for any purpose without the expressauthority of RCT. The drawing is to be returnedto RCT, on demand.

PAYLOAD EXTERNALDISPLAY (TRUCK

UNIT)

EXTERNAL LAYOUT

www.rct.net.au

UNCONTROLLED DOCUMENT

REV

4DWG No 477z

STATUS

NTSSCALE

Released

SHEET 1 of 1

BY EYDRN CW DATE 20/05/13APPD BT DATE 11/02/14

STOCKCODE ET-TRK-PLD-ADV

PARTNO 12082

3rd ANGLEPROJECTION

ALL DIMENSIONS IN MILLIMETERS

REV ZONE DESCRIPTION BY DATE

1 MODIFIED AND ADDEDTO TABLES AD 28/05/14

2 ALL

Added 3258, 12021,8893, antenna, comms2,

channel select oninterface, 12135 to table,

panel modified

AD 23/10/14

3 A7

APN for aerial changed

AD 21/09/15

4 A2-C5,D2

8893 updated to 11594,APN 12082 added

JB 29/09/17


LOADER PAYLOAD INTERFACE EXTERNAL WIRING (524v)

CHANNELSELECTION

POWER /DATA

PROGRAMMINGPORT

A F

E

DC

B A C

B

1 2

4 3

DISPLAY 2COMMS 2

ANTENNA

1 2

4 3

DISPLAY 1

PR

OG

RA

MM

ING

LO

OM

(331

4)

PROGRAMMING PORTSERIAL BAUD RATE 38400

PIN FUNCTION

A RXB 0 VC TX

PAYLOADLOADER INTERFACE

(12175)

ANTENNA(9755)

CABLE & BASE(9522)

BRACKET(4723)

PAYLOAD DISPLAY(12201)

USB PORT DIS

PLA

Y L

OO

M F

OR

PA

YLO

AD

(118

93)

MACHINE MAKE ANDMODEL

PAYLOADSYSTEM

REQUIREDLOOM

CAT EARLY TPMS 8256CAT LATE VIMS 1446KOMATSU 630E PLM2 2061KOMATSU 730E PLM2 2061KOMATSU 830E PLM2 2061KOMATSU 830E PLM3 3789KOMATSU 930E PLM3 3789KOMATSU HD1500-5 PLM2 2061KOMATSU HD1500-7 VHMS 2061KOMATSU HD785-3 PLM3 3276KOMATSU HD785-3 PLM2 3276KOMATSU HD785-5 PLM2 3276KOMATSU HD785-7 VHMS 3276HITACHI EH1100-3 HTMC 12135HITACHI EH1700-3 HTMC 12135

POWER AND DATAPORT

PIN FUNCTION

A +VEB RS232 RXC RS232 TXD GNDE CAN HIF CAN LOW

87654321

A

B

C

D

E

F

G

H

I

J

K

L

A

B

C

D

E

F

G

H

I

J

K

L

87654321

A4

COPYRIGHT - ALL RIGHTS RESERVEDThis drawing is the property of REMOTECONTROL TECHNOLOGIES PTY LTD (RCT),and is not to be copied or used in whole or inpart for any purpose without the expressauthority of RCT. The drawing is to be returnedto RCT, on demand.

SERIES 2 PAYLOADLOADER 470 MHZ

EXTERNAL WIRING

www.rct-global.com

UNCONTROLLED DOCUMENT

REV

5DWG No 524v

STATUS

NTSSCALE

Released

SHEET 1 of 1

BY ADDRN RH DATE 27/10/14APPD AD DATE 30/10/14

STOCKCODE ET-LD-PLD-ADV

PARTNO 12175

3rd ANGLEPROJECTION

ALL DIMENSIONS IN MILLIMETERS

REV ZONE DESCRIPTION BY DATE

1 A6-7 APN for aerial updated AD 21/09/15

2A1-D4,A6,D6,C6,I4

16 ch selector replaces 8ch, ch select plu gto 6 pin,antenna/loom apnsupdated

AD 14/07/16

3 I5-K7,J8, K3

added table and titlechange, change todisplay text/apn

DH 06/06/17

4 B2-C6 11594 removed JB 29/08/17

5 L3payload display APN

changed MT 08/08/18


SYSTEM LAYOUT (524u)

LAR

GE

DIG

IT DISPLAY

(4557)

OP

TION

AL E

XTERN

ALLA

RG

E D

IGIT

DIS

PLA

Y B

OAR

DS

DIS

PLA

Y C

ON

NEC

TOR

SS

ER

IAL B

AU

D R

ATE 2400P

INFU

NC

TION

1+VE

2-V

E3

RX

4TX

AN

TENN

A(9755)

CH

AN

NEL

SE

LEC

TION

PO

WE

R /

DA

TAP

RO

GR

AM

MIN

GP

OR

T

PA

YLO

ADTR

UC

K IN

TERFA

CE

(12082)

AFE

DC B

AC

B

12

43

DIS

PLA

Y 2C

OM

MS 2

AN

TENN

A

12

43

DIS

PLA

Y 1

CH

AN

NEL

SE

LEC

TION

PO

WE

R /

DA

TAP

RO

GR

AM

MIN

GP

OR

T

PA

YLO

ADLO

AD

ER

INTER

FACE

(12175)

AFE

DC B

AC

B

12

43

DIS

PLA

Y 2C

OM

MS 2

AN

TENN

A

12

43

DIS

PLA

Y 1

3314(O

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CO

NN

EC

TED FO

RP

RO

GR

AM

MIN

G)

(ON

LY C

ON

NE

CTED

FOR

PR

OG

RA

MM

ING

)

LARGE DIGIT DISPLAY LOOM(10064)

LARGE DIGIT DISPLAY LOOM(1554)

LAR

GE

DIG

IT DISPLAY

(4557)

PROGRAMMING LOOM(3314)

CA

BLE

& B

ASE(9522)

BR

AC

KET(4723)

AN

TENN

A(9755)

CA

BLE

& B

ASE(9522)

BR

AC

KET(4723)

16 CH

ANN

EL SE

LEC

TOR

(11594)

15

37

82

64

ABC

HA

NN

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RO

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EA

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TRA

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LAYO

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PA

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ADS

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TEM

REQ

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EDLO

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CA

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LYTP

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8256C

AT LATE

VIM

S1446

KO

MA

TSU

630EP

LM2

2061K

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ATS

U 730E

PLM

22061

KO

MA

TSU

830EP

LM2

2061K

OM

ATS

U 830E

PLM

33789

KO

MA

TSU

930EP

LM3

3789K

OM

ATS

U H

D1500-5

PLM

22061

KO

MA

TSU

HD

1500-7V

HM

S2061

KO

MA

TSU

HD

785-3P

LM3

3276K

OM

ATS

U H

D785-3

PLM

23276

KO

MA

TSU

HD

785-5P

LM2

3276K

OM

ATS

U H

D785-7

VH

MS

3276H

ITACH

I EH

1100-3H

TMC

12135H

ITACH

I EH

1700-3H

TMC

12135

PO

WE

R A

ND

DATA

PO

RT

PIN

FUN

CTIO

NA

+VEB

RS

232 RX

CR

S232 TX

DG

ND

EC

AN H

IF

CAN

LOW

TO LO

ADER

24V S

UPPLY

PA

YLO

AD

DISPLAY

(12201)

USB PO

RT

DISPLAY LOOM FOR PAYLOAD(11893)

POWER LOOM LOADER(3002)

12

34

56

78

910

1112

B ACDEFGH

B ACDEFGH

12

34

56

78

910

1112

A4

CO

PY

RIG

HT - A

LL RIG

HTS R

ESERVED

This draw

ing is

the property

of R

EM

OTE

CO

NTR

OL TE

CH

NO

LOG

IES P

TY LTD (R

CT),

and is not to be copied or used in whole or in

part for

any purpose

without

the express

authority of RC

T. The drawing is to be returned

to RC

T, on demand.

SE

RIE

S 2 PAYLO

ADS

YS

TEM

OV

ERVIEW

470 MH

Z

EXTER

NA

L WIR

ING

ww

w.rct.net.au

UN

CO

NTR

OLLE

D D

OC

UM

ENT

REV4

DW

G N

o524u

STA

TUS

NTS

SC

ALE

Released

SH

EET1 of 1

BYAD

DR

NR

HD

ATE24/10/14

APPD

ADD

ATE30/10/14

STO

CK

CO

DE

----

PAR

TN

O----

3rd AN

GLE

PR

OJE

CTIO

N

ALL D

IMEN

SIO

NS IN

MILLIM

ETER

S

REV

ZON

ED

ESC

RIP

TION

BYD

ATE

1

A1-C

4,A

7-C9,

A5-C

5,A

10-C1

0,B11,F9

16 ch selector replaces 8ch, ch select plug to 6 pin,antenna/loom

apnsupdated

AD14/07/16

2A

2-A9,G

4-H5,

H8-9

added table, headingsand page title, change todisplay text/apn

DH

06/06/17

3B

7-C10 11594 rem

oved fromdigger/m

achine layoutJB

29/09/17

4H

8payload display A

PNchanged

MT

08/08/18


TRUCK LOOM CONFIGURATION SELECTION

In order to communicate with different manufacturer payload systems, trucks may require different looms. Use the lookup table below to select the appropriate loom for each truck type that is compatible with the interface.

TRUCK MAKE TRUCK MODEL

PAYLOAD SYSTEM REQUIRED LOOM DRAWING NUMBER

CAT (LATE) ALL VIMS VIMS 1446 059j

CAT (EARLY) ALL TPMS TPMS 8256 018k

KOMATSU 630E PLM2 2061 064a



KOMATSU 830E PLM3 3789 268y

KOMATSU 930E PLM3 3789 268y

KOMATSU HD1500-5 PLM2 2061 064a

KOMATSU HD1500-7 VHMS (PLM3) 2061 064a

KOMATSU HD785-3 PLM3 3276 063ga



KOMATSU HD785-7 VHMS (PLM3) 3276 063ga

HITACHI EH1100-3 HTMC 12135 513d

HITACHI EH1700-3 HTMC 12135 513d


VIMS LOOM CONFIGURATION (059j)

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WIR

E 972

WIR

E 876

WIR

E 875

BUOR

BU

TO V

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ME

TRY

PO

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PLU

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24 VO

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PTY LTDTECHNOLOGIESREM

OTE CONTROL

PERTH

Unit 2-5, 511 A

bernethy Rd

Kew

dale WA

6105P

h:Fax:

+61 8 9353 6577+61 8 9353 6578

KA

LGO

OR

LIE24 P

ercy Rd

Kalgoorlie W

A 6430

Ph:

Fax: +61 8 9021 1600+61 8 9091 4927

MT. ISA

1A R

yan Rd

Mt Isa Q

LD 4825

Ph:

Fax: +61 7 4749 0233+61 7 4749 0232

DES

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CO

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NO

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PTY

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CT), and is not to be copied or used in w

hole orin part for any purpose w

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CT, on dem

and.

LOO

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1446B

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mD

ATA

DB

K-3

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- 3mm

GR

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--

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CATERPILLAR (EARLY) LOOM CONFIGURATION (018k)

ABCDEA B C D E F

1234W

IRE 4

WIR

E 3

WIR

E 2

WIR

E 1

NO

T USED

NO

T USED

(5050)

(0322)

(0320)


OTE CONTROL

PERTH

(HEA

D O

FFICE)

Unit 2-5, 511 A

bernethy Rd

Kew

dale WA

6105P

h:Fax:

+61 (0) 8 9353 6577+61 (0) 8 9353 6578

DE

SC

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AFR

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KOMATSU LOOM 1 CONFIGURATION (064a)

ABCDE

FEDCBAY

L-FVT

TO K

OM

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LM D

OW

NLO

ADP

OR

T

GN

/YL-FVT

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BK

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10K

10K

0.25W

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24 VOLTS

IN

PLU

G(5050)

BAY

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ETP

LUG

(0353)

TO EA

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TRAC

KR

PDS TR

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12

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56

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B ACDEFGH

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12

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A4

CO

PY

RIG

HT - A

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HTS R

ESERVED

This draw

ing is

the property

of R

EMO

TEC

ON

TRO

L TECH

NO

LOG

IES PTY LTD

(RC

T),and is not to be copied or used in w

hole or inpart

for any

purpose w

ithout the

expressauthority of R

CT. The draw

ing is to be returnedto R

CT, on dem

and.

RE

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1change plug 0353 pins tosockets

GS

09/10/06

2C

1,C11

plug descriptionschanged

EY

28/11/14

3V

ar.w

ires changed to FVTG

JS20/02/17


KOMATSU LOOM 2 CONFIGURATION (268y)

GN

D. W

IRE 35L2

RX W

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TX WIR

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THE

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OTE CONTROL

PERTH

Unit 2-5, 511 A

bernethy Rd

Kew

dale WA

6105P

h:Fax:

+61 8 9353 6577+61 8 9353 6578

KA

LGO

OR

LIE24 P

ercy Rd

Kalgoorlie W

A 6430

Ph:

Fax: +61 8 9021 1600+61 8 9091 4927

MT. ISA

1A R

yan Rd

Mt Isa Q

LD 4825

Ph:

Fax: +61 7 4749 0233+61 7 4749 0232

DES

C:

AP

N #:

STO

CK

CO

DE:

DES

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ED

BY:C

HE

CK

ED

BY:D

RA

WN

BY:D

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RA

WIN

G N

UM

BER:

REV

DETAILS

BYD

ATE

CO

PYR

IGH

T - ALL R

IGH

TS RE

SER

VED

This drawing is the property of R

EM

OTE

CO

NTR

OL TE

CH

NO

LOG

IES

PTY

LTD (R





CT, on dem

and.

LOO

M C

ON

FIGU

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3789B

TM

C

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LM3-L

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268yA

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TITLE BLOC

K05/08/11

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MW

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PLM

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KOMATSU LOOM 3 CONFIGURATION (063ga)

YL-FVT

TO KO

MA

TSUP

LM D

OW

NLO

ADP

OR

T

GN

/YL-FVT

RD

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GN

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24 VO

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ABCDEA B C D E F

12

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910

1112

B ACDEFGH

B ACDEFGH

12

34

56

78

910

1112

A4

CO

PY

RIG

HT - A

LL RIG

HTS R

ESERVED

This draw

ing is

the property

of R

EM

OTE

CO

NTR

OL TE

CH

NO

LOG

IES PTY LTD

(RC


hole or inpart

for any

purpose w

ithout the


CT. The draw


CT, on dem

and.

RE

MO

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ADIN

TERFA

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CABLE

TO SU

IT KO

MATSU

HD

1500-7, HD

785-3,H

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Text changes to pluglabels and 0322

descriptionE

Y28/11/14

0322 PLUG

CO

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SP

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CO

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NC

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A-

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B-

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SP

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CO

LOU

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AR

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24 V DC

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N-FVT

GR

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RE

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/YE

LLOW

- FVTD

ATAD

BK-FVT

BLA

CK

- FVTG

RO

UN

DE

--

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--

-

All

Redraw

nG

S18/09/07


HITACHI LOOM CONFIGURATIONI (513d )

ABC

WH

-FVTBE

BN

-FVTB

F

(2183)(2024)

TO H

TMC

CA

N B

US 2

PO

RT

AB

K-FVTC

ABCDEF

RD

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WH

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BN

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BK-FVT BD

RD-FVT BA

TO EP

D-H

TMX

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GR

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CA

N H

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CA

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GROUND

24 VO

LTS INC

(5050)P

LUG

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ED

ES

CR

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BY

DA

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12

34

56

78

910

1112

B ACDEFGH

B ACDEFGH

12

34

56

78

910

1112

A4

CO

PYR

IGH

T - ALL R

IGH

TS R

ESER

VEDThis

drawing

is the

property of

REM

OTE

CO

NTR

OL TEC

HN

OLO

GIES PTY LTD

(RC


hole or inpart

for any

purpose w

ithout the


CT. The draw


CT, on dem

and.

LOO

M TO

SU

ITE

PD

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X-E

D-TX

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FIGU

RA

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ww

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CO

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D D

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Released

SH

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1 of 1

BY

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RH

DA

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AP

PDJB

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STO

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LOADER LOOM CONFIGURATION (019v)

BU-4

BN-4

GR

OU

ND

+VE

24 VOLTS

IN

MS 3106E14S-6S

TO EO

D-R

D

A B C D E F

12

34

56

78

910

1112

B ACDEFGH

B ACDEFGH

12

34

56

78

910

1112

A4

CO

PYR

IGH

T - ALL R

IGH

TS RESER

VEDThis

drawing

is the

property of

REM

OTE

CO

NTR

OL TEC

HN

OLO

GIES P

TY LTD (R

CT),

and is not to be copied or used in whole or in

part for

any purpose

without

the express

authority of RC

T. The drawing is to be returned

to RC

T, on demand.

RE

MO

TE PAYLO

ADP

OW

ER C

ABLE

LOO

MC

ON

FIGU

RATIO

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ww

w.rct.net.au

UN

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22/04/04A

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CMP PAYLOAD MONITORING AND CONFIGURATION Connecting the unit to a computer via a 3314 programming lead and a serial adaptor allows you to monitor the payload and vehicle information and configure the unit. Using the CMP payload application you can easily monitor the payload and/or configure the unit to support the required vehicle type. CONNECTING TO THE PAYLOAD CONFIGURATION LOOM To connect to the payload configuration tool, follow the instructions provided below:

1. Connect the device to a computer that has the CMP Payload application.

2. Run the application, and select the correct COM port in the popup window.

MONITOR PAYLOAD STATUS

1. The start-up screen that is displayed is the Monitor Payload tab. This screen shows you the weight of the payload and the pressure being subjected to individual struts along with other useful data.

2. If the monitor payload screen is not displayed, simply select the Monitor Payload tab from the tab selections.


CONFIGURING THE PAYLOAD INTERFACE

1. Select the Configure tab from the tab selections.

2. The Configure page allows you to change most of the task specific settings for any application.

1. NODE TYPE: This option decides the type of vehicle that the interface is installed onto. The options are

truck or loader. 2. PROTOCOL: This option tells the interface what onboard payload system the unit will be communicating

with. This is essential for trucks; however, the loader units do not need to communicate with the onboard payload systems. Options include TPMS (Caterpillar early models), VIMS (Caterpillar), VIMS 3G (Caterpillar new), PLM2 (Komatsu early), PLM3 (Komatsu) and HTMC (Hitachi).

3. MODEL: Selecting the truck model specifies the truck specific details to the interface such as maximum

weight. This setting does not affect loader units. 4. RADIO: This option sets up the communication method for the unit; currently, the units only support

MAXON radios. 5. ON AIR PROTOCOL: This option is used to specify what application the unit is being used for and what

protocol to use for COMs. Payload interfaces should have payload protocol selected. A series of inputs and check options are also available. These are EEProm size, unit ID, monitor only, latch display, US ton conversion, overload display, DIP truck select enable, and factory test. To apply any changes, click the Write Device button and power cycle the interface. The device will now use the specified configuration. Selecting the save configuration will allow users to create a ‘config file’ that can be loaded into any other units using the load configuration button.


USING THE MONITOR AND CONFIGURATION TOOL To retrieve the logs from a loader payload interface, follow these steps:

1. Connect to the interface with a programming loom (part number 3314) and a USB-serial converter.

2. Open the payload monitor and configuration utility, and connect to the appropriate port.

3. Navigate to the Logs tab across the top on the utility

window. To download the logs, select the Export button and save the file to your computer. This CSV file can be opened using Microsoft Excel software; if the information is not readable, try expanding the column width.

READING THE LOG FILES Log files are generated as comma-separated values files (CSV). These files will have a name generated automatically using the Loader ID and the time stamp the filename will be named as follows: Log_[Loader ID]_[YYYYMMDDHHMMSS]. For example: Log_LD1_20141213143612 is a log taken from LD1 at 2:36pm on the 13th of December 2014. The CSV log file can be opened using Microsoft Excel software, if the information is not readable try expanding the column width.

The fields shown in the log file can be interpreted as follows:

Log ID: The log number for each load increments by 1 every load recorded (does not increment when a missed load is added).

Record Date: The date the record was made shown by year, month and date 00YY-MM-DD. First Pass time:

The time at which the first shovel load was detected for a new truck in 24 hour time.

Last Pass time: The time when the last shovel load was detected for a truck. Final Payload: The final payload weight in tonnes recorded. Shift Number: The shift number can be set on the loader using the configuration utility. Up to 3 shifts

can be setup and are defined by a range of hours in the day. Truck ID: The ID number set by the EarthTrack® Payload system for a truck (0-255). Missed Loads: This shows the total number of trucks that were input by the user. The loader operator

can increment the missed loads on the payload display; currently no log information is created for this truck.


DIAGNOSTICS MODE Diagnostics mode is an option that can be used to see all data that each unit receives either a truck or a loader. On each model it is currently only activated by switching the 1st dipswitch on the CMP board to the on position. DIAGNOSTICS DIGGING LOADER If diagnostics mode is turned on in a loader unit the unit will no longer record truck logs, instead the log file will contain every packet that the loader receives. This assists by allowing technicians to see what trucks are transmitting and when there are transmission difficulties. The logs add up quickly and when full the unit will automatically overwrite the oldest logs. These logs can be extracted the same way as normal logs through the USB port on the payload or using a 3314 programming loom. DIAGNOSTICS LOGGING TRUCK If diagnostics mode is turn on in a truck unit the unit will log every change in details from the manufacturer’s payload system. This gives technicians a look into how the manufacturers equipment in functioning and will help see why logs may not be as expected for example when a loader creates a log that is significantly lower than the maximum payload weight. These logs can be extracted using a 3314 programming loom and the CMP payload utility. READING LOG DATA When the diagnostic logs are extracted the column titles will remain the same as for normal logs from a loader, the column will need to be renamed using the table below:

REGISTER NAME (REGULAR LOG FIELD) DIAGNOSTIC LOG FIELD Log ID Log ID Record Date Date 1st Pass Time Time Last Pass Time - Final Payload weight Payload Weight Shift Number Truck State Truck ID Truck ID Source Pit Truck state (on air) Source Bench Truck Model (Truck diagnostics only) Source Block Left Front Strut Pressure Source Blast Right Front Strut Pressure Material Type Left rear Strut Pressure Destination Right rear Strut Truck Wait time Accumulated error count

Some fields will not be used in the loader diagnostic logs such as Truck Model. The truck state is defined using a number from 0 to 6. These number correspond to the following states:

TRUCK STATE (NUMERIC) TRUCK STATE STATE SHORT HAND 0 Stopped empty SMT 1 Travelling empty TMT 2 Loading LDG 3 Stopped loading SLD 4 Travelling loaded TLD 5 Dumping DMP 6 Communication failure CF


PARTS LIST

PART NO. DESCRIPTION 12175 Payload loader interface 12082 Payload truck interface 3258 Aerial and lead 4885 Power loom to suit loader 3314 Programming loom 12208 Payload display 11594 Channel Selector 16 position 10032 Channel selector plug (CH1) 10033 Channel selector plug (CH2) 10034 Channel selector plug (CH3) 10035 Channel selector plug (CH4) 10036 Channel selector plug (CH5) 10037 Channel selector plug (CH6) 10038 Channel selector plug (CH7) 10039 Channel selector plug (CH8)

* Refer to the Truck Loom Configuration Selection section on page 17 for information on truck looms.

TROUBLESHOOTING

FAULT REMEDY No weights or load distribution being displayed in loading machine.

1. Check the loading machine and truck are on the same channel. 2. Check that the four LCDs on the interface show the correct details, if they do, check the

payload display connections. (This may have been installed under the instrument panel.)

3. Set up the 0000 portable display near the loading machine and on the correct channel; then check if the portable device will show weights. a. If the portable unit displays correctly:

i. Confirm that the loading machine display supplies voltage greater than 22 volts DC.

ii. Check the loading machine display connections and antenna. iii. Check that the loading machine channel select switch is functioning

correctly. b. If the portable unit does not display any information:

i. Confirm that the portable display supply voltage is greater than 13 volts DC.

ii. Ensure that the OEM payload system is functioning correctly. iii. Confirm that the truck interface fitted is the correct configuration/part

number for the application. iv. Check the truck interface connections and antenna. v. Check that the truck interface channel select switch is functioning

correctly. vi. Check the version number of both the truck interface and remote

receivers to ensure they are the same version. If any units are found to differ in version numbers, contact RCT for assessment and quote for upgrade.

No weight shown on the truck large digit display or loader

1. Check that the truck interface is connected with a 24 V supply. 2. Check if the 4-line LCD display on the truck interface shows the weight. If it does, check

that the LCD is plugged correctly with the end labelled ‘To Display’ connected to the display.

3. Clear any logs in the manufacturer’s logging system. (For VIMS, this requires CAT VIMS PC software.)

Any unit found to have a suspected fault should be clearly marked with the reported fault, who identified the fault and what model machine it was fitted to, and then returned to RCT for assessment and quote on repair.


GLOSSARY

WARRANTY Please see the RCT standard warranty, available on our website - www.rct-global.com.

A Amp (Ampere) mW Milli Watts

AC Alternating Current N/A Not Applicable

AMS Advanced Management System N/C Normally Closed

Aux Auxiliary Output N/O Normally Open

CAN Controller Area Network OEM Original Equipment Manufacturer

CMIO Control Master Input Output PCB O/P Outputs

CMR Control Master Receiver Out Output

CMT Control Master Transmitter PB Push Button

CM2200 Control Master 2200 Remote Set PC Personal Computer

COMMS Communications PCB Printed Circuit Board

CPU Central Processor Unit PIN Personal Identification Number

DC Direct Current PLC Programmable Logic Controller

E.G. For example POT Potentiometer

ETR Energised To Run PPM Pulses Per Metre

ETS Energised To Stop PWM Pulse Width Modulation

ESD Engine Shutdown PWR Power

FET Field Effect Transistor Rev Revision

GND Ground RF Radio Frequency

H Hours RH Relative Humidity

HEX Hexidecimal Numbering System RPM Revolutions per minute

ID Identity RX Receiver

i.e That is

RS232 Recommended Standard (number 232) for serial data transfer

In Input Source The output can supply/drive current out

IP Ingress Protection SYS System

kg Kilogram TOV Text On Video

Km/h Kilometres Per Hour TX Transmitter

LCD Liquid Crystal Display V Volts

LED Light Emitting Diode °C Degrees Centigrade

LK Link # Number

M Minutes < Less Than

mA Milli Amps > Greater Than

MAX Maximum % Percentage

MCU Multi Control Unit

MFU Multi Function Unit

MHz Mega Hertz (million(s) cycles per second)

MIN Minimum

mm millimetres

http://www.rct-global.com/


NOTES

Discover more: www.rct-global.com [email protected] AUSTRALIA: +61 (0) 8 9353 6577 AFRICA: +27 (0) 83 292 4246 CANADA: +1 705 590 4001 RUSSIA / CIS: +7 (910) 411 11-74 SOUTH AMERICA: +56 9 8731 9925 USA: +1 801 938 9214

payload monitor system - assets.rct-global.com

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