Parts and Service

Manual

Manual # 99905492
16000SIII Radio Remote Control Revision Date: 05-03-2012
 Table of Contents
1 G2B System Overview …………………………………………………………………………………………………………… 3

2 CU Installa on and Wiring …………………………………………………………………………………………………………… 4

2.A Loca ng the CU ………………………………………………………………………………. 4
2.B Grease Contacts ……………………………………………………………………………... 4
2.C Feed Cable ……………………………………………………………………………… 4
2.C Secure Cable ……………………………………………………………………………… 4
2.E Terminal Schema c ……………………………………………………………………………… 5
2.F Special Logic Func ons ……………………………………………………………………………… 6
2.G Wire I/O ……………………………………………………………………………… 6

3 CU (Receiver) Overview …………………………………………………………………………………………………………… 7

3.1 CU Layout and Indicators …………………………………………………………………………………………. 7
3.2 RF Antenna ………………………………………………………………………………………... 7
3.3 Remote / Off / Manual Switch ………………………………………………………………………………………... 7
3.4 Tether/Programming Connector ………………………………………………………………………………………... 7
3.5 DV and Status LED’s ………………………………………………………………………………………... 8
3.6 Internal LED Display ………………………………………………………………………………………... 8
3.6.1 Opera onal Indicators ……………………………………………………………………………... 8
3.6.2 Error Indicators ……………………………………………………………………………... 9

4 PCU (Transmi er) Overview …………………………………………………………………………………………………………… 11

4.1 Switch and Paddle Layout …………………………………………………………………………………………. 11
4.2 Power / Stop / Micro Switch Panel ………………………………………………………………………………………... 12
4.3 Ba ery and Charging ………………………………………………………………………………………... 12
4.4 Powering the PCU ………………………………………………………………………………………... 13
4.5 Micro Speed Switch Opera on ...……………………………………………………………………………………... 13
4.6 Downloading ID: Pairing PCU and CU ………………………………………………………………………………………... 14

Revision Date Name Notes

1 05/03/2012 Initial Release

Manual # 99905492 Rev 1

1 G2B System Overview
This guide is intended as a complement to the Service Manual and Remote Control System RC400 G2 Instruction
manual. It is a brief overview of the important features of a specific radio remote control system. Installers and Op-
erators must read the Service Manual and Instruction manual before installing / operating the system and adhere to
all warnings and recommendations.

The G2B Radio Control (RC) System offers the machine operator an extremely advanced remote control
system with speed, precision, control and maximum safety. The G2B RC System is comprised of the following com-
ponents:

5
2 4

6 7

No SNA Part Number Description Qty

1 70734704 Portable Control Unit (PCU) Mini 1

2 70734708 Central Unit (CU) (70734705 incl 2-5) 1

3 70734711 Battery charger 1

4 70734710 Battery cassette (NiMH 7.2 VDC) 2

5 70734709 Tether cable (10 meters) 1

6 Cable kit; supply cables + digital outputs (custom Weather 1

Pack DV)
7 Cable kit; valves cables / analogue outputs (DT06-2S x 12) 1

Manual # 99905492 MAN-G2B-17 Rev 1 3

2 CU Installa on and Wiring
The following instructions will help an installer wire the Central Unit to the controls of your specific machine. The in-
staller may choose to make the wiring harness himself or use the generic Scanreco wiring harnesses for ease of in-
stallation. Please consult your sales representative for more information regarding generic wiring harnesses.

Read this entire section before proceeding with the installation. In order to maximize product life and prevent invol-
untary service, this section must be followed when installing and wiring your CU.

Important Notice About Welding!

If you plan to do any welding on the machine after the CU has been installed; the CU’s electrical con-

! nections must always be disconnected! Power supply cables (+ and -), all valve contacts, tether and
all other wiring to the CU must be disconnected. Welding can cause severe damage to all vehicle elec-
tronics and if detected may void your warranty.

A. Loca ng the CU  For optimum radio communications the CU or exter-

nal antenna should be located as high on the machine
and free from obstructions as possible. An antenna
screened and surrounded by fixed objects (especially
metal) will considerably reduce radio range

 The antenna pin must not touch any metal object

 The central unit should be mounted in a vibration free

location and not be subjected to strong sources of heat
BEST No No (for example exhaust pipes etc.)

B. Apply Grease to Contact Pins

If grease is not already applied to all the connector pins of the CU (shown in
the picture); be sure to add water resistant grease suitable for electronic
applications to the areas noted.

C. Feed Cable Through Membrane D. Secure Cable

Pierce the membrane and feed the cable

through. A tight fit ensures a good seal. Secure the inner side of the
cable with a cable tie or similar.

MANUAL # 99905492 MAN-G2B-17 Rev 1 4

 E. Terminal Schema c
K7 Main
Pin no Function
K7.1 Supply (+12/24VDC)
K7 K1 Analog 1-4
K7.2 Ground (GND)
K8
K7.3 Dump Valve Out (DV+)
K4 EX1 K3 Analog 5-8
K7.4 DV GND

Note: An electrically controlled dump valve should always K6 EX2

be connected, for safety reasons, between the function
valves and the hydraulic tank. During a system stop DV+
will be off to ensure the system is without hydraulic pres-
Note: Pin 1 starts on the Left for all connectors.
K1 Analog Outputs K3 Analog Outputs
Pin no No Function Name Pin no No Function Name
K1.1 Crane Rotate CW K3.1 Fork Rotate CW
1A 5A
K1.2 GND K3.2 GND
K1.3 Crane Rotate CCW K3.3 Fork Rotate CCW
1B 5B
K1.4 GND K3.4 GND
K1.5 Fork Down K3.5 Extension Out
2A 6A
K1.6 GND K3.6 GND
K1.7 Fork Up K3.7 Extension In
2B 6B
K1.8 GND K3.8 GND
K1.9 Inner Boom Down K3.9 Unused PWM +
3A 7A
K1.10 GND K3.10 GND
K1.11 Inner Boom Up K3.11 Unused PWM +
3B 7B
K1.12 GND K3.12 GND
K1.13 Outer Boom Down K3.13 Unused PWM +
4A 8A
K1.14 GND K3.14 GND
K1.15 Outer Boom Up K3.15 Unused PWM +
4B 8B
K1.16 GND K3.16 GND
K4 EX1—Digital Outputs / Inputs K6 EX2—Digital Outputs / Inputs
Pin no Function Pin no Function
K4.1 Engine Speed K6.1 Unused Digital Output 7
K4.2 K6.2 Unused Digital Output 8
K4.3 Engine Start K6.3 Unused Digital Output 9
K4.4 Engine Stop K6.4 Unused Digital Output 10
K4.5 Horn K6.5 GND
K4.6 Unused Digital Output 6 K6.6 Unused Digital Output 11
K4.7 GND K6.7 Unused Digital Output 12
K4.8 Digital input 1 K6.8 Unused Digital Output 13
K4.9 Digital input 2 K6.9 On with Link
K4.10 Digital input 3 K6.10 GND
K4.11 Input supply (+VDC) K8 EX3—Op onal Features
Pin no Function
K8.1 CAN High
K8.2 CAN Low
K8.3 CAN GND
K8.4 Not Used
K8.5 Not Used
MANUAL # 99905492 MAN-G2B-17 Rev 1 5
F. Special Logic Func ons
Engine Speed—The output is latched on when in HIGH. When in AUTO it is activated with paddle movement. It will
remain on for 1 second after the last paddle has been released.

G. Wire Inputs / Outputs

Inputs and Outputs need to be wired to the ap-
propriate functions on the machine and in the CU.
Leave unused and spare functions un-terminated.

Install 22-18AWG wire, appropriate for current

consumption of loads (1.5 Amps max per output)
with proper sized Ferrell cable end.

Orient cables as shown and apply water resistant

grease suitable for electronic applications to the
terminal connectors.

MANUAL # 99905492 MAN-G2B-17 Rev 1 6

 3 CU (Receiver)
3.1 CU Layout and Indicators
The Central Unit is equipped with 2 individual positions where status and operational indications can be read, the
external LED’s: DV and STATUS provide basic information. The internal LED display provides more detailed infor-
mation. Below is the layout of the CU:

1 1
No Description
1 RF Antenna

2 Remote / OFF / Manual Switch

3 Tether / Programming Connector

2 2 5
4 DV and STATUS LED’s

3 3
5 Internal LED Display
DV 4
Status Note: For CU’s build before Fall 2010
the CU cover must be removed to view
the Internal LED Display; for later units
there is a viewing window as shown.

3.2 RF Antenna
The Central Unit show has a standard whip antenna with TNC connector. Optional antennas are available for various
types of installations and range requirements. Please consult your sales representative for more information.

3.3 Remote / OFF / Manual Switch

The Central Unit is equipped with a Remote / OFF / Manual Switch to power the CU in different modes of operation:

 OFF: there is no power to the internal electronics, Dump Valve or any outputs

 REMOTE: electronics are powered; PCU can link to CU and Dump Valve and outputs operate as specified

 MANUAL: there is no power to the internal electronics or any outputs; Dump Valve is ON. This bypasses
the Dump Valve output to enable operation of manual or hand lever controls, if equipped.

3.4 Tether / Programming Connector

Pin No Description
The CU can be connected through the Tether Connector to the PCU
via a 5 wire tether cable. The cable has M12 connectors at each end. 1 Data

2 Ground
The tether cable disables the RF transmission and charges the PCU battery, if
installed. The cable is available in standard lengths of 10 meters. 3 RS232 TX
1 2
The CU can also be connected to a PC for programming an cali- 5 4 RS232 RX
bration. Refer to Service Manual and WinSCI Manual for further
4 3 5 + Battery (VDC)
details.

MANUAL # 99905492 MAN-G2B-17 Rev 1 7

3.5 DV and STATUS LED’s
Operational status indications can be read from the DV and STATUS LED’s as follows:

Status LED Description DV LED Description

CU is OFF or not powered (Dump Valve)
OFF
OFF Dump Valve Output is OFF
RED CU is ON with no link to PCU
RED Dump Valve Output is ON
GREEN CU is ON and linked with PCU (via cable
or RF)
RED Flashing Error code on Internal LED Display
(see Section 3.6.2)

DV
Status

3.6 Internal LED Display

3.6.1 Opera onal Indicators
The Central Unit will indicate various operational states via the Internal LED display as shown below:

Indication
Meaning
Block 1 Block 2

(Rota ng CCW) CU is powered and not Linked to PCU

N/A Primary PCU is linked to CU via Radio, Hopping (IH flashes as link gets weaker)

N/A CU is linked to primary PCU (ID programmed) via tether cable

N/A CU is linked via tether cable to PCU (ID not programmed)

ID Programming ini ated. See sec on 4.6 for details

ID Programming Blocked; reset power on CU and Download ID again. See sec on

4.6 for details

MANUAL # 99905492 MAN-G2B-17 Rev 1 8

3.6.2 Error Indicators
The Central Unit will indicate detected errors via the internal double 7-segment LED display. If the Central Unit de-
tects an error it will be indicated by the STATUS LED flashing red; while the Internal LED Display indicates the error
code. The digits “Er” are flashed, followed by two blocks with the corresponding error code.
Example of an error code sequence:
Block 1 Block 2 Block 3

-> -> Repeated 3 times

The example above would indicate that there is a Short Circuit on PWM Output 1A

The error code sequence will repeat itself three times if the error is considered a soft error and reboot to standby
mode to try and clear the error. If the error is considered a hard error the error code sequence will repeat until the
power is disconnected.
Below is a list of error codes and their meaning:

Block 2 Block 3 Description Cause Action

01 01 EEPROM Fail- Incorrect checksum on EEPROM, last Reset system, if persistent; Re-load
ure stored data will be set. application program.
01 02 Flash Memory Incorrect checksum on flash Reset system, if persistent; Re-load
Failure memory. application program.
01 03 Stack Memory Incorrect sizes of data in CANopen System will self reset automatically. If
Failure protocol, incorrect dataflow or stack persistent; Re-load application pro-
overflow. gram.
01 04 RAM memory Incorrect RAM and/or hardware System will self reset automatically. If
failure identification. persistent; Re-load application pro-
gram.
02 01 Illegal voltage DV-output (DV+) externally supplied Check DV-output connection. Remove
DV-output System will self reset. terminal connector and reset system.
02 02 Short circuit DV-output error; DV output (DV+) System will self reset. Check DV-
DV-output short circuited or overloaded. output connection. Remove terminal
connector and reset system.
02 03 Safety switch Safety switch output read back error, System will self reset. Remove all ter-
error incorrect voltage (High instead of minal connectors and reset system.
Low).
02 04 Safety switch Safety switch output read back error, System will self reset. Remove all ter-
error incorrect voltage (Low instead of minal connectors and reset system.
High).
02 05 CAN Safety Incorrect status of CAN safety loop. System will self reset. Check CAN safe-
loop error ty loop connection. Reset system.
03 00 Illegal voltage Digital output (1-14) illegal voltage, System will self reset. Check digital
Digital output expected low signal but read as high output connections. Remove terminal
(could be any of the available 14). connector and reset system.
04 00 Short circuit; Digital output (1-14) short circuited System will self reset. Check digital
Digital output or overloaded (could be any of the output connections. Remove terminal
available 14 outputs). connector and reset system.
05 00 Error input Error signal for Danfoss valve trig- System will self reset. Check analog
triggered gered (Could be any of the available output connections. Remove terminal
(Danfoss CU 8 inputs) connector and reset system.
only)
06 xx Illegal voltage Wrong voltage on analog output System will self reset. Check analog
Analog output (Block 3 declares related output; output connections. Remove terminal
1A,1B….). connector and reset system.

MANUAL # 99905492 MAN-G2B-17 Rev 1 9

3.6.2 Error Indicators (cont’d…)

Block 2 Block 3 Description Cause Action

07 xx Illegal voltage Wrong current on analog output System will self reset. Check connec-
Analog output (Block 3 declares related output; tions. Remove terminal connector and
1A,1B….). reset system.
08 01 CAN Passive CAN bus in passive mode. System will self reset. Check CAN con-
nections. Check other nodes on bus
and reset system.
08 02 CAN I/O buffer CAN overrun; either the CAN input or System will self reset. Reset system,
overflow CAN output buffer are full. re-initiate via CAN controller.

08 03 CAN physical Bad communication/transmission. System will self reset. Check CAN con-
layer error nections. Check other nodes on bus
and reset system.

08 04 CAN PDO PDO length is to long. System will self reset. Reset system,
length re-initiate via CAN controller.
exceeded
08 05 CAN PDO PDO length is too short. System will self reset. Reset system,
length error re-initiate via CAN controller.
08 06 CAN Transmit To many collisions on CANbus. System will self reset. Check CAN con-
COB-ID nections. Check other nodes on bus
collision and reset system, re-initiate via CAN
controller.
10 N/A PCU failure; Error transmitted from PCU: Illegal System will self reset. Check
E-Stop signal from PCU emergency stop emergency stop switch on PCU.
switch.
11 N/A PCU failure; Error transmitted from PCU: Analog System will self reset. Ensure all ana-
Analog input input active on start-up. logue inputs on PCU are at zero/
neutral position. Restart PCU.
13 N/A PCU failure; Error transmitted from PCU: Signal System will self reset. Diagnose PCU
Analog input redundancy test; illegal signal from via TEST MODE.
analog input.
14 01 ID program- ID-code and/or parameter settings System will self reset. Retry ID-
ming failure not accepted. programming procedure.
14 02 Program fail- Programmable logic parameter error. System will self reset. Reset applica-
ure tion program.
15 xx PWM output Analog output short circuited or System will self reset. Check analog
failure overloaded. (Block 3 declares relat- output connections. Remove terminal
ed output; 1A,1B….). connector and reset system.
16 xx PWM output Analogue output not connected System will self reset. Check analog
failure (programmable feature). (Block 3 output connections. Remove terminal
declares related output; 1A,1B….). connector and reset system.
17 01 Low supply Low power supply (Below 8.5 VDC). System will self reset. Check power
power supply and supply connections.
17 02 High supply High power supply (Above 36 VDC). System will self reset. Check power
power supply and supply connections.

MANUAL # 99905492 MAN-G2B-17 Rev 1 10

4 PCU
4.1 Mini Switch and Paddle Layout
Switch Legend
L Latched or Detent
M Momentary or Spring return
LK Locking—Li to operate
UNI-POT Uni-Directional Potentiometer (0-10)
BI-POT Bi-Directional Potentiometer (10-0-10)

AXIS
P1 P2 P3 P4 P5 P6

S1 S2 S3 S4 S6 S7 S8 S9

S5 S10

Paddles

Position Function in UP (A) Direction Function in DOWN (B) Direction

P1 Crane Rotate CW Crane Rotate CCW
P2 Fork Down Fork Up
P3 Inner Boom Down Inner Boom Up
P4 Outer Boom Down Outer Boom Up
P5 Fork Rotate CW Fork Rotate CCW
P6 Extension Out Extension In

Switches

Function A Function B
Position Axis Center
Type Name Type Name
S1 X L Engine Speed Auto OFF L Engine Speed High
S2 X M Engine Stop OFF M Engine Start
S3 X L OFF N/A M Horn
S4
S5
S6
S7
S8
S9
S10

MANUAL # 99905492 Rev 1 11

4.2 Power / Stop / Micro Speed Switch Panel
1 2
No Description
1 Micro Speed (Green) / RF Indicator (Red) LED

2 Power ON / Low Battery LED

3 Micro Speed Switch

4 Stop Function Mushroom Button; twist to reset

5 Power / Function Button

3 4 5
The above figure and table detail the layout of a Maxi generic Power / Stop / Micro Speed Switch panel. Mini switch panels are
very similar in layout with the same func onality. Indicators and switch func ons are detailed in the sec ons below.

4.3 PCU Ba ery and Charging

 Each Ba ery needs to be fully charged before use. Connect charger Power on = Solid Red
to 10-32 VDC or 120 VAC depending on type supplied. Charging = Flashing Green
 PCU ba ery compartment is located in the bo om of the PCU hous- Ready = Solid Green
ing. Ba eries are keyed to ensure correct orienta on.

 Ensure terminals are clean and free from debris before installa on of a ba ery

 A new fully charged ba ery will last approximately 8 hours on a charge. Extremely cold
condi ons can reduce ba ery performance.

 PCU’s are typically programmed with a 5 minute inac vity meout as a ba ery saving
feature; turning off the PCU a er X minutes of paddle / joys ck inac vity. This is a configurable
feature that can be adjusted or removed as requested.

X3
Low Ba ery is indicated on the PCU when the internal Buzzer beeps 3 mes
and the Power ON / Low Battery LED flashed Red.

Manual # 99905492 MAN-G2B-17 12

4.4 Powering the PCU

A. B. C.
Install charged ba ery or
connect tether cable

Rotate E-Stop CW Press and hold Power Bu on un l Power

X4 ON LED will illuminates solid RED
D.
Note: If no link is established the RF indicator LED will flash RED 4 mes then turn off. Con nue to Sec on 4.6 Downloading ID:
Pairing PCU and CU.

Tether Note: Tether connec on has priority over RF transmission, if a tether link is present between the PCU and CU the radio will
be disabled and ba ery will be charged (if installed). The PCU inac vity meout will also be disabled when connected via tether
cable.

4.5 Micro Switch Opera on

The Micro Speed Switch can be programmed to reduce the maximum speed of any Propor onal Paddle / Joys ck outputs. Typically
in five (5) steps as indicated in the table below. The number of steps and percentage of reduc ons is adjustable.

Micro / RF LED Green Indication

not lit 0 to 100 % speed (normal speed)

1 blink every third second 0 to 60 % speed

2 blink every third second 0 to 50 % speed

3 blink every third second 0 to 40 % speed

4 blink every third second 0 to 30 % speed

5 blink every third second 0 to 20 % speed

Pressing the Micro Speed switch to the Turtle posi on will decrease the propor on-
al outputs by one step in the above table.

Pressing the Micro Speed switch to the Rabbit posi on will return the propor onal
outputs to 100% opera on.

• For safety reasons, a return to 100% steering can only be made if all Paddles / Joys cks are in their center posi ons.

• When the green LED is blinking, the Micro-speed func on is ac vated. The number of blinks indicates the opera ng speed as
defined in the table above. If the Stop Func on is pressed on the PCU, the PCU will start from the last chosen speed.

Manual # 99905492 MAN-G2B-17 Rev 1 13

4.6 Downloading ID: Pairing PCU and CU
Programs the unique ID-code required for radio communica on between the Portable Control Unit and Central Unit. Typically the
CU may store a maximum of 1 PCU ID-code. If another PCU is required to operate the CU via radio, the ID-code procedure is re-
quired to be done and the previous ID-code will be overwri en.

A. B.
Remove ba ery from PCU and connect
tether cable between CU and PCU.

Release E-Stop; Rotate CW

X1
C. Remote / OFF / Manual Switch D.
Cycle power on CU -> Toggle OFF
switch from OFF (center) to Re-
mote (up) posi on. Step D. must
REMOTE
be done within 45 seconds of C.

Press and hold Power Bu on (approx. 10 Seconds) un l

Power ON LED illuminates solid RED and Buzzer in PCU
beeps once.

PCU ID is now being sent to CU.

E.
The PCU will beep in quick succession to
confirm programming is completed.
F.
If this procedure does not work, repeat the programming
( see items B-E ). If it s ll does not work, contact Scanreco
North America.

Manual # 99905492 MAN-G2B-17 Rev 1 14