RCL Instruction Manual

Instruction Manual
RCL
Safety System

MANUAL # 99903244
REVISED 20071126
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 RCL Instruction Manual

Contents:

Chapter Page

1. Introduction. 5
2. The Function of the Loader Safety System 5
2.1 The RCL 5100 Safety System. 6
2.2 The RCL 5200 Safety System. 7
2.3 Warning when working with the loader safety system! 9
3. Basic Configuration 10
3.1 Safety System RCL 5100, standard loader 10
3.2 Safety System RCL 5100, TS, Single Circuit/Dual Circuit 10
3.3 Safety System RCL 5200, standard loader 11
3.4 Safety System RCL 5200, TS, Single Circuit/Dual Circuit 11
4. The Controller’s Indicator Panel 12
4.1 Press Buttons and Indicators 12
4.2 Function of Press Buttons and Indicators 13
5. Starting Up and End of Loader Operation 15
5.1 Starting Up of the Loader 15
5.2 End of Loader Operation 15
5.3 The Controller in Stand-By Mode 15
6. Signalling during Loader Operation 16
6.1 Load Indication 16
6.2 Indication of 90% Load Moment 16
6.3 Load Moment between 80% and 100% 17
7. Signalling in Case of Overload – RCL 5100 18
7.1 When the max. load moment is 100%,
the controller indicates as follows: 18
7.2 After a short dump period, the controller indicates as follows: 19
7.3 Erroneous Operation after a Dump Period: 20
7.4 Absolute Stop in Case of Overload 21
8. Signalling in Case of Overload – RCL 5200 22
8.1 When the max. load moment is 100%,
the controller indicates as follows: 22
8.2 When all the control valve’s levers are back in neutral position again: 23
8.3 Erroneous Operation after Deactivation of the TCL: 24
9. The Override Function 25
10. Absolute Stop in Case of Override 26
11. “Last Chance” Emergency Operation 27
12. Emergency Stop 28
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13. Supplementary Functions 29

13.1 Disconnection of Buzzer 29
13.2 Registering of Data 29
14. Oil Temperature Monitoring (RCL 5200) 30
14.1 Warning at High Oil Temperature 30
14.2 Stop of Loader in Case of Critically High Oil Temperature 31
15. 2-Stage Load Moment Limitation (LMB) 32
15.1 The Safety System 32
15.2 Configuration – RCL 5100, 2-Stage LMB 33
15.3 Configuration – RCL 5200, 2-Stage LMB 33
15.4 Working in the Stable Slewing Area 34
15.5 Slewing with a too Large Load Moment towards the Unstable Area 35
15.6 Working in the Unstable Slewing Area 36
16. EVS-Electronic Vehicle Stability 37
16.1 The EVS system 37
16.2 Configuration of the System 38
16.3 Mode of Operation of the EVS System 39
16.4 Load Moment Limitation (LMB) and Electronic Vehicle Stability (EVS) 40
16.5 Calibration of the EVS system 41
16.5.1 Calibration when starting up 42
16.5.2 Automatic Calibration 42
16.5.3 Calibration during Loader Operation 43
16.5.4 Optimisation of Calibration 44
16.5.4 Manual Calibration 47
16.8 Starting Up of the Loader 48
16.9 Starting Up Procedure 48
16.10 Signalling during Loader Operation 49
16.11 Signalling in Case of too much Heel 50
16.12 Especially for Loaders equipped with HDL 53
16.13 Override and EVS 53
16.14 Good Advice for Unproblematic Operation of the Loader 54
16.15 Warning 55
17. Safety System, Stand-Up Controls, HS 56
17.1 The Safety System 56
17.2 Configuration – RCL 5100, Stand-Up Controls (HS) 57
17.3 Configuration – RCL 5200, Stand-Up Controls (HS) 57
17.4 Slewing limitation, Stand-Up Controls 58
17.5 Warning during Slewing Movement over Stand-Up Controls 59
17.6 Combination of 2-Stage LMB and
Safety System for Stand-Up Controls 59
18. Heavy Duty Lifting, HDL 2 61
18.1 The HDL-System 61
18.2 Configuration – RCL, HDL 2 61

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18.3 RCL 5100 and the HDL-System 62

18.4 RCL 5200 and the HDL-System 62
18.5 Proportional HDL 63
18.5 Micro Operation 64
18.6 HDL Indication 65
19. Safety System, Fly-Jib 66
19.1 The Safety System 66
19.2 Configuration, Fly-Jib 66
19.3 Mode of Operation of the Safety System 67
19.4 Loader Operation with and without Fly-Jib 69
19.5 Loader Operation with Fly-Jib 69
19.6 Loader Operation without Fly-Jib 69
19.7 Signalling during Loader Operation with Fly-Jib 70
19.8 When the max. load moment of the Fly-Jib is 100%, the controller
indicates as follows: 71
19.9 Warning when Working with Loader and Fly-Jib 72
20. Safety System, Winch 73
20.1 The Safety System 73
20.2 Configuration, Winch 74
20.3 Mode of Operation of the Safety System 75
20.4 The Functions of the Safety System 76
20.5 Signalling during Loader Operation with Winch 81
20.6 Warning when Working with Loader and Winch 83
21. Activation of Optional Extras 84
22. Electric Activation, Loader Functions / Stabilizers 85
22.1 Operation of the Stabilizer Functions 86
22.2 Operation of the Loader Functions 87
22.3 Emergency Operation of the Stabilizer Functions 87
23. Indication of Errors/ Emergency Operation of the Loader 88
23.1 Indication of Errors 88
23.2 Emergency Operation of the Loader 90
24. Troubleshooting 91
24.1 How to troubleshoot 91
24.2 Explanation to the Troubleshooting Sheets 91
25. Technical Data RCL 98

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1. Introduction.

This operation manual on electronic safety systems is meant for the user of the
loader and must be considered as a supplement to the Instruction Manual for
the individual loader series.

Certain safety systems are described in the manual; these systems are not
standard with the loader, but an optional extra.

The electronic loader safety systems are based on two different types of
controllers:
The RCL 5100 used on small and medium-range loaders.
The RCL 5200 used on larger loaders as well as on loaders with certain types
of optional extras.

A common characteristic of both safety systems is that the controller is

constantly monitoring the loader’s conditions as regards load moment,
operation and function.

2. The Function of the Loader Safety System

The basic principle of the RCL safety system is to secure the loader against
overloading and the consequences of this. I.e. independent of the operators
doings, the system prevents that the max. permissible load moment is
exceeded (load moment limitation).

The controller monitors a pressure transducer mounted on the boom cylinder.

The pressure transducer registers the hydraulic pressure, which is an
indication of the load moment on the loader. The controller registers from the
signal from the pressure transducer when the loader has reached its max.
permissible load moment and gives signal to the hydraulic system of stopping
the load moment incereasing movements.

Intervention from the safety system depends on the type of controller:

• The RCL 5100 stops all loader movements for a shorter or longer period,
depending on the way the loader is operated.
• The RCL 5200 stops the loader selectively. I.e. only load moment
increasing movements are stopped, but load moment reducing movements
can still be activated.

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2.1 The RCL 5100 Safety System.

Movements blocked in case of overload:

• In case of max. load moment (the diodes up to 100% are lit) all loader
movements are stopped as indicated by the arrows.
• The control levers can be operated but building up of a hydraulic pressure
in the system is not possible (the dump valve opens so that the oil from the
pump flows to tank).
• After a certain non operational time – dependent on how many times the
loader has been working with load moment increasing movements, as well
as on how big an increase it has been exposed to – all loader functions can
be operated again (the dump valve closes so that the oil from the pump can
flow to the loader cylinders).

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2.2 The RCL 5200 Safety System.

Load moment increasing movements blocked in case of overload:

Jib at an angle between 0° and + 90°.

Boom down
Jib down
Extension out

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Jib at an angle below 0°

Jib up
Extension out

• In case of max. load moment (the diodes up to 100% are lit) the load
moment increasing movements are stopped as indicated by the arrows.
• The control levers can be operated by activating load moment increasing
loader movements as indicated by the arrows, but building up of a hydraulic
pressure in the system is not possible (the dump valve opens so that the oil
from the pump flows to tank).
• Load moment reducing loader functions as well as the slewing movement
can be operated freely (the dump valve closes so that the oil from the pump
can flow to the loader cylinders).

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2.3 Warning when working with the loader safety system!

• The loader safety system increases safety in connection with loader

operation, but being the operator you are still responsible for safe operation
of the loader.

• Press the stop button if a dangerous situation occurs.

• Be careful when cleaning the loader. Avoid spraying on water and never
use high-pressure rinsing for cleaning the electronic components. Also be
careful not using noxious chemicals and detergents.

• Troubleshooting must only take place according to this manual; then

contact an authorized IMT service point.

• Remove the cable for the power supply, if the battery of the vehicle is
discharged, and connect a “boost starter” to start the engine.

• Remove the cable for the power supply, if you are to weld on the vehicle.

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3. Basic Configuration

3.1 Safety System RCL 5100, standard loader

1: RCL 5100 controller

2. Dump valve
3: Pressure transducer
4: Spool sensor (Boom)
5: Power supply
6: External stop button

3.2 Safety System RCL 5100, TS, Single Circuit/Dual Circuit

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3.3 Safety System RCL 5200, standard loader

1: RCL 5200
controller
2: Dump valve
3: Dump valve,
2-circuit
4: Pressure
transducer
5: Spool sensors
(Boom, Jib,
Extension)
6: Power supply
7: Mercury switch
8. External stop
button

3.4 Safety System RCL 5200, TS, Single Circuit/Dual Circuit

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4. The Controller’s Indicator Panel

4.1 Press Buttons and Indicators

It is important that the operator is familiar with and knows the function of the
press buttons and indicators on the controller’s indicator panel.

Apart form a few exeptions as to function, the indicator panels on the RCL
5100 and 5200 are identical. The RLC 5200 is larger and also has a plug or
connection of a service terminal or a PC.

Press buttons and indicators as shown below are the same both controllers:

• The RUN diode is green

• The FUNC diode is yellow.
• The other diodes are red.

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4.2 Function of Press Buttons and Indicators

Press Function
button
1- Red Override in case of overloading and instability / indication of errors
/ manual HDL.
2 – Yellow Alternative function mode.
3 – Green System activation / deactivation of buzzer.

Indicator Flashing light Constant light

Periodic signal Constant signal

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BUZZER Load moment >90% / override / Any reason for stopping the
system error. loader (Dump)
RUN System error. Normal operation mode.

100% SLM stop (dump period) Load moment >100%

95% SLM stop (dump period) Load moment >95%

90% SLM stop (dump period) Load moment >90%

85% SLM stop (dump period) Load moment >85%

80% SLM stop (dump period) Load moment >80%

FUNC Alternative function mode

(F1, F2, F3, F4, F5)
SVING / F1 Load moment > max. permissible Slewing limitation.
load moment in reduced working
area. (2-stage LMB)
The heel of the vehicle has Loader stop (the EVS system)
exceeded the max. permissible
limit (the EVS system).
P1 / F2 Load moment, loader >80%+ Overload stop – loader.
loader with largest load moment.
P2 / F3 Load moment, Fly Jib>80% + Fly Overload stop – Fly Jib
Jib with largest load moment.
SPIL. / F4 Load moment, winch.>100% / Winch stop.
Wireudløb / -Wireoverløb.>100%
/ wire run-out / wire overflow.
TEMP / F5 Warning at too high oil Loader stop at too high oil
temperature. temperature.

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5. Starting Up and End of Loader Operation

5.1 Starting Up of the Loader

Before starting up, the operator must carry out the following:

• Connect the pump (PTO); the controller is thus powered.

• Push the green press button (the system is activated).
• The green diode RUN is now constantly lit, indicating that the safety system
is ready for operation.
• Prepare the loader for starting up according to the Instruction Manual for the
loader.

5.2 End of Loader Operation

After loader operation, stop the pump (PTO), the power for the controller is
thus interrupted.

5.3 The Controller in Stand-By Mode

The controller has been programmed to switch into stand-by mode after 10
minutes.
I.e. if a certain loader function (with spool sensor) has not been operated for
the last 10 minutes, the controller will automatically turn off and go into stand
by mode where the power consumption is reduced to 10%.

The following factors reactivate the controller:

• When pushing the green press button.

• When activating the control lever for the boom function (or dependent on
which optional extra is used, any of the control levers with a spool sensor).

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6. Signalling during Loader Operation

6.1 Load Indication

• During loader operation, the red diodes indicate the load moment in
percentage between 80% and 100%.
• When the maximum load moment is between 80% and 100 %, the red diode
P1 also flashes.

6.2 Indication of 90% Load Moment

• At a load moment of 90%, the red diodes indicating 80%, 85% and 90% are
lit.
• The buzzer gives a periodic signal.
• The red diode P1 continues to flash (between 80% and 100%).

The signalling described continues till the load moment gets below 90% again.
Please note: that the diodes do not immediately indicate this reduction
of the load moment. A delay has been built into the system to keep the
indications of the diodes stable during variation of load.

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6.3 Load Moment between 80% and 100%

If the loader is fitted with a Fly Jib, the loader and the Fly Jib will rarely have
the same load moment.

As to the RCL 5200:

• When the red diode P1 flashes, it means that the loader has the largest load
moment.
• When the red diode P1 flashes, it means that the Fly Jib has the largest load
moment.
• The red diodes 80% through 100% are constantly related to either P1 or P2
(the load moment of the loader or the Fly Jib).

Only one of the diodes, P1 or P2 is lit at a time. It will

thus be possible during loader operation to follow whether the loader or the Fly
Jib has the largest load moment. This offers the possibility of using the
loader/the Fly Jib to its maximum.

Example: The loader has the largest load moment (85%).

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7. Signalling in Case of Overload – RCL 5100

The loader’s load moment is constantly checked by an SLM (Superior Load

Monitoring) safety system, which is activated if the max. permissible load
moment of the loader is exceeded.

7.1 When the max. load moment is 100%, the controller

indicates as follows:

• All red diodes 80% - 100% are flashing (SLM is activated)

• The buzzer gives a constant signal.
• The diode P1 is constantly lit.
• The dump valve opens to tank during a certain period (the dump period),
and all loader movements are stopped.

Please note: When the max. load moment is 100% and all loader movements
are stopped, all control levers must immediately get back into neutral position.

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7.2 After a short dump period, the controller indicates as

follows:

• All red diodes 80% - 100% are constantly lit (SLM is deactivated).
• The buzzer gives an interrupted signal.
• The diode P1 flashes.
• The dump valve closes to tank, and it will be possible to operate the loader
again (the movements must be load moment reducing).
• It will however not be possible to operate the loader before the control lever
for the boom function (and the slewing function, dependent on optional
extras), has been into neutral position.

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7.3 Erroneous Operation after a Dump Period:

In a situation where the loader can be operated again after a dump period, it
will be possible to make load moment increasing movements by making an
erroneous operation.

In this case of further overloading of the loader, the SLM safety system will be
reactivated and a new and longer dump period will follow (with the
diode/buzzer indications as earlier mentioned).

In case of further erroneous operation (overloading) the subsequent dump

periods will be increased accordingly.

Please note!

• Abusing the SLM-system to deliberately overload the loader is not

permitted.
• The first time a loader movement is stopped by the SLM-system because of
overloading, all control levers must immediately get back into neutral
position.
• The number of times the loader has been overloaded, how long time it has
been overloaded, and how much it has been overloaded, is registered in
memory registers. Please see chapter on Registering of Data.
• When the loader is overloaded (the SLM-system is activated), and all loader
movements are stopped, the movements must be load moment reducing
movements, when the SLM-system is deactivated after a dump period.-

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7.4 Absolute Stop in Case of Overload

After the loader having been into SLM-stop and then by erroneous operation
into a further number of stops (with long dump periods), the SLM-safety
system will finally go into an absolute stop, and the loader can no longer be
operated.

Indication of absolute stop:

• The 85%, 95% and P1 diodes flash.

• The 80%, 90% and 100% diodes are constantly lit.
• The buzzer gives a constant signal.

In order to get out of this situation (loader stop), it is necessary to push the
override button, and at the same time operate load moment reducing
movements until the load moment of the loader is below 100%. Afterwards the
loader can be operated as usual.
Please also see the chapter on The Override Function.

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8. Signalling in Case of Overload – RCL 5200

The loader’s load moment is constantly checked by a TCL (Traditional

Capacity Limitation) safety system, which is activated if the max. permissible
load moment of the loader is exceeded.

8.1 When the max. load moment is 100%, the controller

indicates as follows:

• All red diodes 80% - 100% are constantly lit (TCL is activated).
• The buzzer gives a constant signal.
• The diode P1 is constantly lit.
• The dump valve opens to tank and the loader movement causing the
overload is stopped.

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8.2 When all the control valve’s levers are back in neutral
position again:

• All red diodes 80% throuch 100% are constantly lit.

• The TCL is deactivated
• The buzzer gives a periodic signal.
• The diode P1 flashes.
• The dump valve closes to tank, and it will be possible to operate load
moment reducing movements.

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8.3 Erroneous Operation after Deactivation of the TCL:

In a situation (after TCL-stop), where a load moment increasing function is

operated unintentionally, the controller indicates as follows:

• All red diodes 80% - 100% are constantly lit (TCL is activated again).
• The buzzer gives a constant signal.
• The diode P1 is constantly lit.
• The dump valve opens to tank again until the control valve lever is in neutral
position. (Levers for control valve functions which have a spool sensor).

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9. The Override Function

If the loader is “stuck” in an overload situation, where, for different reasons, it is

not possible to make load moment reducing movements, the safety system
can be overrided (bypassed) by holding down the red press button and
operate the loader to get the loader out of the overload situation.

While holding down the red press button (the buzzer gives a periodic signal),
the loader can be operated for 5 seconds, to get the load out of the locked
situation, if possible.

If it is not possible to bring the load into a sufficiently favourable position within
these 5 seconds, it will be possible – with an interval of 30 seconds – to
operate the loader again during 5 seconds.

The 30 seconds non-operational time is only reset after 5 seconds override.

I.e. if only 3 seconds are used during the first override period, the controller
remembers that the second time, the system is only able to override during 2
seconds.

The override function is also used for “releasing” the main boom (downwards),
if it has been operated into its extreme position (vertical position).

After turning on the controller, it takes 30 seconds before the override function
can be used.

The override function is only active in connection with overloading.

It does not work in case of a system error.

Please note!
Abusing the override function is not permitted, as this may lead to very
dangerous situations such as for instance unstability of the vehicle or
overloading of the loader.
Furthermore, in case of abusing the override function, the SLM safety system
will cause a very long dump period (a long non-operational time before the
loader can be operated again).

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10. Absolute Stop in Case of Override

If the loader has been very overloaded as a consequence of using the override
function, the safety system will go into an absolute stop, and the loader can no
longer be operated.

Indication of absolute stop:

• The 85%, 95% and P1 diodes flash.

• The 80%, 90% and 100% diodes are constantly lit.
• The buzzer gives a constant signal.

In order to get out of this situation, the only possibility is a “last chance”
emergency operation. Please see chapter on “Last Chance” Emergency
Operation.

Please note!
In case of an error from the pressure transducer (or a short circuit of the signal
wire) the safety system can also go into an absolute stop.

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11. “Last Chance” Emergency Operation

If, during loader operation, a situation occurs where for example the electric
connection between the power supply (the battery of the vehicle) and the
controller fails, a manual override push button on the dump valve can be
pressed at the same time as the control valve is being operated.

Please note that before pressing the override push button, the seal has to be
broken.

This is how emergency operation is made possible, and the loader can be
brought out of a dangerous position, if necessary, and then be folded so that
the vehicle can drive away.

Please note!
Abusing this safety detail is not permitted, it must only be used for emergency
operation.
In case of using the manual override function, the button must be sealed again
(at an authorised IMT service point).

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12. Emergency Stop

If a dangerous situation occurs, push the stop button. The controller then
interrupts the power supply to the loader (the dump valve opens and the oil is
led to tank).

Starting up after emergency stop:

• Pull out the stop button.

• Push the green press button.
• The green diode RUN is now constantly lit, indicating that the safety system
is ready for operation.

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13. Supplementary Functions

13.1 Disconnection of Buzzer

In cases where loader operation takes place, particularly in the load moment
area exceeding 90%, the buzzer will correspondingly give an interrupted signal
the most of the time.

The interrupted signal from the buzzer during some time may seem very
disturbing, and therefore it is possible to disconnect it.

After the sounding of the buzzer (an interrupted signal) for 5 seconds, it is
disconnected by pushing the green press button.

From the moment the buzzer changes status (i.e. the load moment gets below
90%), it will automatically go out of disconnection mode again. I.e. if the load
moment exceeds 90%, the buzzer will start giving an interrupted signal again.

13.2 Registering of Data

The controller has a black box-function currently registering data in memory

registers, i.e. information on load moment, operation, function and service
conditions.

The information is read by connecting either a service terminal or a PC during

the annual service overhaul at an IMT service point.

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14. Oil Temperature Monitoring (RCL 5200)

By connection of a temperature sensor (fitted in the tank connection), the RCL

5200 controller can check the temperature of the hydraulic oil.

14.1 Warning at High Oil Temperature

If the max. permissible operation temperature of the oil is exceeded, the

controller indicates as follows:

• The diode for oil temperature flashes.

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14.2 Stop of Loader in Case of Critically High Oil Temperature

If the oil temperature increases further, the controller interferes and stops the
loader before the oil is superheated and damages the hydraulic system.

In case of loader stop the following is indicated:

• The RUN diode flashes.

• The RUN diode flashes.
• The buzzer gives a constant signal.
• The dump valve opens to tank and the loader stops.

Please also see chapter on Troubleshooting regarding indication.

Loader operation cannot be started again until the oil has been sufficently
cooled. I.e. after the pump circuit has been running for some time and the RUN
diode no longer flashes.

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15. 2-Stage Load Moment Limitation (LMB)

15.1 The Safety System

If the vehicle is not stable in the entire slewing area of the loader (for example
in front of the driver’s cab), the RCL safety system is extended with a 2-stage
load moment limitation (LMB).

The 2-stage LMB ensures that the lifting capacity of the loader is reduced in
the slewing area where the vehicle is unstable.

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15.2 Configuration – RCL 5100, 2-Stage LMB

1: RCL controller
2: Dump valve
3: Pressure
transducer
4: Spool sensors
5: Power supply
6: External stop
button
7: Proximity switch
8: Mercury switch

15.3 Configuration – RCL 5200, 2-Stage LMB

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15.4 Working in the Stable Slewing Area

• If working with a load moment lower than the capacity in the unstable area,
no indication will occur on the controller.
• If working with a load moment higher than the capacity in the unstable area,
the controller will indicate as follows: the diode with the slewing limitation
symbol flashes and warns the operator of the slewing movement being
stopped, if this movement gets into the unstable area.

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15.5 Slewing with a too Large Load Moment towards the

Unstable Area

If, (despite the warning) the slewing movement has a too large load moment
from the stable to the unstable area, the slewing movement will be stopped
and the controller indicates as follows:

• The diode with the slewing limitation symbol is constantly lit.

• The buzzer gives a constant signal.
• The dump valve opens to tank (the slewing movement is stopped).

To be able to move into the unstable slewing area, the load moment should
now be reduced to the capacity in this area.

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15.6 Working in the Unstable Slewing Area

If working with the loader in the unstable slewing area, the monitoring of the
load moment functions exactly as in the stable area, but the max. permissible
load moment is reduced.

I.e. the diode/buzzer indications function as normal but at a lower level

(indication with the 100% diode means that the load moment is at the max.
permissible limit corresponding to the capacity in the unstable area).

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16. EVS-Electronic Vehicle Stability

16.1 The EVS system

As described in the beginning of this instruction manual, the main purpose of

the RCL safety system is to ensure that the loader’s max. permissible load
moment is not exceeded.

The EVS (Electronic Vehicle Stability) is a load dependent system, which is

monitoring and securing the stability of the vehicle during loader operation in
the critical working areas.

Generally the loader’s max. load moment cannot be utilized in the entire
working area, due to lacking stability of the vehicle.
If the loader is equipped with an EVS system, its lifting capacity can constantly
be utilized to its max. limit in relation to the stability of the vehicle.

By loading the vehicle in the right way, i.e. placing the first burdens so that
their weight increases the stability of the vehicle, it will be possible to obtain
sufficient stability for utilizing a larger part of the loader’s load moment.
In other words, the loader’s load moment is constantly adapted up to the limit
of the vehicle’s stability, no matter where in the working area the lifting
movement is carried out.

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16.2 Configuration of the System

1: RCL 5200 controller

2: Dump valve
3: AIC-unit
4: Pressure transducer
5: Spool sensors
(Slewing, Boom, Jib,
Extension)
6: Power supply
7: Mercury switch
8. External stop button

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16.3 Mode of Operation of the EVS System

The AIC-unit (Advanced Inclination Controller) is fitted to the base of the loader
and has two built-in heel sensors, measuring the heel of the vehicle to the left
and right (X-direction), to the front (Y1-direction), and to the back (Y2-
direction).

During loader operation the AIC-unit is thus constantly monitoring the heel of
the vehicle.
When the heel reaches a marginal value, i.e. when the vehicle starts being
unstable, a signal from the AIC-unit is sent to the RCL 5200 safety system.

In the same way as the loader’s load moment increasing movements are
stopped because of overloading (Load Moment Limitation – LMB), the RCL
system reacts in case of too much heel and stops the stability reducing loader
movements (Electronic Vehicle Stability – EVS).
Also a slewing movement registered as a stability reducing movement will be
stopped.
All stability increasing loader movements can still be operated.

The safety system will interfere in the following sequence:

• The heel reaches the marginal value

• The marginal value of the heeling is registered by the AIC-unit
• The AIC-unit sends a signal to the RCL controller
• The EVS system stops the stability reducing loader movements

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16.4 Load Moment Limitation (LMB) and Electronic Vehicle

Stability (EVS)

Load moment limitation (LMB) and Electronic Vehicle Stability (EVS) is an

integrated safety system controlled by the RCL controller.

If the loader is equipped with an EVS system (option), two types of interfering
can be experienced during loader operation, if a critical situation occurs:

1. The load moment of the loader is at the max. permissible limit and the LMB
is activated.
or
2. The loader has stressed the vehicle to the max. permissible heel limit and
the EVS is activated.

No matter which of the two systems are activated, the load moment increasing
or stability reducing movements are stopped (the dump valve opens so that
the oil from the pump flows to tank).

Load moment reducing or stability increasing functions can be operated freely

(the dump valve closes so that the oil from the pump can flow to the loader
cylinders).

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16.5 Calibration of the EVS system

The ground is not always completely horizontal where loader operation takes
place. Also, the vehicle is not in horizontal position and has thus a so-called
initial heel.

The AIC-unit registers the heel of the vehicle during loader operation. The
loader’s load moment can make the vehicle heel up to a max. marginal value
called the heel margin.

The total heel, i.e. the initial heel plus the heel margin must not exceed a
marginal value called the max. heel.

Initial heel

Max. heel

Heel margin
Please note!
The max. heel is pre-set at 5 degrees (depending on the vehicle). I.e., if the
vehicle heels a lot so that the max. heel exceeds 5 degrees, the RCL system
and thereby the loader cannot be activated.

In any case of starting up loader operation, the vehicle will as a starting point
heel a little bit and thus have an initial heel, which is registered by the AIC-unit.

When starting up the RCL system a calibration has to be carried out in order to
zeroize the heel, which the AIC-unit has registered.

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16.5.1 Calibration when starting up

When starting up loader operation, after having extended the stabilizers and
lowered the stabilizer legs, the vehicle is not in horizontal position but has an
initial heel. To ensure that the EVS system can function correctly, the initial
heel has to be zeroized, i.e. the current registered angle of heel is set at zero
degrees.

When starting up the RCL-system, the AIC-unit registers the initial heel of the
vehicle. Provided that the load moment of the loader is less than approx. 25%
(depending on the design of the loader and the loader equipment), the system
carries out an automatic calibration, i.e. zeroizing of the initial heel.

When the system has been calibrated, the buzzer confirms by 3 beeps.

During loader operation to both sides of the vehicle, it will be an advantage if

the EVS system calibrates at as low a load moment as possible. The best
possible calibration is obtained when the loader is folded in stowing position
during start up. Please see chapter on “Optimisation of Calibration”.

If the load moment exceeds approx. 25% when the RCL system is started up,
the system does not carry out any calibration and the loader is derated. I.e. the
loader can only be loaded up to the level where the vehicle is stable in the
entire slewing area of the loader.

16.5.2 Automatic Calibration

During loader operation, the EVS system will try to optimize the calibration.
Each time the load on the loader gets below the level where it was last
calibrated, a new calibration is carried out.

Each time the system calibrates, the buzzer confirms by 3 beeps.

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16.5.3 Calibration during Loader Operation

During loader operation, three situations may occur, causing the EVS system
to carry out a new calibration:

1. In case of electric changing over to stabilizer operation

2. In case of manual changing over to stabilizer operation
3. In case of a stabilizer leg sinking into the surface

Re.: item 1
If the loader has an electric change over between the loader functions and the
stabilizer functions, and the operator has operated the stabilizer (push the
yellow press button twice), the system will calibrate again at the moment
where a loader function is operated. Please see chapter on Start Up
Procedure.

Re.: item 2
If the loader has a manual change over (ball valve) between the loader
functions and the stabilizer functions, and the operator has operated the
stabilizer, the system will calibrate again at the moment where a loader
function is operated.
The calibration is only carried out, if the heel of the vehicle has changed more
than 50% of the max. permissible heel (heel margin), and at the same time the
load on the loader is below approx. 25%.

Re.: item 3
If, during loader operation, a situation occurs where a stabilizer leg sinks a bit
into the ground, the heel of the vehicle will change, and this will be registered
by the EVS system as beginning instability. In this way the loader’s lifting
capacity can only be utilized corresponding to the reduced stability.

If the heel of the vehicle exceeds the marginal value for instability as a
consequence of a stabilizer leg sinking a bit into the surface, all loader
movements are stopped for 4 seconds. After this, only stability increasing
loader movements can be operated.

Now the load has to be placed on the ground or moved in the direction towards
the vehicle (stability increasing direction). Afterwards a new calibration is
carried out.

Please note!
Whether the loader has a manual or electric reverser between the loader and
stabilizer functions, it is necessary to push the yellow press button on the RCL

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indicator panel twice (or the remote control box) before operating the stabilizer
functions.

16.5.4 Optimisation of Calibration

If the working tasks demand slewing a load from one side of the vehicle to the
other, asymmetric stability might occur.
I.e., if a load is to be moved from point A to point C in the opposite side, the
EVS system might be activated and the slewing movement stopped already in
point B.

In such a working situation it is necessary to optimise the calibration, i.e. the

EVS system calibrates at as low a load moment as possible.

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Optimal calibration at a low load moment on the loader is carried out as

follows:

• When the loader is folded in stowing position

• When the boom system is raised into vertical position

The 80, 85, 90, 95, and 100% diodes on the RCL indicator panel indicate, right
before the calibration is carried out, the size of the current load moment on the
loader:

• The 80% diode indicates the worst calibration (at the highest load moment)
• The 100% diode indicates the best calibration (at the lowest load moment)

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Example of optimisation of calibration:

• There is no load on the hook

• Raise the boom into vertical position to a position where the load moment is
estimated to be low, and put the levers of the valve block into neutral
position.
• If the load moment in this position is lower than at the previous calibration, a
diode indicates the current load moment at the moment when you operate a
loader movement again (e.g. boom down).
• E.g. if the 90% diode is lit and the buzzer gives a constant signal for as long
as the lever is kept in this position. The loader does not move. A constant
signal from the buzzer indicates that the dump valve opens and the oil flows
to tank.
• The new, improved calibration is being carried out at the moment when the
levers of the valve block are back in neutral position.
• When the calibration has been carried out, the buzzer confirms by 3 beeps.
• Then loader operation can start.

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If you want to improve the calibration further, repeat the procedure by moving
the boom close to vertical position. With this boom position the load moment of
the loader is low and the best possible calibration can be obtained. This is
indicated by the 100% diode being lit.

Please note:
The main boom must not be completely raised and extended to its extreme
position. In this case the hydraulic system will build up a high pressure, which
is registered as a high load moment by the RCL/EVS system. Therefore the
EVS system will not carry out any calibration.

16.5.5 Manual Calibration

During loader operation it is possible to carry out manual calibration. E.g. if you
want an optimisation of the calibration. Please see previous chapter.

Provided that the load moment of the loader is less than approx. 25%, a
manual calibration can be carried out when pushing first the yellow and then
the green press button on the RCL indicator panel.

Now one of the 80, 85, 90, 95, or 100% diodes on the RCL indicator panel
indicate the size of the current load moment on the loader.
Please see chapter on “Optimisation of Calibration”.

At the first activation of one of the levers of the valve block, the buzzer gives a
constant signal, indicating that the dump valve opens and the oil flows to tank.
The loader does not move.

When the lever is moved into neutral position, the system calibrates, and the
buzzer confirms by 3 beeps. During 5 seconds one of the %-diodes indicates
how optimal the calibration was that has just been carried through (100% is the
best possible calibration).

Then loader operation can start.

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16.6 Starting Up of the Loader

Before starting up, the essential safety regulations have to be respected, just
as the general procedure in connection with starting up of the loader has to be
followed. Please see the Instruction Manual of the loader.

Especially during the starting up procedure it is important that the vehicle is

stabilized correctly, when the stabilizer legs are lowered to the ground.
This is to ensure that the loader can lift the max. permissible load without the
vehicle’s heel reaches the marginal value, and the EVS system is activated.

16.6.1 Starting Up Procedure

Before starting up, the operator must carry out the following:

• If the vehicle is air-sprung, the air bellows have to be bled.

• Connect the pump (PTO); the controller is thus powered.
• Push the green press button on the RCL indicator panel.
• The RUN diode is now constantly lit and the RCL-safety system is
activated.
• Push the yellow press button twice to choose the stabilizer function
• Extend the stabilizer beams and lower the stabilizer legs (with plates under
the footplates, if necessary) until the chassis of the vehicle is lifted approx. 5
cm.
• Activate one of the levers of the valve block to unfold the loader from its
stowing position.
• A diode* (e.g. the 85% diode) is lit and the buzzer gives a constant signal
for as long as the lever is kept in this position. The loader does not move.
• Move the lever of the valve block into neutral position, after which the EVS
system is calibrating.
• When the calibration has been carried out, the buzzer confirms by 3 beeps.
• Then loader operation can start.

∗ The diode states how well the EVS system is calibrated. Please see chapter
on “Optimisation of Calibration”.

• If the loader does not have an electric change over for operating the
stabilizer functions, the procedure is the same (also in this case push the
yellow press button twice), however, change over manually by means of a
ball valve.
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16.7 Signalling during Loader Operation

During loader operation, there will be different indications of the diodes and
different signals from the buzzer.

The different indications will state whether it is the load moment limitation
(LMB) or the heel of the vehicle (EVS) that causes the interference from the
RCL safety system.

Indication in connection with LMB is described previously in this manual.

In connection with EVS, the diode with the slewing symbol, the diode P1 and
the buzzer indicate as follows:

• The slewing symbol and the P1 diode flashing as well as an interrupted

signal from the buzzer indicate: The heel of the vehicle has exceeded the
max. permissible limit (the heel margin).

• The slewing symbol and the P1 diode constantly lit as well as a constant
signal from the buzzer indicate: The loader is stopped (the dump valve
opens so that the oil from the pump flows to tank).

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16.7.1 Signalling in Case of too much Heel

Example:
If, during loader operation a heavy burden is moved from the truck body and
over the side, the heel of the vehicle will increase. If the heel exceeds the max.
permissible limit where the vehicle becomes unstable (heel margin), the
following is indicated:

• The 80 through 100% diodes are constantly lit.

• The slewing stop symbol and the P1 diode are constantly lit.
• The buzzer gives a constant signal.
• The dump valve opens to tank during 4 seconds (the dump period), and all
loader movements are stopped.

Indication of a load moment of 100% means that the lifting capacity of the
loader has been reduced (derated) to the lifting capacity of the loader at the
moment when the loader was stopped.

Any other kind of loader function, which in the same way makes the heel of the
vehicle exceed the max. permissible limit of unstability, entails the same loader
stop as in the above example.

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After Loader Stop:

The load becomes steady thanks to the loader stop and after 4 seconds, the
following is indicated:

• The 80 through 100% diodes are constantly lit.

• The slewing stop symbol and the P1 diode are flashing.
• The buzzer gives an interrupted signal.

By stopping the loader, the EVS system warns the operator of the vehicle
starting to become instable and that stability increasing loader movements
have to be operated.

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Please note! In case of loader stop in certain positions, it might be necessary

to operate stability increasing movements by for instance the “extension
retract” movement up to one metre, before the EVS system is deacitivated,
thus allowing normal lifting capacity.
This is due to the chassis’ slowness to “draw itself up” after heeling
(hysteresis).

If, after a loader stop, the operator accidentally operates a lever for a stability
reducing loader movement, the following is indicated:

• The 80 through 100% diodes are constantly lit.

• The slewing symbol and the P1 diode are constantly lit.
• The buzzer gives a constant signal.
• The dump valve opens to tank.

The EVS system intervenes against the erroneous operation, and the loader
never gets to move.

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16.8 Especially for Loaders equipped with HDL

When a loader is working in HDL-mode the working speed is reduced to

approx. 20% of the loader’s normal speed.

This principle is utilized in connection with the EVS system.

When the heel of the vehicle is 70% of the max. permissible limit (the heel
margin), the HDL is activated, and the working speed of the loader reduced.

This function indicates that there will soon be a loader stop. Furthermore this is
to ensure a “soft stop” thanks to the reduced speed, which is an advantage, in
particular in case of a slewing movement.

Please see chapter on HDL.

16.9 Override and EVS

If the loader is “stuck” in a position, where it is not possible to make stability

increasing movements, the EVS system can be overrided (bypassed) when
pushing the red press button on the RCL indicator panel.

In case of for instance a very fast slewing movement with a heavy load, the
loader is stopped because the EVS system is activated – this overload might
entail that it is not possible to make a slewing movement back into a stability
increasing direction.

In this situation it is possible to hold down the red press button and the loader
can thus be operated for 5 seconds.

Please also see description of the Override Function previously in this manual.

Please note!
Consider thoroughly the next movement/s and operate the loader carefully,
when the override function is used.
Be careful not to operate a stability reducing function by mistake when using
the override function.

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16.10 Good Advice for Unproblematic Operation of the Loader

• Always extend stabilizer beams completely to obtain max. stability of the

vehicle.
• Make certain that the ground is sufficiently firm and that there is no risk of a
stabilizer leg being able to break through for instance a frozen layer on the
ground.
• Always use plates under the footplates of the stabilizer legs, when
necessary.
• If a stabilizer leg sinks a bit into the ground during loader operation, the
calibration becomes incorrect.
• To obtain max. lifting capacity, it is necessary to carry out a new calibration
of the EVS system. Please see chapter on “Calibration of the EVS system”.
• Always drive as close to the load to be lifted as possible.
• Make lifting movements with the main boom as close to horizontal as
possible (the boom position where the loader has its max. load moment).
• Generally operate the loader movements in a calm and considerate way, in
particular getting near the critical heel of the vehicle.
• Always operate the loader slowly when moving a burden at a long reach.
• Always consider that it increases the vehicle stability if the load is placed in
the right place when starting the loading work.

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16.11 Warning

• If for example a stabilizer leg sinks into the ground, entailing the risk of the
vehicle overturning:

• Drive the load closer to the vehicle. Even though the EVS system is
activated, the “extension retract”-function can always be operated.
• If the jib extension is retracted, and the slewing movement cannot be
operated, use the override function to get out of the situation.
• When starting up again, then follow the starting up procedure again.

• Abusing the override function is not permitted, as this may lead to very
dangerous situations.
• Avoid inappropriate use of the loader, e.g. fast loader movements with the
load at a long reach.
• Avoid oscillation of the load during loader operation, especially when the
load is in a long sling, or when working with winch and a long wire rope.
• Operate the loader carefully when the vehicle is empty. Peak loads might
occur and thereby activation of the EVS system.
• Avoid slewing a load quickly from one side of the vehicle to the other.
Loader stop might occur, due to the fact that the EVS system has not been
calibrated in the best possible way. Please see chapter on “Optimisation of
Calibration”.

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17. Safety System, Stand-Up Controls, HS

17.1 The Safety System

If the loader is fitted with stand-up controls (HS), the RCL safety system is
extended with one of the following systems dependent on the country to which
the loader is to be delivered:

• Slewing limitation, stand-up controls

• Warning during slewing movement over stand-up controls

The safety system must protect the operator against being pinned by the
boom, when he operates the loader from the stand-up platform.

If the operator stands on the ground operating the loader, this safety system is
not activated, and the slewing movement can be operated freely, provided that
the vehicle is stable (please see chapter on 2-stage load moment limitation
(LMB)).

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17.2 Configuration – RCL 5100, Stand-Up Controls (HS)

1: RCL controller
2: Dump valve
3: Pressure transducer
4: Spool sensors
5: Power supply
6. External stop button
7. Proximity switch, HS
8. Proximity switch,
slewing
9: Mercury switch

17.3 Configuration – RCL 5200, Stand-Up Controls (HS)

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17.4 Slewing limitation, Stand-Up Controls

If the operator is standing on the stand-up platform and the slewing movement
is to the right, the slewing movement will be stopped before the boom moves
over the stand-up platform.
The slewing movement cannot be moved over the operator.
The controller indicates as follows:

• The diode with the slewing limitation symbol is constantly lit.

• The buzzer gives a constant signal.
• The dump valve opens to tank (the slewing movement is stopped).

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17.5 Warning during Slewing Movement over Stand-Up

Controls

If the operator is standing on the stand-up platform and the slewing movement
is to the right, the buzzer will give an interrupted signal before and while the
boom moves over the stand-up platform.
The slewing movement is not being stopped.

If the operator tries to use the “boom down”-function in the area over the
platform, the controller indicates as follows:

• The diode with the slewing limitation symbol is constantly lit.

• The buzzer gives a constant signal.
• The dump valve opens to tank (the boom down-movement is stopped).

This is to prevent that the operator accidentally lowers the boom over himself.

17.6 Combination of 2-Stage LMB and Safety System for

Stand-Up Controls

Sensors and other equipment are the same as used in connection with Safety
System, Stand-Up Controls.
Only in this case the controller has been programmed to control both safety
systems.

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18.3 RCL 5100 and the HDL-System

The HDL-system is semi-automatic, which means that the system is

automatically activated at the normal lifting capacity limit of the loader, but by
means of the red press button, the operator must manually disconnect the
system again.

This disconnection implies that the load moment is below the loader’s normal
lifting capacity limit.

The buzzer gives a periodic signal as usual at 90% of the max. permissible
load moment (90% of the HDL lifting capacity limit.

18.4 RCL 5200 and the HDL-System

The HDL-system is fully automatic, which means that the system is

automatically activated when the load moment has been increased to the
loader’s normal lifting capacity limit, and it is automatically disconnected when
the load moment is reduced below this limit.

However, the automatic disconnection implies that all control levers have been
into neutral position at the same time as the load moment is below the loader’s
normal lifting capacity limit.

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18. Heavy Duty Lifting, HDL 2

18.1 The HDL-System

The HDL-system offers the possibility of increasing the nominal load when
reducing the working speed at the same time.

When the loader reaches its normal lifting capacity limit, the HDL-system will
automatically couple in, irrespective of the operator’s doings, and the oil flow to
the control valve will be reduced (by means of an HDL-valve being operated by
the controller) to approx. 20% of the normal oil flow.

This is how the loader’s lifting capacity is increased by approx. 10% in the
entire working area of the loader.

When the HDL-system couples in, the operator will be able to continue
extending the load without interruption, although at reduced speed.

18.2 Configuration – RCL, HDL 2

1: RCL controller
(5100 / 5200)
2: Dump valve
3: HDL-valve
4: Pressure
transducer
5: Spool sensors
6: Power supply
7: Mercury switch
8. External stop
button

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18.3 RCL 5100 and the HDL-System

The HDL-system is semi-automatic, which means that the system is

automatically activated at the normal lifting capacity limit of the loader, but by
means of the red press button, the operator must manually disconnect the
system again.

This disconnection implies that the load moment is below the loader’s normal
lifting capacity limit.

The buzzer gives a periodic signal as usual at 90% of the max. permissible
load moment (90% of the HDL lifting capacity limit.

18.4 RCL 5200 and the HDL-System

The HDL-system is fully automatic, which means that the system is

automatically activated when the load moment has been increased to the
loader’s normal lifting capacity limit, and it is automatically disconnected when
the load moment is reduced below this limit.

However, the automatic disconnection implies that all control levers have been
into neutral position at the same time as the load moment is below the loader’s
normal lifting capacity limit.

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18.5 Proportional HDL

In connection with the IRC-system, activation of the HDL-system is

proportional, i.e. step-less.

Example:
A heavy load is extended at max. speed at a longer out-reach by means of the
“extension out”-function.
When the loader has reached 70% of its capacity limit, the HDL is
automatically activated independent of the operator’s doings.

Now the speed of the “extension out” movement is reduced proportionally

down to 20% of the nominal working speed.

Correspondingly the working speed is increased proportionally to 100%, if the

load is retracted to a shorter reach by means of the “extension in”- function.

The example describes how the HDL-system works in connection with the
extension-function. The proportional HDL-activation functions in the same way
in connection with all other loader functions, which increase or reduce the load
moment of the loader.

When the HDL-system is activated, this is indicated on the RCL indicator panel
by the FUNC diode flashing.

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18.6 Micro Operation

If, for instance the loader is to carry out positioning tasks, it will be possible to
reduce the working speed of the loader by means of the HDL-system.

Irrespective of the loader’s load moment, the working speed of the loader can
be reduced to approx. 20% by pushing the red press button.

When pushing the red press button, the buzzer confirms by a short signal.

When normal speed is required again, push the red press button again.
Again the buzzer confirms by a short signal.

However, operating with normal speed again implies that all control levers
have been into neutral position at the same time as the load moment is below
the loader’s normal lifting capacity limit.

HDL On / Off

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18.7 HDL Indication

When the HDL-system is activated, this is indicated on the RCL indicator panel
by the FUNC diode flashing.

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19. Safety System, Fly-Jib

19.1 The Safety System

On larger IMT loader models, a Fly-Jib can be fitted at the end of the jib
extensions. The Fly-Jib makes loader operation flexible, but at the same time,
it entails many situations where there is a risk of overloading either the loader
or the Fly-Jib.

When connecting the sensors of the Fly-Jib to the RCL 5200 controller, the
safety system is monitoring both the loader’s and the Fly-Jib’s conditions as
regards load moment, operation and function.

19.2 Configuration, Fly-Jib

1: RCL 5200 controller

2: Dump valve
3: Dummy plug
4: Pressure transducer
Loader (Boom)
5: Spool sensors
6: Power supply
7: Mercury switch, loader
8. External stop button
9. Pressure transducer,
Fly-Jib (up)
10. Pressure transducer,
Fly-Jib (down)
11. Mercury swithch, Fly-Jib

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19.3 Mode of Operation of the Safety System

The basic principle of the RCL safety system is to secure both the loader and
the Fly-Jib against overloading and the consequences of this. I.e. independent
of the operator’s doings, the system prevents that the max. permissible load
moment of both the loader and the Fly-Jib is exceeded. (Load moment
limitation – LMB).

The RCL 5200 controller monitors the two pressure transducers mounted on
the boom cylinder. The pressure transducers register the hydraulic pressure,
which is an indication of the load moment on the Fly-Jib.

The Fly-Jib can either have a positive load moment (at an angle moving away
from the jib) or a negative load moment (at an angle moving under the jib).

The RCL 5200 registers according to the signal from one of the two pressure
transducers, in which of the two positions the Fly-Jib has reached its max. load
moment.

No matter which position the Fly-Jib has in relation to the jib, the controller will
at any time give a signal to the hydraulic system of stopping the load moment
increasing movements.

The control levers can be operated by activating load moment increasing Fly-
Jib movements, but building up of a hydraulic pressure in the system is not
possible (the dump valve opens so that the oil from the pump flows to tank).

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Load moment reducing Fly-Jib functions as well as the slewing movement can
be operated freely (the dump valve closes so that the oil from the pump can
flow to the Fly-Jib cylinders).

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19.4 Loader Operation with and without Fly-Jib

The Fly-Jib can be removed and fitted to the loader as required. Therefore, a
plug is fitted at the end of the jib extensions, so that it will be possible to
separate the electric connection to the sensors.

19.5 Loader Operation with Fly-Jib

When the Fly-Jib is mounted on the loader, the electric plug must always be
fitted. When the plug is fitted, this is also a signal to the RCL 5200 controller
for activating the safety system so that it also includes the Fly-Jib.

19.6 Loader Operation without Fly-Jib

When working with the loader without Fly-Jib, there must be fitted a dummy
plug instead of the electric plug from the Fly-Jib.

When the dummy plug is fitted this is also a signal to the RCL 5200 controller
of the Fly-Jib not being fitted and that the safety system must be activated so
that it only includes the loader.

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19.7 Signalling during Loader Operation with Fly-Jib

When the Fly-Jib is mounted on the loader, the diodes of the controller indicate
whether it is the loader or the Fly-Jib that has the largest load moment:

• At for instance a load moment of 80% (when the 80% diode is constantly
lit), also the P1 or the P2 diode starts to flash.
• When the diode P1 flashes, it means that it is the loader that has a load
moment of 80%.
• When the diode P2 flashes, it means that it is the Fly-Jib that has a load
moment of 80%.
• The diodes 80% through 100% are constantly related to either the P1 or the
P2 diode (the load moment of the loader or the Fly Jib).

The loader has the largest load moment (85%)

The Fly-Jib has the largest load moment (85%).

Only one of the diodes, P1 or P2 is flashing at a time. It will thus be possible

during loader operation to follow whether the loader or the Fly Jib has the
largest load moment.
This offers the possibility of using the loader/the Fly Jib to its maximum.
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19.8 When the max. load moment of the Fly-Jib is 100%, the
controller indicates as follows:

• All diodes 80 through 100% are constantly lit.

• The diode P2 is constantly lit.
• The buzzer gives a constant signal.
• The dump valve opens to tank and the Fly-Jib movement causing the
overload is stopped.

Please note!
The Fly-Jib is overloaded but it is still possible to increase the load moment of
the loader.

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19.9 Warning when Working with Loader and Fly-Jib

• The loader safety system prevents the loader and Fly-Jib from being
overloaded, but being the operator you are still responsible for safe
operation of the loader/Fly-Jib.

• The Fly-Jib increases the loader’s out-reach considerably. Therefore

generally operate the loader carefully.

• Lower a load carefully, when working at big heights with loader and Fly-Jib.
The load moment is increased suddenly and very fast, and can easily lead
to serious overloading/unstability.

• Always carry out a slewing movement carefully. Especially when moving a

heavy load at a long reach.

• When the Fly-Jib is mounted on the loader, also the electric plug must be
fitted. Working with loader and Fly-Jib is not permitted while the dummy
plug is fitted. In this case the safety system for the Fly-Jib is not activated.

• When the Fly-Jib is removed, the dummy plug must be fitted. Otherwise the
RCL 5200 controller indicates an error (the RUN diode flashes and the
buzzer gives a constant signal), and the loader cannot be operated.

• Remember to press the stop button on the RCL 5200 controller before
removing the electric plug. Otherwise the controller indicates an error, which
is registered in the black box of the controller.

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20. Safety System, Winch

20.1 The Safety System

On several IMT loader models it is possible to fit a hoisting winch. The winch is
mounted on the jib, and the wire runs through a wire pulley placed in the hook
suspension of the loader. At the end of the wire is fitted a swivel hook.

A winch can also be used on loaders fitted with Fly-Jib.

When working with loader and winch, many situations might occur, where
there is a risk of overloading the loader and the winch system.

When connecting the sensors of the winch to the RCL 5200 controller, the
safety system is monitoring the loader’s, the Fly-Jib’s, as well as the winch’s
conditions as regards load moment, operation and function.

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20.2 Configuration, Winch

1: RCL 5200 controller

2: Dump valve
3: Power box
4: Pressure transducer
(boom)
5: Spool sensors
6: Power supply
7: Mercury switch
8. External stop button
9. Pressure transducer
(winch)
10. Proximity switch, (Winch
up)
11. Proximity switch, (Winch
down)

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20.3 Mode of Operation of the Safety System

The basic principle of the RCL safety system is to secure both the loader and
the winch system against overloading and the consequences of this. I.e.
independent of the operators doings, the safety system protects against
overloading of the loader, the Fly-Jib, the winch, and the wire.

Apart from the load on the loader and the Fly-Jib, the RCL 5200 controller is
monitoring the following sensors on the winch:

• A pressure transducer registering the wire pull and thereby the load on the
winch. In case of overloading, all loader and winch movements increasing
the wire pull are stopped.

• A proximity switch registering how many winds of cable that are left on the
cable drum. When there are 3 winds of cable left on the drum, the ease
movement is stopped.

• A proximity switch registering whether the wire is wound correctly on the

cable drum. In case of the wire overfilling the cable drum, the hoist
movement is stopped.

The control levers can be operated even though the above mentioned
movements are stopped, but building up of a hydraulic pressure in the system
is not possible (the dump valve opens so that the oil from the pump flows to
tank).

Load moment reducing movements, as well as movements in the opposite

direction in relation to the movements leading to the loader stop, can be
operated freely (the dump valve closes).

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20.4 The Functions of the Safety System

The safety system for winch protects the loader, winch, and wire against
overloading in the following situations:

• In case of trying to lift a load exceeding the max. permissible wire pull, the
wire is protected in the following way:

• If there are several winds of cable on the cable drum (i.e. 4 layers),
a relief valve will relieve the hydraulic pressure corresponding to
this max. permissible wire pull. Therefore the winch cannot lift the
load.

• If there are few winds of cable on the cable drum (i.e. 1 layer), the
pressure transducer gives signal to the controller of the winch up
movement should be stopped.

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• If the hook is hoisted up to the bracket of the hoist stop, so that the max.
permissible wire pull is exceeded, the wire is protected in the following way:

• If there are several winds of cable on the cable drum (i.e. 4 layers),
a relief valve will relieve the hydraulic pressure corresponding to
this max. permissible wire pull. Therefore the winch cannot lift the
load.

• If there are few winds of cable on the cable drum (i.e. 1 layer), the
pressure transducer gives signal to the controller of the winch up
movement should be stopped.

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• If the hook is hoisted to the bracket of the hoist stop, and the extension out
function is operated by mistake, the wire pull is increased, and at the max.
permissible wire pull, the pressure transducer gives signal to the controller
of the extension out function should be stopped.

• In case of trying to lift a load that is heavier than the max. permissible wire
pull at a short range by means of the boom up or the jib up function, the
wire can easily be overloaded. In this case, the pressure transducer gives
signal to the controller of the boom up and jib up movements to stop.

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• If the loader is fitted with a Fly-Jib and the hook is hoisted up to the bracket
of the hoist stop, and the Fly-Jib up function is operated by mistake, this
movement can entail that the load on the wire exceeds the max. permissible
limit. In this case, the pressure transducer gives signal to the controller of
the Fly-Jib up movement to stop.

• If the loader is fitted with a Fly-Jib, and a load that exceeds the max.
permissible limit is lifted by means of the boom, jib, Fly-Jib or winch
functions, these movements can entail that the load on the wire exceeds the
max. permissible limit. In this case, the pressure transducer gives signal to
the controller of the boom up, jib up, Fly-Jib up and winch up movements to
stop.

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• Please note!
If the loader is fitted with a Fly-Jib while working with a winch, the max.
permissible load moment on the winch is reduced to:
600 kg for Fly-Jib 5 and 900 kg for Fly-Jib 900.

If the Fly-Jib is removed, and the winch is operated, the max. permissible
load moment on the winch is increased to the normal level.

• Please note!
When working with winch, and there is a load exceeding 600 kg hanging in
the wire, it is not possible to operate the extension out function neither on
the loader nor the Fly-Jib

Only if working with the winch down function at the same time, it will be
possible to move a load exceeding 600 kg with the extension out function.

• When the wire is eased from the cable drum and there are approx. 3 winds
of cable left on the cable drum, the largest proximity switch gives signal to
the controller of the winch ease movement to be stopped.

The inductive sensor has two diodes with the following indications:

• During loader operation, the green diode – POWER - is lit (otherwise

it is turned off).
• When there are more than 3 winds of cable left on the cable drum,
the yellow diode LOAD ON is lit.
• When there are only 3 winds of cable left on the cable drum, and the
winch down movement has been stopped, the yellow diode LOAD
ON is no longer lit.

• In case of too much wire on the cable drum (i.e. overfilling or lopsided
winding of the wire) the smallest proximity switch gives signal to the
controller of the winch up movement to be stopped.

The inductive sensor has a diode, which during loader operation, indicates
as follows:

• When the winch is working correctly and the cable drum is not
overfilled, the yellow diode is lit.
• In case of too much wire on the cable drum, and the winch up
movement has been stopped, the yellow diode is no longer lit.
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20.5 Signalling during Loader Operation with Winch

During loader operation with winch, the RCL 5200 controller’s diodes indicate if
the loader, the Fly-Jib, the winch or the wire is overloaded.

When the safety system interferes due to one of the following situations

• The wire pull is to big

• There are only 3 winds of cable left on the cable drum
• There is too much wire on the cable drum

the controller indicates as follows:

• The diode with the winch symbol flashes.

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If the control levers, in relation to the above mentioned situations, are operated
in a direction where the function

• increases the wire pull

• operates the winch down movement
• operates the winch up movement

the controller indicates as follows:

• The diode with the winch symbol is constantly lit

• The buzzer gives a constant signal
• The dump valve opens, and the above mentioned movements cannot be
operated.

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20.6 Warning when Working with Loader and Winch

• The loader safety system prevents the loader and winch system from being
overloaded, but being the operator you are still responsible for safe
operation of the loader/winch.

• Do not try to lift a load that weighs more than indicated on the SWL label on
the swivel hook. The value indicates the max. permissible stress on the
wire.

• Always operate the winch in a considerate way, and make sure that the wire
has a correct winding and not for instance lopsided winding.

• Never make diagonal movements with the winch. Only make vertical lifts
with a winch.

• Never drag a load across a surface. The winch is only meant for lifting
vertically.

• Constantly keep the wire tight when working with a winch. Stop the winch
down movement as soon as the load is placed on the surface.

• Always operate the winch up movement carefully when the hook reaches
the hoist stop.

• Avoid fast movements with the winch when working at a long reach.

• Avoid oscillation of the load when it is hanging in a long wire.

• Operate the winch carefully up and down, when working at big heights with
loader and Fly-Jib, if any.

• Extend the jib extensions to the position where the load is to be handled by
means of the winch. Avoid extending the extensions on the loader and the
Fly-Jib when a load is hanging in the wire.

• Always respect when the safety system stops the loader/winch function and
check what was the reason for the loader stop.

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21. Activation of Optional Extras

The RCL-system can be extended, offering the possibility of activating optional

extras on the loader from the controller.

This equipment can be activated as follows:

• Push the yellow press button a number of times (dependent on the

equipment)
• The yellow FUNC diode and one of the diodes (F1 through F5) are
constantly lit in 10 seconds.

The right column of diodes now indicates alternative functions F1 through F5.
Up to 5 different kinds of optional extras can be connected and the diodes F1
through F5 now indicate which optional extra is connected at the moment.

A further description of alternative functions is available in this manual.

Example:

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22. Electric Activation, Loader Functions / Stabilizers

IMT-loaders can be equipped with an electric change-over valve connected to

the RCL-controller.

The change-over valve is activated by means of a press button on the

controller. The change-over valve leads the oil flow either to the loader valve
block or the stabilizer valve block.

Please note!
Every time the controller is started up, the change-over valve is automatically
in a position where the valve block for the loader functions is ready for
operation.

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22.1 Operation of the Stabilizer Functions

Before loader operation, extend the stabilizer beams and lower the stabilizer
legs to the surface.

To be able to operate the stabilizer functions, carry out the following:

• Connect the pump (PTO); the controller is thus powered.

• All stop buttons must be pulled out (there is a stop button at each control
position).

• Push the green press button on the RCL indicator panel

• The RUN diode is now constantly lit and the RCL-safety system is
activated.
• Push the yellow press button twice to choose the stabilizer function and the
following is indicated:

• The yellow FUNC diode and the red diode F5 are constantly lit
in 2 seconds.
• Both diodes are turned off again after 2 seconds, but the
stabilizer function is still activated.

Now the stabilizer legs can be lowered to the ground.

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22.2 Operation of the Loader Functions

When the stabilizer beams have been extended and the stabilizer legs
lowered, and the vehicle thus supported, the following must be carried out
before operating loader functions:

• Either: activate one of the loader’s control levers (a function with spool
sensor)
• or: push the yellow press button twice.
• It will now be possible to operate the loader functions.

22.3 Emergency Operation of the Stabilizer Functions

If the power supply for the change-over valve fails, it is not activated, and the
stabilizer functions cannot be operated.

In this situation it is possible to turn a thumbscrew on the change-over valve

outwards. The change-over valve is thus activated manually, and the
stabilizers can then be operated.

Turn the thumbscrew inwards again, when operating the loader functions
again.

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23. Indication of Errors / Emergency Operation of the Loader

23.1 Indication of Errors

If, during loader operation, a system error occurs internally in the controller or
externally in plugs, cables, sensors, etc., the controller indicates as follows:

• The RUN diode starts to flash

• The buzzer gives a periodic signal.
• In case of dangerous system errors the buzzer gives a constant signal
and the dump valve opens to tank (all loader movements are stopped).

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System errors are graduated into 3 levels as regards danger, i.e. which
intervention the safety system should make:

0. Relatively undangerous system errors demanding a warning (indication)

1. Less dangerous system errors demanding warning/derating

(indication/reduction of lifting capacity)

2. Dangerous system errors demanding stop of the loader (the dump valve
opens)

When pushing the red press button, the diodes will flash in a combination
indicating where to find the error in the system.

The left column of diodes indicates the category of error type, and the right
column of diodes specifies where to find the error on the loader.

In the chapter – Troubleshooting – is stated where the error can be found in

relation to the indications of the diodes.

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23.2 Emergency Operation of the Loader

In connection with a dangerous system error:

• The RUN diode flashes

• The buzzer gives a constant signal
• The dump valve opens to tank.

emergency operation of the loader can take place at the same time as the red
press button is kept down.

Please note that at the same time, the diodes will flash in a combination
indicating where to find the error in the system.

Please note!
No matter which level of system error (category of error), the error must be
found and remedied. Please see chapter on Troubleshooting.

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24. Troubleshooting

24.1 How to troubleshoot

If the controller indicates a system error – the RUN diode flashes and the
buzzer gives a periodic/constant signal (please see chapter on Indication of
Errors) – the operator must search for errors in the following way:

Push the red press button (Please note: before pushing the red press button,
make sure that the control levers are in neutral position (not activated)), and
keep it down, the following is indicated:

• The RUN diode flashes

• The buzzer gives a periodic signal (or constant signal dependent on the
type or error)
• Some of the red diodes are flashing in a combination indicating the type of
error.

24.2 Explanation to the Troubleshooting Sheets

When comparing the flashing combination of diodes with the following sheets,
it will be possible to determine the type of error, the cause of the error as
well as how to remedy the error.

In the field intervention from the safety system a code number is stated:

0. Indication:
It is a relatively harmless system error and the present loader operation can be
finished.

1. Reduction of the lifting capacity to 90%

It is a less dangerous system error and the present loader operation can be
finished; however the lifting capacity will be reduced.

2. Stop of the Loader

It is a dangerous system error stopping the loader movements. It will be
possible to make an emergency operation (please see chapter on Emergency
Operation of the Loader), i.e. fold the loader and remedy the error.

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Please note! No matter which category of error, the error must be found and
remedied.

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In the field emergency operation of the loader a code letter is stated:

Y: means that emergency operation can be made (dangerous system error)

N: means that emergency operation is not possible (relatively harmless/less

dangerous system error). The present loader operation can be finished.

In the field controller is stated which type of controller the indication of error
concerns. Given that the RCL 5100 has fewer facilities than the RCL 5200,
there are consequently fewer types of indications.

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There are more types of errors than indicated in the above tables.

If such a type of indication should occur, please contact an IMT service point.

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25. Technical Data RCL

DATA RCL 5100 RCL 5200

Micro processor 80C592 80C592

Clock frequency 16Mhz 16Mhz
Flash EPROM 128Kbytes 128Kbytes
Non volatile RAM 32 Kbytes 32 Kbytes
Digital input 8 29
Analogue input 1 8
Digital output - 4
PWM prop.output 2 2
Output capacity 2 Amp 2 Amp
System bus CAN bus CAN bus
Communication RS-232 RS-232
PC/terminal connection Internal Internal/external
Fuses 2 x 4 Amp 2 x 6 Amp
Approx. power 10 Watt 20 Watt
consumption
Dimensions 170x124x75 170x248x75
Approx. weight 2.5 kg 4.0 kg

IN GENERAL
Power supply 11-30 Volt DC
Type of print clamp Amp, 1½ mm2 stainless clamps
Density IP65
Temperature area -30°C through 70°C
EMC According to EN50081-1 and EN50082-1

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