516 Trommel

Electrical Operations Manual

 Introduction
Copyright © 2013 JMG Systems Ltd. JMG Systems Ltd. reserves the right to modify this
document and product software content without
All JMG Systems Ltd. products are manufactured to prior notice to incorporate improvements where
the highest quality, incorporating highly sensitive necessary.
components and parts. In the interest of continuous
plant reliability, it is essential that the equipment is
maintained with meticulous care and attention. JMG Systems Ltd.
66-68a Derry Road,
This manual has been produced to assist the user to Omagh, County Tyrone,
determine and source parts associated with the N. Ireland, BT78 5ED
machine.
No copies or reproductions may be made from this  Tel +44 (0) 28 8224 4131
manual without prior consent of JMG SYSTEMS Ltd.  Email info@jmgsystems.co.uk
This manual, complete or in part, must not be loaned  Fax +44 (0) 28 8225 2686
to a third party without the authorization of JMG
Systems Ltd.  Web www.jmgsystems.co.uk

Document information
Issue Comment / Description Date of Issue JMG Reference
1 Redraft of existing 512R information (dated February 2013 MMC/RC
27/5/2009) into new format and expanded
for the 516 machine

2 Contents
Contents

Table of Contents

Introduction......................................................................................2
Document information..........................................................................2
Contents ...............................................................................................3
Safety ..................................................................................................5
Safety introduction..............................................................................5
Machine Shutdown Procedure..................................................................5
Electrical Safety.................................................................................6
Safety before and during Operation...........................................................6
General Maintenance ...........................................................................7
Electrical Welding ...............................................................................7
Familiarisation ........................................................................................8
Typical Machine components .....................................................................8
Control Panel layout overview....................................................................9
Trommel 412.....................................................................................9
Trommel 512/516 ...............................................................................9
Trommel 621 & 733 .............................................................................9
Panel Warning Indicators .......................................................................... 10
Indicator Lamps logic ......................................................................... 12
Engine Start up ..................................................................................... 13
Pre-heat feature............................................................................... 14
Radio Remote Control.............................................................................. 15
“Mini” remote control operation............................................................... 15
Tracking – Doglead.................................................................................. 16
Tipping Grid ......................................................................................... 17
Overview ....................................................................................... 17
Standard Operation ........................................................................... 17
Receiver functions – how to set timings .................................................... 18

Contents 3
 Receiver functions – how to operate grid manually ....................................... 18
Tipping Grid programming options .......................................................... 18
Tipping Grid – Care and maintenance....................................................... 19
Variable Valve systems ....................................................................... 20
Troubleshooting Guide ............................................................................. 21
Manual Doglead Troubleshooting ............................................................ 22
Tipping Grid Remote troubleshooting....................................................... 23
Remote Control troubleshooting............................................................. 24
Schematic Wiring Diagrams........................................................................ 26
Spare Parts Listing.................................................................................. 32

4 Contents
Safety
Before operating this Machine you must
WARNING read the Safety instructions as detailed in
the Operational manual

Safety All personnel who operate this equipment must be trained to

correctly and safely use it as it was intended
introduction
Before operation the operator must:

- Have received specific and adequate training in the task to

be carried out.
- Have read and understood the machine operating Manual
and the Safety signs on the Machine
- Know the location and function of controls and safety
features such as remote Machine Stop buttons and isolator
switches.
- Be aware of all moving parts on the Machine

Machine General JMG Systems Control units are equipped with various
shutdown options:
Shutdown
- Fixed Machine Stops: typically 2 to 6 stops are located
Procedure around the machine
- Doglead Machine Stop: if Doglead is supplied
- Panel On/Off key switch: should be used for normal
starting and stopping of the machine

The machine stops are located at around the machine and the
operator should make themselves aware of the positions before
starting the equipment. (See familiarisation section for more
detail)

 In the event of any emergency shutdown you should consult the

machine operational manual for any “Lock-Out” and “Restart”
procedures


Safety 5
 Electrical While this equipment is rated at only 24 volts safety should not be
taken lightly. This equipment can cause serious burns and injuries
Safety if connected wrongly or if tampered with. Remember batteries can
explode.

- Never work on the electrical system of any equipment

unless you are thoroughly familiar with the systems details.
- Work on the electrical system must only be carried out by
a qualified electrician.
- Special care should be taken when disconnecting, replacing
and/or charging the batteries. Ensure that the batteries
are re-connected correctly. Contact across the terminals
can cause sparks or explosions.
- The electrical equipment of the Machine should be
inspected at regular intervals. Damaged cables or loose
connections must be repaired immediately. Use only the
manufacturer’s replacement parts with the specified
current rating, especially fuses.
- ALWAYS Isolate the batteries when welding on the Machine

- Read and understand your Operation Manual before you

Safety start the Machine. Study the DANGER, WARNING, CAUTION
and IMPORTANT safety signs on your Machine.
before and - Before starting walk completely around the Machine. Make
during -
sure no one is under it, on it or close to it.
Let all other operators and bystanders know you are
Operation starting up and do not start until everyone is clear of the
Machine.
- Ensure that all control levers are in the neutral position.
- Check that all electrical connections including battery
connections are fitted correctly and are not damaged or
worn.
- Only use Remote stop buttons or Remote stop lines (if
fitted) in Emergency situations or during safety drills.
- Before moving the machine, ensure everyone is clear from
the surrounding area

6 Safety
General JMG control panels are specifically manufactured precise
pieces of equipment. Therefore, to ensure that the equipment
Maintenance continually operates effectively the owner should ensure that
the following "Good housekeeping" measures are carried out:

- Ensure that only qualified and trained personnel operate

and/or maintain this equipment.
- Electrical connections are susceptible to wet and dirt,
therefore, every step should be taken to avoid such
elements affecting this equipment:
- Always keep the Control Panel Lid closed and locked at
all times. Keep the key of the Panel in a safe place.
- Regularly check the Control Panel and all connectors such
as Battery Terminals and Solenoid Connectors etc. for
corrosion or build-up of dirt.
- When carrying out any repairs ensure that the equipment is
kept covered from rain and that all dirt etc. has been
cleaned from the equipment.
- Ensure that the electrical system is adequately protected
during any machine power washing, and that no jets of
water are pointed directly at the electrical systems.
- Check daily for any damaged or worn gauges, switches,
wires or connectors and replace immediately if necessary.
- Never adjust any of the components on this equipment
without the authorization of JMG Systems. Warranty may
be affected where unauthorized adjustments have been
made.
- Always replace damaged or faulty components/parts with
compatible replacements. Always check ratings before
replacement.

Electrical In cases where electric welding is required on the machine

observe the following rules:
Welding
- Stop the machine and switch off the ignition switch
- Isolate the system by disconnecting the negative battery
terminal
- Do not use electrical components to earth the welder
- Connect the welder earth clamp to the machine as close to
the part to welded as possible

Safety 7
 Familiarisation
Typical Machine components

Manual Tracking Doglead E/Stop & Track Buzzer; Pull Stops on Conveyors
Machine Stops located on (optional)
both sides of machine

Tracks Control Panel Tracks Solenoids Tipping Grid receiver Tipping Grid solenoids
(optional) (optional)

Main Control Panel Engine ECM connector Oil Cooler Connection

Fuel Contamination Sensor Inspection Lamp 30Amp Main Fuse / 40Amp Heater Fuse (both on
(Powerunit main harness)
compartment)

Alternator Connection Starter Connection Engine Earth Connection Battery & Main Leads

Battery Isolator Earth Connection

8 Familiarisation
Control Panel layout overview
Trommel 412
Engine Alarm &
Function LED
indicators (see next
section for details)

Ignition switch
(with preheat)

Control panel is equipped with display screen which is used to report hours run, engine
rpm, as well as plugged connectors for main harness. System uses preheat function.

Trommel 512/516

Engine Alarm &

Function LED
indicators (see next
section for details)

Ignition switch
(with preheat)

Control panel is equipped with display screen which is used to report hours run, engine
rpm, as well as plugged connectors for main harness. System uses preheat function.

Trommel 621 & 733

Engine Alarm & Inspection Lamp
Function LED On/Off
indicators
Engine Speed
(see next section for Ramp
details)
Ignition Switch

Control panel is equipped with display screen which is used to report hours run, engine
rpm, as well as plugged connectors for main harness.

Familiarisation 9
 Panel Warning Indicators
The following table gives an overview of the most common fault indicators located on the
front of JMG Systems Control Panels. Some of these are optional depending on the
application.

Image Fault indicator Description of Effect

operation
Lights as soon as key switch
is turned to the "on"
Battery Charge position. As soon as the
Engine starts it should go
out.
If it fails to illuminate when the key is
turned on or if it illuminates when the
engine is running, it indicates that there
is a fault in the charging circuit.
Stop the engine and have the circuit
Checked.

Lights when the key switch

is turned to the "on" If a fault occurs in the oil pressure
Oil Pressure position. As soon as the system the light will illuminate and the
Warning Engine starts it should go Engine will shut down after 2 seconds.
out.

Engine Lights only if overheating The Engine will shut down 5 seconds
Temperature occurs in the coolant
system. after the fault has been detected.
Warning

Coolant Level Lights if the coolant drops The Engine will shut down 5 seconds
Warning to a low level. after the fault has been detected.

Air Intake Lights if a problem occurs in The light will remain on continuously
Pressure Warning the air breather system. until the fault has been repaired.

This will immediately shut down the

Lights only when a Machine
Machine Stop Stop has been pressed or
Activated when a pull-stop has been
used.
Engine.
- Flashing light indicates one or
more of the Machine Stops has
been pressed;
- Constant light refers to Doglead
Machine Stop button

Lights when the key is
turned to the "on" position
Engine Run Light and will remain on at all
times.
If it goes out then a Machine Stop has
been pressed and the Engine will shut
down immediately.
The Engine will not start if this light is
not illuminated.

10 Panel Warning Indicators

Image Fault indicator Description of Effect
operation
Lights when the ignition key
is turned to the Start The Engine will not start if this light is
Fuel on Light. position to indicate that the not on. Whilst the engine is running this
fuel solenoid circuit has light will remain on.
been energized.

Hydraulic Oil Lights only if the hydraulic The Engine will shut down 5 seconds
Level Warning oil level is low. after the fault has been detected.

Lights only when the pre-

Engine Pre-heat heat system is operating Not present on 621/733 trommels.
indicator during start up.

Engine Warning See following table for

Light information.

Not on 407/412 or 512/516 range of

trommels

Engine Shutdown See following table for

Light information.

Panel Warning Indicators 11

 Indicator Lamps logic

12 Panel Warning Indicators

Engine Start up
Before commencing start up procedures, ensure that all stop buttons have been released,
manual and remote tracking switches are set to default positions, and that the operator is
fully aware in the operation of the machine.
Switch Description
Operation
Key Switch in
If available as an option on the control panel, ensure that the Neutral
Handset/Remote switch is in the neutral position as shown. Position

Apply power to the electrics by turning the ignition key to Key Switch in
the “On” position (all LEDs will illuminate for 1second as part of the “On”
a Self Test) position

If any of these lamps

Note – At this point the Charge Light, Oil Pressure Light, Engine do not light this
Run Light and Fuel light should all be illuminated as shown. indicates that a
problem exists. If a
Note – If an Automatic Pre-Heat system has been installed the problem occurs refer
Pre-Heat light will also illuminate when the key is turned to to the Fault Finding
the “on” position (if heating is required). section of this
manual.

Warning: Do not attempt to start the engine unless the

following warning lamps are illuminated at this stage.

Start & Crank engine

- turn the ignition key to the "Start" position. At this point the Key Switch in
fuel solenoid will energize and the start delay siren will sound; the “Start”
- Hold the key in this position for approx. 10seconds until the position
engine starts.
Engine Run Key Switch in
- as soon as the engine starts, release the ignition key so that it the “On”
returns to the “On” position position

Note – As soon as the engine has started the ‘Oil’ and ‘Battery’ If any other lights
lights will go out on the display panel. Only the ‘Fuel On’ and illuminate when the
‘Engine run’ lights will be illuminated at this stage. engine is running it
indicates a fault

Engine Stop
- to stop the engine simply turn the ignition key to the neutral / Key Switch in the
off position as shown “Off” position

Engine Start up 13
 Pre-heat feature
This is an optional feature.
Automatic Pre-heat:
- the ignition key must be turned to the “Pre-heat” position, as shown The Pre-Heat light
- the Ignition key should then be held in this position for the period of will illuminate
time as specified in the engine manufactures operation manual. during the Pre-Heat
Manual Pre-heat: sequence and will go
out when the ignition
- whilst engaging the start-up sequence above, the ignition must be key has been released
turned to the ON position, whilst the pre-heat button located at the
side of the control panel must be pressed at the same time.

14 Engine Start up
Radio Remote Control
The layout and operation of the remote controls and function buttons may vary according
to the machine specification or configuration.

“Mini” remote control operation

On Off Engine Stop

Forward Tracks Forward Tracks
Reverse Tracks Reverse Tracks

Ensure that the remote lead is connected to the control panel.

Start the Engine as per the Engine start up procedure in previous sections.
Switch the handset/remote select switch as shown.
Power on the radio remote control using the on/off button on the transmitter
handset
Note: At this point the Tracking Safety Siren should sound. There is a safety delay
period on the handset before the Tracks will operate.
Ensure that the Jacking Legs are raised before operating the Tracks.

The Machine can now be tracked using the forward and reverse controls on the
Remote handset – before manoeuvring machine, ensure that all personnel are
at a safe distance, and that there is sufficient clearance around the machine
to move.

Note: Remote Engine Stop will only be active when the radio system
has been enabled

Radio Remote Control 15

 Tracking – Doglead
This device is used for machine movement, when not in use it should be stored in a safe
place to avoid damage.

Manual Handsets Old type Dummy Plug

1 Engine Stop Button: red or yellow button located at top of handset.

2 Tracks On/Off Switch - A green L.E.D. will illuminate when the switch is in the on position.

3 Right hand & Left hand track forward/reverse switches

4 Optional function button - dual tracks forward/reverse switch. If available, the user may use this
switch to activate both tracks at the same time, useful for single handed operation.

(Note: When disconnected, depending on the machine configuration, the user may have to install
the Handset blanking plug in place of the handset otherwise the control system will not operate)

Tracking operation is outlined below

Ensure that the Dog-lead is connected to the Machine as shown and that the Dog-lead
Machine Stop is not pressed.
If dog-lead is not being used, then the dummy plug must be fitted in
order to run the machine
Start the Engine as per the Engine start up procedure in previous sections.
Switch the handset/remote select switch as shown.

Switch the Tracking "On/Off" Switch, located on the Dog-lead

Handset, to the "On" position.
Note: At this point the Tracking Safety Siren should sound. There is a safety delay period
on the handset before the Tracks will operate.
Ensure that the Jacking Legs are raised before operating the Tracks.
The Machine can now be tracked using the forward and reverse controls on the handset, as
shown – before manoeuvring machine, ensure that all personnel are at a safe
distance, and that there is sufficient clearance around the machine to move.

16 Tracking – Doglead
Tipping Grid
There are various configuration options for JMG Systems Tipping grids, used to operate
functions such as belt feeders, tipping grid movements and so on.
Each remote control comes in various frequency options depending on location of use
worldwide – please ensure that the unit frequency is ordered correctly for the appropriate
region.
This section outlines basic operation of the grid system, as well as programming and setup
steps to vary timings for use.

Overview
Each Tipping Grid comes with a transmitter and a receiver. Remotes can have up to 8
different operating functions dependeant on the custoemr requirement.

Region Operating Decal

Frequency Colour
Europe (CE) 869 MHz Blue
USA/Canada 914 MHz Grey
Japan 426 MHz Yellow
Australia 433 MHz Light Blue

Standard Operation
Warning: Before activating the Grid Tipping Cycle using the Remote Control, ensure that the
Grid is fully down.

To activate the remote control transmitter, press the ON button twice – the red LED will
flash once to show that the remote is now active.
1. To activate the Tipping Grid cycle press button 1 once (the red LED will flash each time a
button is pressed)
2. To stop the grid during the cycle press button 2 once.

To restart the grid cycle press button 1 again – note that the Grid cycle has to finish – if
the Grid has been stopped during the raise cycle it will continue upwards to the highest
position, before lowering again.
Operational Notes:
- The Remote Control transmitter has a 2 minute automatic turn off feature to save battery
life.
- The range of operation is up to 100metres but longer or shorter distances will depend on
the location of the Receiver box on the machine in relation to the Transmitter location.

Tipping Grid 17
 - Surroundings may have an impact on range, and all units have been designed to operate
with an internal aerial.

Receiver functions – how to set timings

The time in which it takes the Grid to tip out material using the remote control, and the
angle that the Grid rises to, needs to be set when the system is first installed.
Ensure that the Engine is running and that the Grid is
fully down.
Locate the top button on the side of the Receiver Box
(A), and press this twice and release – press and hold
for a third time to enter the programming phase.
The Grid will start to rise – once it has reached the
required angle, release the button and the Grid will
stop.
Press the second button on the Receiver Box (B) twice
and release – press and hold button (B) for a third
time.
The Grid will lower its position … again once it has
reached the desired position release button (B) and
the Grid will stop.
The Upper and Lower settings for the grid will now be
set each time the Tipping Grid remote is in operation.

Receiver functions – how to operate grid manually

To raise and lower the grid manually using the receiver box use buttons (C) and (D)

Raise the Grid manually by pressing and holding button

(C) until the Grid reaches the desired position.
Release button (C) to stop the Grid motion.
Lower the Grid by pressing and holding button (D) until
the Grid is in the desired position.

Tipping Grid programming options

Each Remote Control Transmitter and Receiver has a unique operating code. If a Remote
Control or Receiver Box is replaced then the Receiver Box has to be programmed to
recognize the new Remote Control Transmitter.
If a Remote Control Transmitter is taken from one Machine or system and used to operate
another system, the original Receiver Box should be disabled by removing the 2 amp fuse
on the printed circuit board (see below).

18 Tipping Grid
Label the Receiver with instructions to reprogram it before putting it back into service.
Otherwise the situation could arise that one Remote Control will operate 2 different
systems.

The following section outlines the steps to re-program a receiver unit.

Remove the cover from the Receiver Box by unscrewing

the 4 fixing screws, as shown at (A).

Ensure that “LED1”, as shown at (E), is turned on. This

led indicates that the Receiver has a correct power
supply.

Set the “Program ID” switch, as shown at (C), to the

programming position by moving the switch lever to the
left position.

Press and release the “Program ID” push button, as shown

at (D). The “Program” LED, as shown at (B), will turn on.

Ensure that the Remote Control Transmitter is turned on.

Press and hold any button on the Remote Control

Transmitter (Except the "ON" button).
The “Program” LED, as shown at (B), will turn off and the
“Valid Signal” LED, as shown at (F), will turn on.
Note: Do not hold the Remote Control closer than 500mm
from the Receiver Box.

Release the Transmitter button.

Set the “Program ID” switch, as shown at (C), to the

operating position by moving the switch lever to the right
position.

Replace the lid on the Receiver Box and tighten the 4

mounting screws.

Tipping Grid – Care and maintenance

The Remote Control should be kept in a safe location and protected from falling debris
and water contamination. If the Remote Control is being operated from a loader then it
may be possible to clip or secure the Transmitter to the loader's sun visor or some other
suitable fixture. To do this use the belt clip located on the rear of the Remote Control
housing.
Ensure that the Remote Control is protected from vibration or impact damage.

Tipping Grid 19
 If the Remote Control gets damaged, tampered with or malfunctions in any way it should
be disabled immediately by removing the batteries. It should then be replaced and/or
returned to JMG Systems for examination.

The Tipping Grid Remote Control battery life depends on its frequency of use.
Low batteries are indicated when the LED on the Remote Control goes dim. When a button
is pressed and/or the functions do not operate.
When this happens the batteries should be replaced immediately. The batteries consist of
2 x 1.5volt AAA alkaline batteries located in the rear of the Remote Control.
Before replacing Transmitter batteries turn off the Receiver Box by disconnecting its
power supply.
To replace the batteries:

1. Undo the 3mm screw securing the battery compartment cover at the rear of the Remote
Control.
2. To remove the cover - raise the end adjacent to the belt clip on the Transmitter and
swing the cover out and lift off.
3. Remove the exhausted batteries.
4. Fit 2 new AAA size alkaline batteries taking special care to ensure that the battery
polarity symbols align with the corresponding symbols embossed on the base of the battery
compartment. Incorrect polarity may damage the Transmitter. Do not mix old and new
batteries.
5. Refit the cover by engaging the small catches at the bottom edge of the cover with the
slots on the lower edge of the battery compartment and then fold the cover towards the
belt clip.
6. Secure the cover with the 3mm screw.

Variable Valve systems

Variable Valve systems also use a tipping grid remote control system. The layout of the
key features is shown below:

1-Not used 2-Not Used

3-Feeder Start 4-Feeder Stop
5-Feeder Speed decrease 6-Feeder Speed increase
7-Engine Stop 8-Engine Stop

20 Tipping Grid
Troubleshooting Guide
The following section outlines some of the basic checks to take when faults are reported
by the system.
Prior to commencing any of the steps outlined in the following sections it is recommended
that operators are fully aligned with the safety operations of the machine involved.
To successfully carry out the various checks suggested in this manual, certain test
instruments are essential. The following details the basic requirements in this respect. It
should be noted that in addition to these instruments a comprehensive kit of tools is also
essential. For fault finding purposes this need not include any specialised tools.
Item 1 – Digital Multimeter
The Multimeter is a comprehensive test instrument for measuring voltage, current and
resistance. It should be capable of measuring the following ranges:-
Voltage AC 0-250-500-1000 Volts

Voltage DC 0-25-100-250 Volts

Amperes DC 0-10 Amps

DC Resistance 0-10k (ohms) or 0-2k (ohms)

0-100k (ohms) or 0-20k (ohms)

0-1M (ohms) or 0-200k (ohms)

Item 2 – Tachometer or Frequency meter

This instrument can be used for measuring the shaft speed of the alternator and should be
capable of measuring speeds between 0 and 5000 revolutions per minute, (RPM).
An alternative to the tachometer is a frequency meter - however the alternator must be
generating its normal output voltage for this instrument to be accurate.

Troubleshooting Guide 21
 Manual Doglead Troubleshooting

General checks when having problems tracking using the Dog-lead Handset

 Is the Dog-lead Handset E-stop pulled out?

 Is the Dog-lead Handset connected properly?
 Are the Track Solenoid connectors tight and free from corrosion?
 Are there any fuses blown in the Control Box?
 Are all connections tight in the Control Box?
 Are the Hydraulic Levers in the Tracking Position?
Machine stops when handset is connected

Check that the stop button is pulled out

Manual handset stop circuit is active
and not active
Doglead Handset not working

Confirm that ALL switches on control

Option may not be enabled
panel and handset are switched on

Ensure that any jack legs or other such

Are jacking legs fully up on machine (if fitted?)
equipment are set correctly

Engine is running but nothing is operating from the Dog-lead Handset

Dog-lead is not connected properly Check connection & tighten if loose

On/Off switch on the Handset is faulty Check switch & replace if faulty

Fuse on board inside the Control Box has blown Check fuse & replace if blown

Control wiring to Control Box may be damaged Check wiring & repair if faulty
All Tracking Motions working intermittently
Control wiring to Control Box may be damaged Check wiring & repair if faulty

Main Dog-lead connector loose or damaged Check connection & repair if faulty

Some Tracking Motions working intermittently

Connectors loose or corroded on Track Solenoids

Connectors loose on inside of Dog-lead Handset Check connections & tighten

Connectors loose on inside of Control Panel

Control switches on Handset are faulty Check switches & replace if faulty

Wiring damaged going to Track Solenoids Check wiring & repair if faulty
Main Dog-lead connector loose or damaged Check connection & repair if faulty

22 Troubleshooting Guide
Tipping Grid Remote troubleshooting

General checks using Grid Control

 Is remote switched on?

 Has Grid been set to work on manual operation or remote?
 Has Grid rise time been set?
 Is battery pack fully charged?
 Is Remote Control out of range?
 Has remote control clear sight to the receiver?
 Are Tipping Grid Solenoids tightened and clear of corrosion?
 Is there power to Receiver Box?
 Are there any blown fuses on Receiver Box or Control Panel?
Remote Control is turned on but LED not flashing

Battery may be flat Replace batteries

Faulty PCB board inside handset Return to JMG Systems for analysis

Remote Control is broadcasting but Tipping Grid is not operating

Is Remote Control out of range? Bring to a distance of 2m to 20m and retry

Is there power to the receiver unit? Check Power LED inside receiver unit is On
Check status of fuses inside receiver unit and
Receiver unit fuse may be blown
replace if necessary

Receiver set to operate with different Use steps detailed within this document to
transmitter reprogram transmitter / receiver pairing

Tipping Grid works intermittently

Secure antenna connection by opening

Is Antenna connection inside receiver box loose
receiver box

Control wiring to receiver may be damaged Check wiring and repair if faulty

Connectors loose on grid solenoids Check connections and tighten

Wiring damage to Tipping Grid Solenoids? Check wiring and repair if faulty
Loose connectors inside receiver box Check connections and tighten

Buttons faulty on transmitter Check handset and replace if damaged

Troubleshooting Guide 23
 Remote Control troubleshooting
General checks when having problems tracking using the Radio Remote Control

 Ensure that the Tracks on/off switch on Main Control Panel is set to “on” position.
 Is the Dog-lead/Remote switch on Main Control panel set to “Remote” position?
 Is the Remote Control de-activate switch pulled out?
 Is the key switch on Remote handset in the "On" position?
 Is the battery pack fully charged?
 Did you take the Remote Control out of range (100 metres)?
 Are the Track Solenoid connectors tight and free from corrosion?
 Is there power going to the Receiver Box?
 Are there any fuses blown in the Receiver Box?
 In the Receiver Box are all connections tight?
 In the Receiver Box is the internal antenna securely connected?
 Is there power going to the Tracks Control Box?
 Are there any fuses blown in the Tracks Control Box?
 In the Tracks Control Box are all connections tight?
 Are the Hydraulic Levers in the Tracking Position?
The Remote Control is turned on but the LED is not flashing.

Battery may be flat Replace battery or recharge unit

Fuse on board inside Handset has blown Check fuse & replace if blown

Key switch on handset may be broken Check wiring & repair/replace switch if faulty

Board inside handset has failed Contact JMG Systems

All Tracking Motions working intermittently

Check antenna connection on receiver box Tighten external aerial connection

Antenna connection on inside of Receiver Box Open received unit and secure antenna
is loose connection if loose

Control wiring to Control Box may be damaged Check wiring & repair if faulty

24 Troubleshooting Guide
 Check that the ADMO address code on the
Receiver is set for different address code Receiver PCB matches the address code on
the Remote Control

Another Remote Control may be interfering Check for other Remote Controls in the area
with the system and consult the Hetronic manual.

Some Tracking Motions working intermittently.

Connectors loose or corroded on Track

Check connections & tighten
Solenoids

Wiring damaged going to Track Solenoids Check wiring & repair if faulty

Connector loose or damaged at receiver box or

Check connection & repair if faulty
connection to harness loom / main system

The Remote Control is broadcasting but nothing is operating

Pull out the stop button on top of the

The Handset is de-activated
Handset

The Remote Control is out of range (100

Bring back into range.
metres).
Check that the power LED on the inside of
the Receiver Box is on.
No power going to the Receiver Box.
Fuse is blown on the inside of the Receiver
Box. Check fuse & replace if blown.
Check if green LED (LD2) located on PCB on
the inside of Receiver Box is flashing. If not
Receiver is set for different frequency.
check that the receiver frequency channel
matches that of the Remote Control.

Troubleshooting Guide 25
 Schematic Wiring Diagrams
Wiring diagrams of the machines associated with this operational manual

26 Schematic Wiring Diagrams

Schematic Wiring Diagrams 27
28 Schematic Wiring Diagrams
Schematic Wiring Diagrams 29
30 Schematic Wiring Diagrams
Schematic Wiring Diagrams 31
 Spare Parts Listing
The following section outlines some of the basic checks to take when faults are reported
by the system.

32 Spare Parts Listing

Spare Parts Listing 33