Service Manual MUCKMASTER LHD Remote Control System

SERVICE MANUAL
MUCKMASTER LHD REMOTE

CONTROL SYSTEM
\\Hlsdow02\e\HLS Manuals\PDF\Service Manual MUCKMASTER LHD Remote Control System.doc

Revision # (3) November/2004
Created by Admin Department
Service Manual MUCKMASTER LHD Remote Control System
TABLE OF CONTENTS
Section One – System Information

Warranty
System Specifications
Operators Manual
Commissioning and Diagnostic Procedures
Section Two – Bills of Material, Drawings & Schematics

Bill of Material – ASLHDS-2
Bill of Material – ASLHDM-2
Bill of Material – KITLHDDASH1
Bill of Material – ASLHDS-2-11
Drawing # 1747
Drawing # LHD DRIVERBOARDdanphoss(LHD)
Drawing # SLAVEWIRING
Drawing # 3098
Drawing # 3081
Drawing # 11(Layout1)
Approved By: Ryan Siggelkow Printed On: 11/26/04 4:07 PM

SECTION ONE
SYSTEM INFORMATION

Service Manual MUCKMASTER LHD Remote Control System Page 1 of 13
HLS HARD-LINE SOLUTIONS INC.
WARRANTY
HLS HARD-LINE Solutions Inc. warrants its equipment and replacement parts to be free from
defects in material and workmanship for six months from delivery to the first user.
Defective parts returned to HLS during the warranty period will be repaired or replaced in its
discredtion unless exclusions apply. This HLS warranty does not include labour or shipping costs
associated with repair or replacement.
HLS-effected installations of its equipment form part of this warranty, but repair or replacement
will be limited to the individual component proven defective.
This warranty does not apply to equipment or parts found by HLS to have been damaged through
normal wear and tear, misuse, abuse, neglect, accident, or alterations not specifically authorized
by HLS. Wear and tear includes normal deterioration of moving parts, seals, and corrosion of
metal components.
This warranty does not include preventative maintenance, operating services, adjustments, and
inspections, which are the responsibility of the purchaser.
This warranty replaces all statutory and other warranties implied by law. Purchaser has
conducted its due diligence in choosing this HLS equipment and does not rely on any
representation of merchantability or fitness for purpose.
HLS HARD-LINE SOLUTIONS INC. SHALL IN NO EVENT BE LIABLE FOR

CONSEQUENTIAL OR INCIDENTAL DAMAGES ARISING FROM THE USE OF ITS
EQUIPMENT OR PRODUCTS.

SYSTEM OVERVIEW
Modern mining techniques rely extensively on radio remote control systems. Radio remote
controlled LHD’s provide a safe and productive means to move large amounts of ore. The
complete radio remote control system has a Remote Unit and a Vehicle Unit. The control
package should be modular, compact, easy to work with, and adaptable to all types of
equipment, regardless of manufacturer. HARD-LINE Solutions’ MUCKMASTER control
package provides this solution.
FEATURES
MUCKMASTER control systems can be configured On/Off, proportional, or a combination

on any manufacturer's LHD, regardless of machine configuration. MUCKMASTER control
systems enhance safety and operating features by the use of a Microprocessor.
PROGRAMMABLE FEATURES
Operators are forced to follow set procedures when operating the radio remote controlled
LHD. The LHD will shutdown if the correct steps are not followed. MUCKMASTER control
systems force the operator to use safe operating procedures.
SYSTEM COMPONENTS
This system is made of four basic blocks:
1. Master Unit
2. Slave Unit
3. Hydraulic Interface
4. Electric Interface
1. Master Unit
Master Unit contains:
- One Microprocessor
- One 900 MHz Radio
- One Enclosure
- Master Unit LED Board
- Mounting Plate
- 900 MHz Whip Antenna
- One Driver Board
- One Master Unit 10 Socket Connector Wiring Harness
- One Master Unit 19 Socket Connector Wiring Harness
- Connector(s) with LED

The component’s specifications following:
900 MHz Radio
• Wireless Medium: Direct Sequence Spread Spectrum Radio

• Operating Frequency Range: 902 - 928 MHz
• Approvals: US: FCC 15.247
• Radio Data Rate: up to 860 KBPS (FCC, CANADA)
• Maximum Radio Data Rate: 1.35 MBPS (not FCC approved)
• Frequency Resolution: 300 kHz
• Frequency Stability: +/- 5 kHz
• Chipping Rate: selectable up to 9.457 Mcps
• Spread Ratio (Min / Max): 5:1 / 50:1
• Processing Gain (Min / Max): 11 dB / 17 dB
• Output Power: +26.5 dBm
450 mW
• Sensitivity (@10-5 bit error rate): -95 dBm @ 215 KBPS, -87dBm @ 860 KBPS
• Adjacent Channel Rejection: 23 dBc
• Receive / Transmit Turnaround Time: 1 ms
• Modulation: BPSK
Enclosure
• Built with Aluminum die-cast

• Captive stainless steel lid screws
• Recessed neoprene gasket with tongue and groove construction is oil and petroleum
resistant Provide outstanding protection against dust, oil and pressurized water
• Corrosion resistant
• Temperature range of material in continuous use: -40°C to +80°C
• Dimensions 5 x 8 ¾ x 3 ¼ inch ( 127 x 223 x 83 mm )
• Mounting Plates with shock absorbers
• DIN 40050 Standards
• ISO 9001 Specifications
2. Slave Unit
Slave Unit contains:
- One Microcontroller
- Two Joysticks
- One 900 MHz Radio
- One auxiliary Board
- One Antenna Board
- Four On/Off Switches
- Three Momentary On Switches
- One Mushroom Switch
- One Enclosure
- One Skid Plate
- Slave Unit LED Board

The component’s specifications following:
900 MHz Radio
• Wireless Medium: Direct Sequence Spread Spectrum Radio

• Operating Frequency Range: 902 - 928 MHz
• Approvals: US: FCC 15.247
• Radio Data Rate: up to 860 KBPS (FCC, CANADA)
• Maximum Radio Data Rate: 1.35 MBPS (not FCC approved)
• Frequency Resolution: 300 kHz
• Frequency Stability: +/- 5 kHz
• Chipping Rate: selectable up to 9.457 Mcps
• Spread Ratio (Min / Max): 5:1 / 50:1
• Processing Gain (Min / Max): 11 dB / 17 dB
• Output Power: +26.5 dBm
450 mW
• Sensitivity (@10-5 bit error rate): -95 dBm @ 215 KBPS, -87dBm @ 860 KBPS
• Adjacent Channel Rejection: 23 dBc
• Receive / Transmit Turnaround Time: 1 ms
• Modulation: BPSK
Enclosure
• Built with Polyester

• The foamed gasket are bound to the groove and have an exceptionally low compression set,
The gasket is resistant to chemicals and a wide temperature range.
• Excellent Impact Resistance
• Excellent Corrosion Resistance
• Dimensions 13.4 x 6.3 x 3.9 inch (340 x 160 x 100 mm)
• Aluminum Skid Plate
• VO Flammability Rating
• ISO 9001 Specifications
3. Hydraulic Interface
- Hydraulic Manifold(s)
- On/Off Cartridge(s)
- Proportional Cartridge(s)
- Slave Cylinders (if necessary)
4. Electric Interface
- One Selector Switch c/w contact blocks

- Relay(s) 12Vdc or 24Vdc
- Throttle interface 12 or 24Vdc PWM input to 5Vdc output or 10Vdc output (optical isolation)

INTRODUCTION:
• Modern mining techniques rely extensively on radio remote control systems. Radio
remote controlled LHD’s provide a safe and productive means to move large amounts
of ore. The complete radio remote control system consists of a Joystick Unit and a
Vehicle Unit. Both the Joystick Unit and the Vehicle Unit are in constant 2-way
communication. The control package should be compact, modular, easy to work with,
and adaptable to all types of equipment, regardless of manufacturer. HARD-LINE
Solutions’ MUCKMASTER control package provides this solution.
FEATURES:
• MUCKMASTER control systems can be configured as On/Off, proportional, or a

combination of both on any manufacturer's LHD, regardless of machine configuration.
MUCKMASTER control systems enhance safety and operating features by the use of
a Microprocessor.
PROGRAMMABLE FEATURES:
• Operators are forced to follow set procedures when operating the radio remote
controlled LHD. The LHD will shutdown if the correct steps are not followed.
MUCKMASTER control systems force the operator to use safe operating procedures.
INSTALLATION:
• The “MUCKMASTER” is modular and designed for quick installation. A modular

interconnecting system is incorporated to simplify electrical and hydraulic solenoid
connections.
DIAGNOSTIC INDICATORS:
• There are indicators at critical points in the system, including inside the radio and in
the MUCKMASTER control package. Indicators on the MUCKMASTER control box
provide status on the machine operating mode, the engine, and the brake systems.
• With minimum training, operators or maintenance personnel can use the indicators
to quickly find the source of a malfunction and provide reliable information to
management.
PROGRAMMED SAFETY FEATURES:
• Listed below are the main features that are programmed as standard operating
procedures in MUCKMASTER control systems.

OPERATING PROCEDURES:
MANUAL TO REMOTE MODE:
• Drive the LHD to the draw point.

• Bring the LHD to a complete stop near remote operator’s station.
• Put the LHD manual gear selector into “NEUTRAL” position.
• Apply the LHD park brake.
• Switch MANUAL / REMOTE SELECTOR to “REMOTE” position. *Note: The LHD
will continue to run for 60 seconds. The LHD is now under automatic control and
special attention must be given to safe operating procedures.
• Leave the LHD and proceed to remote operator’s station.
• Turn the Joystick Unit SYSTEM POWER switch to “ON” position. *Note: Ensure
the EMERGENCY STOP mushroom switch is in the “UP” position and the park
brake switch is in the applied or on position.
• The LHD is now in radio remote control mode. Proceed with mucking operation.
The LHD will shut down if:

• The LHD manual gear selector is not in “NEUTRAL” and the MANUAL / REMOTE
SELECTOR is switched to “REMOTE”.
• The LHD park brake is not applied and the MANUAL / REMOTE SELECTOR is
switched to “REMOTE”.
• The Joystick Unit SYSTEM POWER switch is “ON” when the MANUAL / REMOTE
SELECTOR is switched to “REMOTE”.
• The Joystick Unit SYSTEM POWER switch is not turned to “ON” within 60
seconds.
• The Joystick Unit SYSTEM POWER switch is turned “ON” and the Joystick Unit
PARK BRAKE switch is “OFF” (released).
RADIO TO MANUAL MODE:
• Bring the LHD to a complete stop near remote operator’s station.

• Put the Joystick Unit FORWARD / REVERSE joystick into “neutral” position.
• Switch the Joystick Unit PARK BRAKE switch to the “Applied” or “ON” position.
• Toggle the Joystick Unit DELAYED SHUTDOWN switch.
• Switch the Joystick Unit SYSTEM POWER switch to “OFF” position. *Note: The
LHD will continue to run for 60 seconds. The LHD is now under automatic control
and special attention must be given to safe operating procedures.
• Leave remote operators station and proceed to the LHD.
• Switch the MANUAL / REMOTE SELECTOR to “MANUAL” position.
• The LHD is now in manual control mode. Proceed with haul dump operation.
The LHD will shut down if:

• The Joystick Unit EMERG. STOP mushroom switch is depressed.
• The Joystick Unit SYSTEM POWER is turned “OFF” without toggling the
DELAYED SHUTDOWN switch.
• The Joystick Unit PARK BRAKE is not applied (ON) before toggling the DELAYED
SHUTDOWN switch.
• The Joystick Unit FIRE SUPPRESS switch is activated.
• The MANUAL / REMOTE SELECTOR switch is not turned to “MANUAL” position
within 60 seconds.

REMOTE CONTROL MODE FUNCTIONS:
• While in remote mode the following functions are available to the operator: Remote
start function with park brake interlock - The park brake toggle on the Joystick Unit
must be in “ON” position to start the machine.
• E-Stop function – Shuts down the engine, stops the machine and applies the
brakes when the E-stop function is activated.
• Delayed shutdown - Allows the machine to run for a predetermined time (60
seconds) before the engine is shutdown. This feature is used when changing from
remote to manual mode.
• Service brake application - They are applied automatically after half a second delay
when the left hand joystick is in “NEUTRAL” position.
• Service brake application - They can be applied as required using the toggle switch
on top of the right hand joystick.
• Forward/Reverse park brake interlock - The control system will not allow the
transmission to go into forward or reverse with the park brake switch on the
Joystick Unit in the “Applied” or “ON” position.
• Engine Start - apply the park brake and press the start button until engine is
running.
• The front and rear lights on the LHD can be turned on or off from the light switch on
the Joystick Unit.
• Engine throttle - The engine throttle can be controlled proportionally from the
Joystick Unit. The engine speed increases as the left-hand joystick is moved from
the “NEUTRAL” position. Applying the Park Brake and moving the left-hand joystick
to the top or bottom can activate engine throttle proportionally while maintaining a
parked LHD.
• Forward/Reverse - The directions are obtained by moving the left-hand joystick in
the direction as indicated.
• Steering - The steering functions are activated by moving the left-hand joystick left
to right.
• Boom and bucket functions are activated using the right hand joystick.
• Fire suppression - The fire suppression is activated by the toggle switch on the
Joystick Unit. When the fire suppression switch is activated and maintained for
three seconds the park brake and service brakes are applied, the engine is shut off
with the transmission in neutral. The switch must be held for 3 seconds to activate
the fire suppression output.

EMERGENCY STOP:
• Press down on the Joystick Unit EMERG. STOP switch. * Note: The LHD
will shift into “NEUTRAL”, park and service brake will activate, and engine
will shut down immediately.
SYSTEM POWER SWITCH SHUTDOWN:
• Switch the Joystick Unit SYSTEM POWER switch to “OFF” position.

* Note: The LHD will shift into “NEUTRAL”, park and service brake will
activate, and engine will shut down immediately.
JOYSTICK UNIT TILT SHUTDOWN:
• If the Joystick Unit is tilted over for one-quarter of a second. * Note: The
LHD will shift into “NEUTRAL”, park and service brake will activate, and
engine will shut down immediately.
FIRE SUPPRESSION SHUTDOWN:
• Pull pin and hold the Joystick Unit FIRE SUPPRESS switch for 3 seconds.
* Note: The LHD will shift into “NEUTRAL”, park and service brake will
activate, engine will shut down immediately, and fire suppression will
activate.
• To reset system, the Joystick Unit system power has to be switched off and
then on.
DUAL VALVE BRAKE SYSTEM:
• The MUCKMASTER LHD Radio Remote Control System uses a Dual

Valve Brake system. This means that there are two brake valves that work
independently of each other. In the even that one brake fails, the other
brake can be used to safely stop the LHD.
PARK BRAKE VALVE:
• The Park Brake Switch activates the Park Brake Valve to release the Park
Brakes when the switch is in the OFF position. When the Park Brake switch
is moved to the ON position, the Park Brake Valve applies the brakes.
SERVICE BRAKE VALVE:
• The Service Brakes can be applied by using the Service Brake Switch on
top of the right hand joystick or by allowing the left hand joystick go to the
neutral position. The brakes will apply after a half second delay when the
joystick is in neutral or immediately when pressing the switch. This valve is
the Service Brake Valve.
OPERATOR TRAINING:
• The operating procedures, as outlined by the manufacturers of the RRC

and LHD control package, and the mine site, must be completely
understood by the operator. Machine downtimes can be minimized if both
operator and service personnel have had the proper training on the
complete remote control system. Training services are available from
HARD-LINE Solutions Inc.

INDICATOR LIGHTS FOR THE MASTER UNIT (VEHICLE UNIT):
• Power on - Indicates that the voltage is sufficient.

• Ready - Indicates that the LHD park brake is applied, that the transmission is in
neutral and the selector switch is selected remote
• Link - Indicates that Vehicle Unit and Joystick Unit are communicating
• Diagnostics – Light will turn on when:
a) The LHD Park Brake has not been applied.
b) The LHD transmission is not in Neutral before switching from Manual to
Remote
c) The Manual/Remote switch is defective.
Correct any of the above conditions and reselect Remote
INDICATOR LIGHTS FOR THE SLAVE UNIT (JOYSTICK UNIT):
• Power on - Indicates that the voltage is sufficient. Flashing or cycling lights

indicates insufficient supplied voltage.
• Link - Indicates that Slave Unit and Master Unit are communicating
• Diagnostics – Light will turn on when:
a) The Delayed Shutdown feature is activated.
b) The Joystick unit is tilted over for more than one-quarter of a second while
in Link.
c) The switch closure test is performed.
d) The Joystick Unit is powered up before switching from Manual to Remote.
e) The LHD Park Brake is not applied and or the transmission is not in
Neutral before switching from Manual to Remote.
f) The switches on the Joystick Unit are not in their safe power up positions
when turning Joystick Unit on.
Correct any of the above conditions and reapply power to the Slave unit.

GUIDELINES TO FOLLOW FOR REMOTE CONTROL SAFETY:
a) Always work with SAFETY FIRST in mind at all times.

b) Always do a pre-check of the LHD for proper operation in Manual and also in Remote. Be
sure of proper brake application in Manual and that the service brakes work properly in
Remote. NOTE: If a problem exists in Manual control it will also exist in Remote control. If
any problems exist in manual, especially brakes, LHD must be serviced before operating in
remote control.
c) Never turn your attention away from a remote operated machine unless it is stopped and the
brakes are applied.
d) Never operate remote control equipment if you are not trained. Advise the training
department that you need training and this can be set up with HLS.
GUIDELINES TO FOLLOW FOR REMOTE CONTROL CARE:
a) Never carry Slave unit by the joysticks. They are not built for such a purpose.
b) Do not wash the Slave unit or Master unit when washing the LHD.
c) Never boost or weld on LHD without disconnecting the Vehicle Unit.
d) Do not carry any HLS RRC equipment in the bucket of the LHD.
e) Do not continue to use RRC package if in ill repair and/or the RRC Slave or Master unit is not
functioning properly. Advise any maintenance staff and the equipment will be repaired.
f) Be sure to use the proper antennas for each application, 900MHz whip for Master and if
Slave unit is modified for external antenna. Use 2.4GHz antenna for the video unit only.
g) Check to verify that all antenna connections are solid, center pin is not pulled back, and that
cables are in good order.
h) If using batteries to power Slave unit, be sure to use a fully charged battery before each shift.
If using power brick adapters, make sure power cables are in safe condition and have not
been modified in any way. The Slave unit operates on 5vdc only.

MUCKMASTER OPERATOR TRAINING

TEST - A
1. As part of the required pre-operation check, the operator should always make sure that:
A) All remote control components are secure

B) There are no oil leaks at any hoses or hydraulic manifolds
C) All functions on Joystick Unit are operational
D) All the above
2. Guidelines for safe operation of the remote control unit are established by:
A) The safest way possible

B) The fastest way possible
C) The safety standards establish at the mine site
D) As the operator sees fit
3. Before leaving the machine to operate in remote, the operator should always:
A) Place wheel chocks under the wheel

B) Apply park brake; engage transmission in first gear and shutdown LHD
C) Apply park brake, place transmission in neutral, and turn the selector switch to
the remote position
D) Apply the park brakes, turn the LHD off and change the selector switch to the
remote position
4. When the green indicating lights on the master unit and dash are illuminated this means that.
A) The Joystick and Vehicle Units are operating correctly

B) The batteries in the Vehicle Unit need changing
C) The LHD is functioning properly
D) There is a fault with one of the components
5. The unattended Joystick unit feature means that: When the Joystick unit is left on, and the
selector switch is turned from the manual to the remote position:
A) The Vehicle Unit will only shut off the engine

B) The Vehicle Unit will apply the brakes and then shut engine off
C) The Vehicle Unit will apply the brakes until the operator releases them with
the Joystick Unit
D) The Joystick Unit is lost and a warning lamp will flash
6. The main purpose of the master unit is to:
A) Monitor the brakes

B) Verify that the LHD is running
C) Aid the troubleshooting process in case of remote breakdown
D) Control front and rear lights
7. The service brake is activated automatically by:
A) Moving the direction joystick back to the center position

B) Using the park brake switch on the slave unit
C) Pressing down the emergency stop button
D) Using the toggle switch on the top of the joystick

8. When welding or boosting on the LHD, you should always:
A) Disconnect the battery

B) Turn the Joystick Unit off
C) Turn the remote switch to manual
D) Disconnect the dash cable (and DDEC if applies)
9. During a delayed shutdown how much time is the operator permitted to return the LHD to
manual mode.
A) 10 seconds
B) 10 minutes
C) 60 seconds
D) 30 seconds
10. The LHD will start only in remote if:
A) The Joystick Unit power is on, the emergency stop button is in the down
position, the park brake switch is in the on position, and the LHD is in neutral
B) The Joystick Unit power is on, the emergency stop button is in the up position,
the park brake switch is in the on position, and the LHD is in neutral
C) The joystick unit's power is on, the emergency stop button is in the up
position, the park brake switch is in the off position, and the LHD is in neutral.
D) The Joystick Unit power is off, the emergency stop button is in the up position,
the park brake switch is in the on position, and the LHD is in neutral
11. The fire suppression system can be activated remotely by:
A) Voice
B) Running to the machine and activating the manual actuator
C) Removing the fire suppression retaining pin and activating the toggle switch
on the Joystick Unit for three (3) seconds
D) All the above
12. When remote mucking is performed the operator is allowed to:
A) Work from the LHD’s bucket

B) Stand beside the LHD
C) Follow the LHD so you can see better
D) None of the above

MUCKMASTER OPERATOR TRAINING

TEST - B
1. The operator must be trained to understand the basic principles of the remote control
package.
TRUE FALSE
2. The remote system has only one way to apply brakes.
TRUE FALSE
3. When the selector switch is moved to the remote position, the operator has 60 seconds to turn
the Joystick Unit on.
TRUE FALSE
4. If the park brake switch on the Joystick Unit is in the on position (i.e. brakes applied), the
transmission will not engage in forward or reverse.
TRUE FALSE
5. If the park brake switch on the Joystick Unit is in the off position (i.e. brakes released), the LHD
will not start in remote mode.
TRUE FALSE
6. Remote mucking is done in the second gear.
TRUE FALSE
7. The remote control unit has no distance limitations.
TRUE FALSE
8. Before any welding or boosting is done on a machine, the dash cable must be disconnected
from the machine control unit (Vehicle unit).
TRUE FALSE
9. The green light on the dash is used to verify proper communication between the Joystick Unit
and Vehicle unit.
TRUE FALSE

1 LHD Radio Remote Control Commissioning and Troubleshooting Page 1 of 35
HLS HARD-LINE Solutions Inc.
LHD Radio Control System

Commissioning and Diagnostics Procedures
©1998 HLS HARD-LINE Solutions Inc.
Revised 2001-04-04
CONTENTS:
Safety considerations when commissioning / troubleshooting.
Terminology
Description of remote control interlocks and timeouts
Radio control overview
Commissioning procedures
Troubleshooting guide
APPENDICES:
Vehicle Unit connector pin-outs
Joystick Unit controls
Joystick Unit control “SAFE” positions
Proportional output scaling table
Proportional control output measurements
Commissioning checklist
Problem report form
Revision history
©1998 HLS HARD-LINE Solutions Inc. Revised 2001-04-04 Printed 2001-04-04 at 4:20PM
Safety considerations when commissioning / troubleshooting.

The following safety considerations are presented in no particular order. These considerations
are in addition to any government regulations and/or company policies regarding the safe
operation of radio controlled vehicles.
• NEVER OPERATE A RADIO CONTROL VEHICLE WITHIN A SERVICE BAY OR GARAGE.

• Radio Control commissioning checks should be conducted in a reasonably level, open area.
• No other Radio Control vehicles should be in operation near the LHD during commissioning.
• The operator conducting commissioning tests should be qualified to operate the LHD and
understand the principles & safety considerations regarding Radio Remote Control vehicle
operation.
• The operator should conduct commissioning tests while in the operator’s cab in order to take
manual control in case of an emergency.
• Observers should maintain a safe distance from the LHD.
• Fire suppression squib should be disconnected to safely perform the fire suppression
commissioning tests.
• Verify that wheel chocks are in place
Terminology
LHD - Load Haul Dump (LHD)
Vehicle Unit – the MUCKMASTER control box which plugs into the LHD via 10- and 19-pin
CANON bayonet connectors.
Joystick Unit – the radio control box, which the operator uses to control the LHD when it is in
radio remote control.
Radio Control System – the Vehicle and Joystick Unit pair.
Radio Control Link – the two-way communication link which is maintained between the Vehicle
and Joystick Units.
HIGH Input – any input voltage levels above 5 volts.
LOW input – any input voltage level below 2 volt.
Continuity – resistance measurement under 2 ohms.
Open Circuit – any resistance measurement over one Megaohms.
D/H – Indicates boom up, down & bucket roll, dump functions
Description of remote control interlocks and timeouts

Engine Start interlock
Start switch will only be processed when the Joystick Unit controls are in their SAFE RESTART
positions.
Delayed Shutdown interlock

Delayed shutdown switch will only be processed when the Joystick Unit controls are in their
SAFE SHUTDOWN positions. When the Delayed shutdown switch is released, the operator has
three (3) seconds to turn off the Joystick Unit. When the Joystick Unit is turned off within this time,
only the RUN output (CANON-19 pin E) is held high. If the Joystick Unit is still on after three (3)
seconds, the delayed shutdown request is cancelled. Turning off the Joystick Unit after canceling
the delayed shutdown request will shut the LHD down as if the emergency stop was pressed.
Unattended Vehicle Timer

When the Delayed shutdown switch is processed, the operator has 60 seconds to board the LHD
and switch from REMOTE to MANUAL control. The Vehicle Unit will hold the RUN output
(CANON-19 pin E) high for this time. When the 60 seconds has elapsed, the LHD will shut down.
Unattended Remote Timer

When the MANUAL/REMOTE switch is turned from the MANUAL to the REMOTE position, the
RUN output (CANON-19 pin E) is held HIGH to keep the engine running. The operator then has
60 seconds to turn on the Joystick Unit and establish a control link. If a control link is not
established in this time, the engine will shut down. After this time, control can still be established,
but it will be necessary to restart the LHD.
Unattended Remote Standby Timer

When the radio control link is broken, the Vehicle Unit will stay in its ACTIVE STATE and attempt
to reestablish the control link for 90 seconds. After 90 seconds, the Vehicle Unit will enter a
SLEEP state. Turning on the Joystick unit will restore the Vehicle Unit to the ACTIVE STATE.
Forward/Reverse – Park Brake interlock

The LHD will only go into forward and reverse when the park brake is released.
Neutral – Service Brake interlock

The LHD service brake is only released when its transmission is set to forward or reverse. When
the direction is returned to neutral, the service brake will be applied after one half second delay.
Manual to remote interlock

When the operator is ready to remotely operate the LHD, he MUST first apply parking brake
and place transmission to neutral position before selecting remote. If the operator does not
the LHD will shutdown automatically. The operator will not be able to continue until fault
conditions are cleared.
Commissioning procedures
Perform each test in the Commissioning Checklist in order.
Place a check in the PASS or FAIL column when each test is completed.
When performing a test, follow the steps in the order indicated.
Example
*** COMMISSIONING EXAMPLE ***

One or more items from the checklist which are tested during this procedure.
Name of Test Procedure
Description of test.
ACTION OBSERVATION
1 Action to be taken in step 1 Output is HIGH
2 Action to be taken in step 2 Output is LOW

; *** COMMISSIONING EXAMPLE completed ***
Check the PASS column of this item before proceeding to do the next step
3 Action to be taken in step 3
Troubleshooting
Step 1 When a problem occurs in step 1, this box lists possible causes and tests to perform:
Output is LOW: The voltage measured between the output and chassis ground is
below 6 volts.
Step 2 Output is HIGH: The voltage measured between the output and chassis ground is
within 2 volts of the input voltage.
*** REMOTE SELECT SWITCH FUNCTION TEST ***
Remote Select Switch Function Test Procedure
This test verifies that the remote select switch functions properly.
High remote select input places the LHD in remote control mode.
Low remote select input places the LHD in manual control.
ACTION OBSERVATION
1 Switch MANUAL / REMOTE SELECTOR to “MANUAL” position. READY light OFF
DIAG. light OFF
2 Apply LHD manual park brake. READY light OFF
DIAG. light OFF
3 Put LHD manual gear selector into “NEUTRAL” position. READY light OFF
DIAG. light OFF
4 Switch MANUAL / REMOTE SELECTOR to “REMOTE” position. READY light ON
DIAG. light OFF
; *** REMOTE SELECT SWITCH FUNCTION TEST completed ***
5 Switch MANUAL / REMOTE SELECTOR to “MANUAL” position.
Troubleshooting
Step 1 READY light ON: Check that the Remote Select input (CANON-19 pin S; Blue wire) is
LOW when MANUAL / REMOTE SELECTOR is in “MANUAL” position.
Step 2 READY light ON: Verify that the Park Brake Confirm input (CANON-19 pin U - Orange
wire) is HIGH when LHD park brake is applied.
Step 3 READY light ON: Verify that the Neutral input (CANON-19 pin T; Black/White wire) is
HIGH when MANUAL / REMOTE SELECTOR is in “REMOTE” position.
*** PARK BRAKE STATUS INPUT TEST ***
Park Brake Status Input Test Procedure
This test verifies that the park brake status input functions properly.
High park brake status input indicates that the LHD’s manual park brake is applied.
Low park brake status input indicates that the LHD’s manual park brake is released.
The radio control link requires the manual park brake be applied when the LHD is switched from
manual to remote control.
ACTION OBSERVATION
2 Apply LHD manual park brake.
3 Put LHD manual gear selector into “NEUTRAL” position.
4 Release LHD park brake. READY light OFF
DIAG. light OFF
5 Switch MANUAL / REMOTE SELECTOR to “REMOTE “position. READY light OFF
DIAG. light ON
6 Apply LHD manual park brake. READY light ON
DIAG. light OFF
; *** PARK BRAKE STATUS INPUT TEST completed ***
Troubleshooting
Step 5 READY light ON:
1) Verify that the Park Brake Confirm (CANON-19 pin U; Orange wire) is LOW
when LHD park brake is released.
2) Perform the Neutral Status Input Test.(Pg. 7)
Step 6 DIAG. light ON:
1) Perform the Remote Select Switch Function Test.(Pg. 5)
*** NEUTRAL STATUS INPUT TEST ***
Neutral Status Input Test Procedure
This test verifies that the neutral status input functions properly.
High neutral status input indicates that the LHD’s manual gear selector is in neutral.
Low neutral status input indicates that the LHD’s manual gear selector is not in neutral.
The radio control link requires the manual gear selector be in neutral when the LHD is switched
from manual to remote control.
ACTION OBSERVATION
4 Put LHD manual gear selector into “FORWARD” position. READY light OFF
DIAG. light OFF
5 Switch MANUAL / REMOTE SELECTOR to “REMOTE” position. READY light OFF
DIAG. light ON
6 Put LHD manual gear selector into “NEUTRAL” position. READY light ON
DIAG. light OFF
DIAG. light OFF
8 Put LHD manual gear selector into “REVERSE” position. READY light OFF
DIAG. light OFF
9 Switch MANUAL / REMOTE SELECTOR to “REMOTE” position. READY light OFF
DIAG. light ON
10 Put LHD manual gear selector into “NEUTRAL” position. READY light ON
DIAG. light OFF
; *** NEUTRAL STATUS INPUT TEST completed ***
DIAG. light OFF
Troubleshooting
1) Verify that the Neutral Confirm (CANON-19 pin T; Black/White wire) is LOW when
manual gear selector is set to “FORWARD” position.
2) Perform the Park Brake Status Input Test.(Pg. 6)
Step 6 DIAG. light ON:
1) Perform the Remote Select Switch Function Test.(Pg. 5)
3) Verify that the Neutral Confirm (CANON-19 pin T - Black/White wire) is HIGH when
manual gear selector is set to “NEUTRAL” position.
1) Verify that the Neutral Confirm (CANON-19 pin T; Black/White wire) is LOW when
manual gear selector is set to “REVERSE” position.
2) Perform the Park Brake Input Test.(Pg. 6)
Step DIAG. light ON:
10 1) Perform the Remote Select Switch Function Test.(Pg. 5)
3) Verify that the Neutral Confirm (CANON-19 pin T; Black/White wire) is HIGH when
manual gear selector is set to “NEUTRAL” position.
*** UNATTENDED VEHICLE TIMEOUT TEST ***
Unattended Vehicle Timeout Test Procedure
This test verifies that the LHD will shut down if the Joystick Unit does not establish a radio
control link within the 60-second timeout.
ACTION OBSERVATION
3 Manually start the LHD.
4 Set MANUAL / REMOTE SELECTOR to “REMOTE” position. READY light ON
Engine continues
to run.
5 Wait for 60-second control link timeout to expire. Engine shuts
down.
; *** UNATTENDED VEHICLE TIMEOUT TEST completed ***
6 Set MANUAL / REMOTE SELECTOR to “MANUAL” position.
Troubleshooting
Step 4 Engine shuts down:
1) Check that the Run output (CANON-19 pin E; Blue/Red wire) has not been tied
LOW or disconnected.
2) Perform the Park Status Input Test.(Pg. 6)
4) Verify if the Joystick unit is powered up before the Manual/Remote Selector is
switched to the Remote position.
Step 5 Engine does not shut down:
1) Check that the Run output (CANON-19 pin E; Blue/Red wire) has not been tied
HIGH between the Normally Open switch (Manual/Remote Selector) and the
Engine Shutdown Solenoid or DDEC Shutdown Input.
2) Check that the Normally Open switch (Manual/Remote Selector) opens the
Shutdown circuit between the Key Switch and the Engine Shutdown Solenoid or
DDEC Shutdown Input.
*** JOYSTICK UNIT POWER SWITCH TEST ***
Joystick Unit Power Switch Test Procedure
This test verifies that the Joystick Unit power switch is functioning and that it is able to turn on.
ACTION OBSERVATION
2 Set Joystick Unit PARK BRAKE switch to “APPLIED” or “ON”
position.
3 Turn the Joystick Unit POWER switch to “ON” position. POWER light ON
4 Turn the Joystick Unit POWER switch to “OFF” position. POWER light
OFF
; *** JOYSTICK UNIT POWER SWITCH TEST completed ***
Troubleshooting
Step 3 POWER light is not ON:
1) The EMERGENCY STOP mushroom switch is in the “DOWN” position.
2) The CAP LAMP battery or POWER SUPPLY is not connected.
3) See the Joystick Unit Wiring schematic for any breaks or shorts in the Power Up
circuit.
*** JOYSTICK UNIT TILT SWITCH TEST ***
Joystick Unit Tilt Switch Test Procedure
This test verifies that the joystick unit recognizes when it has been tilted.
When the joystick unit is tipped over for more than 2 seconds the control link is terminated, the
LHD will shut down and the brakes will apply.
ACTION OBSERVATION
4 Manually start the LHD.
Engine continues
to run.
position.
7 Turn the Joystick Unit POWER switch to “ON” position. POWER light ON
LINK light ON
8 Tip Joystick Unit on its side. Wait for two (2) seconds. DIAG light ON
Engine shuts
down.
9 Return Joystick Unit to the upright position. DIAG light ON
; *** JOYSTICK UNIT TILT SWITCH TEST completed ***
10 Turn the Joystick Unit POWER switch to “OFF” position.
Troubleshooting
Step 8 DIAG light OFF/ Engine continues to run: Return the radio control to the service depot
for servicing.
Step 9 DIAG light OFF: Return the radio control to the service depot for servicing.
*** JOYSTICK UNIT SWITCH CLOSURE TEST ***
Joystick Unit Switch Closure Test Procedure
This test verifies all switch closures for all the functions on the Joystick Unit.
ACTION OBSERVATION
position.
3 Set Joystick Unit FRONT LIGHTS switch to “OFF” position.
4 Set Joystick Unit REAR LIGHTS switch to “OFF” position.
5 Tip Joystick Unit on its side.
6 Turn the Joystick Unit POWER switch to “ON” position.(Wait 2 or 3 DIAG light ON
seconds)
7 Return Joystick Unit to the upright position. DIAG light OFF
Repeat steps 8 to 9 for each of the following control positions:
Set Joystick Unit PARK BRAKE switch to “RELEASED” or “OFF”

position.
Hold down Joystick Unit DELAYED SHUTDOWN switch.
Set Joystick Unit FRONT LIGHTS switch to “ON” position.
Set Joystick Unit REAR LIGHTS switch to “ON” position.
Hold down Joystick Unit START switch.
Hold down Joystick Unit FIRE switch.
Hold down Joystick Unit left FULL BRAKE switch.
Hold down Joystick Unit right FULL BRAKE switch.
Move Joystick Unit right joystick to BOOM DOWN position.
Move Joystick Unit right joystick to BOOM UP position.
Move Joystick Unit right joystick to BUCKET ROLL position.
Move Joystick Unit right joystick to BUCKET DUMP position.
Hold down Joystick Unit FULL THROTTLE switch.
Hold down Joystick Unit HALF THROTTLE switch.
Move Joystick Unit left joystick to FORWARD position.
Move Joystick Unit left joystick to REVERSE position.
Move Joystick Unit left joystick to STEER LEFT position.
Move Joystick Unit left joystick to STEER RIGHT position.
Tip Joystick Unit on its side.
8 Set the control to the indicated position. DIAG light ON
9 Restore the control to its previous position. DIAG light OFF
; *** JOYSTICK UNIT SWITCH CLOSURE TEST completed ***
Troubleshooting
Step 7 DIAG light ON:
Continue test but look for the control that leaves the DIAG light ON in step 9. If no
control leaves the DIAG light ON, then one of the controls may have been improperly
set at the start of the test. If all controls appear to be set correctly, then one of the
toggle switches may have been spun around 180°.
Step 8 DIAG light OFF:
1) Control that was tested was in its initial control test position.
2) Two or more controls are not in their initial control test position.
3) Check for a break or short in the Joystick Unit for the control being tested.
Step 9 DIAG light ON:
1) One control is not in its initial test position.
2) If the DIAG light was ON in step 8, check for a break or short in the Joystick Unit
for the control just tested.
*** CONTROL LINK TEST ***

*** JOYSTICK UNIT POWER UP SWITCH TEST ***
Control Link Test Procedure
This test verifies that the radio control link will not be established until all controls are set in their
SAFE POWERUP positions when the Joystick Unit is turned on.
ACTION OBSERVATION
position.
6 Turn the Joystick Unit POWER switch to “ON” position. READY light ON
LINK light ON
; *** CONTROL LINK TEST completed ***
Repeat Steps 7 to 10 for each of the following control positions:

position.
Hold down Joystick Unit DELAYED SHUTDOWN switch.
Hold down Joystick Unit START switch.
8 Set the control to the indicated position.
9 Turn the Joystick Unit POWER switch to “ON” position. DIAG light ON
LINK light OFF
10 Restore the control to its previous position. DIAG light OFF
LINK light ON
; *** JOYSTICK UNIT POWER UP SWITCH TEST completed ***
Troubleshooting
Step 6 LINK light OFF:
Perform the Joystick Unit Switch Closure Test to verify controls are functioning
correctly.(Pg. 11)
Step 9 LINK light ON:
Perform the Joystick Unit Switch Closure Test to verify controls are functioning
correctly.(Pg. 11)
*** EMERGENCY STOP TEST ***
Emergency Stop Test Procedure
This test verifies that the emergency stop switch will break a radio control link, shut down the
LHD and apply the brakes.
ACTION OBSERVATION
3 Manually start the LHD Engine starts
position.
7 Turn the Joystick Unit POWER switch to “ON” position. LINK light ON
8 Push down the Joystick Unit EMERGENCY STOP mushroom switch. LINK light OFF
Engine off
9 Pull up the Joystick Unit EMERGENCY STOP mushroom switch. LINK light ON
Engine off
; *** EMERGENCY STOP TEST completed ***
10 Turn Joystick Unit POWER switch to “OFF” position.
Troubleshooting
Step 8 LINK light ON / Engine running:
See the Joystick Unit Wiring schematic for any breaks or shorts in the Power Up
circuit.
*** DELAYED SHUTDOWN INTERLOCK TEST ***
Delayed Shutdown Interlock Test Procedure
This test verifies that the LHD will ignore a delayed shutdown request if any of the controls on
the Joystick Unit are not set in their SAFE SHUTDOWN positions.
The operator must turn off the Joystick Unit within three (3) seconds or the delayed shutdown
request will be cancelled.
ACTION OBSERVATION
position.
Repeat steps 6 to 11 for each of the following control positions:

position.
7 Manually start the LHD Engine idling
8 Set the control to the indicated position
9 Toggle Joystick Unit DELAYED SHUTDOWN switch.
10 Turn the Joystick Unit POWER switch to “OFF” position. Engine off
11 Restore the control to its previous position
; *** DELAYED SHUTDOWN INTERLOCK TEST completed ***
Troubleshooting
Step Engine running
10 Perform the Joystick Unit Switch Closure Test to verify controls are functioning
correctly.(Pg. 11)
*** DELAYED SHUTDOWN FUNCTION TEST ***
Delayed Shutdown Function Test Procedure
This test verifies that the delayed shutdown function is working properly.
When activated, the delayed shutdown gives the operator 60-seconds to board the LHD and
switch it over to manual control before turning off the engine.
ACTION OBSERVATION
position.
7 Manually start the LHD Engine idling
8 Toggle Joystick Unit DELAYED SHUTDOWN switch. DIAG light ON for
3 seconds
9 While the DIAG. light is on, turn the Joystick Unit POWER switch to Engine idling
“OFF” position.
10 Wait for delayed shutdown timeout period of 60-seconds to expire. Engine shuts
down
; *** DELAYED SHUTDOWN FUNCTION TEST completed ***
Troubleshooting
Step 9 Engine shuts down:
1) Perform the Joystick Unit Switch Closure Test (Pg. 11) and repeat this test.
2) The 3 second timeout when the Delayed Shutdown switch was activated had
expired before turning off the Joystick Unit.
Step Engine running:
10 1) Perform the Joystick Unit Switch Closure Test to verify if the controls are
functioning correctly.(Pg. 11)
2) Wait an additional 30-seconds. If the engine still does not shut down, return the
radio control to the service depot.
*** UNATTENDED REMOTE TEST ***
Unattended Remote Test Procedure
This test verifies that the LHD will shut down if the Joystick unit is turned on BEFORE the LHD is
switched to remote control.
ACTION OBSERVATION
3 Set MANUAL / REMOTE SELECTOR to “MANUAL” position. LINK light OFF
position.
6 Turn the Joystick Unit POWER switch to “ON” position.
7 Set MANUAL / REMOTE SELECTOR to “REMOTE” position. LINK light OFF,
DIAG light ON
; *** UNATTENDED REMOTE TEST completed ***
Troubleshooting
Step 7 LINK light ON :
Return the radio control to the service depot.
*** REMOTE ENGINE START TEST ***

*** REMOTE ENGINE START INTERLOCK TEST ***
Remote Engine Start Test Procedure
This test verifies that the Engine Start Function can only be performed when all of the Joystick
Unit controls are set in their SAFE RESTART positions.
ACTION OBSERVATION
position.
7 Start the LHD using the Joystick Unit START switch. Engine idling.
; *** REMOTE ENGINE START TEST completed ***
Repeat Steps 8 to 12 for each of the following control positions:

position.
8 Turn the Joystick Unit POWER switch to “OFF” position. Engine off
10 Set the control to the indicated position.
11 Start the LHD using the Joystick Unit START switch. Engine off
12 Restore the control to its previous position.
; *** REMOTE ENGINE START INTERLOCK TEST completed ***
Troubleshooting
Step 7 Engine does not start:
1) Perform the Joystick Unit Switch Closure Test to verify if the controls are
2) Verify that the Start output (CANON-19 pin G; White/Red wire) is HIGH when
the Park Brake button on the Joystick Unit is in the “Applied” or “ON” position.
3) See the LHD wiring schematics for any breaks or shorts in the Start circuit.
Step Engine starts:
11 1) Perform the Joystick Unit Switch Closure Test to verify if the controls are
2) See the Joystick Unit Wiring schematic for any breaks or shorts in the circuit of the
controlled position, which activates the starter.
3) See the LHD wiring schematics for any breaks or shorts in the Start circuit.
*** FIRE SUPPRESSION FUNCTION TEST ***
****
CAUTION
DISCONNECT THE FIRE SUPPRESSION SQUIB BEFORE PERFORMING THE FIRE

SUPPRESSION FUNCTION TESTS. MEASURE THE FIRE SUPPRESSION OUTPUT BY
PLACING A SPECIAL PURPOSE LAMP OR VOLTMETER ACROSS THE SQUIB CONNECTOR
INPUTS.
****
Fire Suppression Function Test Procedure
This test verifies that the Joystick Unit is able to trigger the on-board fire suppression system.
ACTION OBSERVATION
position.
6 Turn Joystick Unit POWER switch to “ON” position. LINK light ON
7 Manually start the LHD Engine starts
8 Hold down Joystick Unit FIRE SUPPRESSION switch. Engine off
9 Wait three (3) seconds while holding down Joystick Unit FIRE FIRE
SUPPRESSION switch. SUPPRESSION
output goes
HIGH
10 Release the Joystick Unit FIRE SUPPRESSION switch.
11 Wait for ten (10) seconds. FIRE
SUPPRESSION
output goes LOW
; *** FIRE SUPPRESSION FUNCTION TEST completed ***
12 Turn Joystick Unit POWER switch to “OFF” position.
Troubleshooting
Step 8 Engine continues to run:
1) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Fire Suppression
function.
2) See the Joystick Unit Wiring schematic for any breaks or shorts in the Fire
Suppression circuit.
3) Perform the Unattended Vehicle Timeout Test. (Pg. 8)
Step 9 Fire Suppression output stays low:

1) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Fire Suppression
function.
2) Verify that the Fire Suppression output (CANON-19 pin F; Orange/Red wire) is
HIGH when the Fire Suppression switch on the Joystick Unit is held for over 3
seconds.
3) See the LHD wiring schematics for any breaks or shorts in the Fire Suppression
circuit.
*** PROPORTIONAL THROTTLE TEST ***

*** PARK BRAKE – FORWARD/REVERSE INTERLOCK TEST ***
*** HALF THROTTLE TEST ***
*** FULL THROTTLE TEST ***
Throttle Test Procedure
This test verifies that the throttle power band is set correctly and that the joystick throttle control
is functioning. The test also verifies that the transmission remains in neutral when the Joystick
unit park brake is set to “applied” or “on” position.
ACTION OBSERVATION
position.
6 Set Joystick Unit POWER switch to “ON” position. LINK light ON
7 Ease Joystick Unit left joystick to maximum “FORWARD“ position. RPM increases
Stop if there is an indication the LHD is moving. No movement
8 Ease Joystick Unit left joystick to maximum “REVERSE“ position. RPM increases
Stop if there is an indication the LHD is moving. No movement
; *** PROPORTIONAL THROTTLE TEST completed ***
; *** PARK BRAKE – FORWARD/REVERSE INTERLOCK TEST completed ***
9 Hold down Joystick Unit HALF THROTTLE switch 50% max. RPM
10 Release Joystick Unit HALF THROTTLE switch Idle RPM
; *** HALF THROTTLE TEST completed ***
11 Hold down Joystick Unit FULL TROTTLE switch. Max. RPM
12 Release Joystick Unit FULL THROTTLE switch. Idle RPM
; *** FULL THROTTLE TEST completed ***
Troubleshooting
Step 7 No RPM increase:
&8 1) Verify that the Throttle output (CANON-19 pin L; Blue/Black wire or CANNON-10
pin K) is HIGH when the FWD/REV/STEER Joystick is moved to the up or down
positions.
2) See the LHD wiring schematics for any breaks or shorts in the Throttle circuit.
Step 7 LHD moves FWD or REV:
&8 1) Verify if the Joystick Unit PARK BRAKE switch is in the “APPLIED” or “ON”
position.
2) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Park Brake function.
Step 9 No RPM increase:
& 11 1) Verify that the Throttle output (CANON-19 pin L; Blue/Black wire or CANNON-10
pin K) is HIGH when the Throttle toggle switches on the FWD/REV/STEER joystick
are activated.
2) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Throttle functions.
3) See the LHD wiring schematics for any breaks or shorts in the Throttle circuit.
*** FORWARD/NEUTRAL/REVERSE FUNCTION TEST ***

*** SERVICE BRAKE FUNCTION TEST ***
*** PARK BRAKE FUNCTION TEST ***
Forward/Neutral/Reverse Function Test Procedure
This test verifies that the transmission gear select, proportional throttle control, service brake
and parking brake controls are working.
ACTION OBSERVATION
position.
6 Set Joystick Unit POWER switch to “ON” position. LINK light ON
8 Set Joystick Unit PARK BRAKE switch to “RELEASED” or “OFF”
position.
9 Ease Joystick Unit left joystick to “FORWARD“ position until the LHD Moves forward
begins moving.
10 Hold down Joystick Unit left FULL BRAKE switch. Stops moving.
11 Release Joystick Unit left FULL BRAKE switch. moves forward
12 Hold down Joystick Unit right FULL BRAKE switch. Stops moving.
13 Release Joystick Unit right FULL BRAKE switch. moves forward
14 Ease Joystick Unit left joystick to “REVERSE“ position until the LHD moves backward
begins moving.
15 Hold down Joystick Unit left FULL BRAKE switch. Stops moving.
16 Release Joystick Unit left FULL BRAKE switch. moves backward
17 Hold down Joystick Unit right FULL BRAKE switch. Stops moving.
18 Release Joystick Unit right FULL BRAKE switch. moves backward
19 Release Joystick Unit left joystick. Stops moving.
; *** FORWARD/NEUTRAL/REVERSE FUNCTION TEST completed ***
; *** SERVICE BRAKE FUNCTION TEST completed ***
; *** PARK BRAKE FUNCTION TEST completed ***
position.
Troubleshooting
Step 9 LHD not moving in Forward:
1) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Park Brake and
Forward functions.
2) Verify if the Park Brake output (CANON-19 pin J; Blue/White wire) goes HIGH
when Joystick Unit Park brake is set to “RELEASED” or “OFF” position.
3) Verify if the Service Brake output (CANON-19 pin H; Red/White wire) goes HIGH
when left joystick is moved to the FORWARD or REVERSE positions.
4) See the LHD wiring schematics for any breaks or shorts in the Park Brake, Service
Brake Throttle and Forward circuits.
*** FORWARD/NEUTRAL/REVERSE FUNCTION TEST ***

*** SERVICE BRAKE FUNCTION TEST ***
*** PARK BRAKE FUNCTION TEST ***
*** Continued ***
Troubleshooting
Step LHD not moving in Reverse:
14 1) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Park Brake and
Reverse functions.
2) Verify if the Park Brake output (CANON-19 pin J; Blue/White wire) goes HIGH
when Joystick Unit Park brake is set to “RELEASED” or “OFF” position.
3) Verify if the Service Brake output (CANON-19 pin H; Red/White wire) goes HIGH
when left joystick is moved to the FORWARD or REVERSE positions.
4) See the LHD wiring schematics for any breaks or shorts in the Park Brake, Service
Brake Throttle and Forward circuits.
Steps LHD Service Brakes not Applying:
10, 12, 1) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Service Brake
15 & functions.
17 2) Verify if the Service Brake output (CANON-19 pin H; Red/White wire) goes LOW
when either toggle on the Right joystick are activated.
3) See the LHD wiring schematics for any breaks or shorts in the Service Brake
circuit.
*** STEER LEFT FUNCTION TEST ***

*** STEER RIGHT FUNCTION TEST ***
Steer Function Test Procedure
This test verifies that the steering power band is set correctly and that the joystick steering
control is functioning.
ACTION OBSERVATION
position.
8 Hold down Joystick Unit HALF THROTTLE switch. LHD slowly turns
Move Joystick Unit left joystick to minimum LEFT position. to the left.
Hold until the LHD is configured for a tight left turn.
9 Hold down Joystick Unit HALF THROTTLE switch. LHD slowly turns
Move Joystick Unit left joystick to minimum RIGHT position. to the right.
Hold until the LHD is configured for a tight right turn.
The turn rate should be about the same as it was for the left.
10 Hold down Joystick Unit HALF THROTTLE switch. LHD quickly turns
Move Joystick Unit left joystick to maximum LEFT position. to the left.
Hold until the LHD is configured for a tight left turn.
11 Hold down Joystick Unit HALF THROTTLE switch. LHD quickly turns
Move Joystick Unit left joystick to maximum RIGHT position. to the right.
Hold until the LHD is configured for a tight right turn.
The turn rate should be about the same as it was for the left.
12 Straighten the LHD.
; *** STEER LEFT FUNCTION TEST completed ***
; *** STEER RIGHT FUNCTION TEST completed ***
Troubleshooting
Steps 8 If the LHD does not steer left, verify that:
& 10 1) The Steer Left Solenoid on the 6 bank manifold illuminates when the steer left
function is activated.
2) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Steer Left
function.
3) Steer Left Output (CANON-10 pin A) varies between dead band and maximum
RMS voltage for steering function.
Steps 9 If the LHD does not steer right, verify that:
& 11 1) The Steer Right Solenoid on the 6 bank manifold illuminates when the steer right
2) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Steer Right
function.
3) Steer Right Output (CANON-10 pin B) varies between dead band and maximum
RMS voltage for steering function.
If the LHD steers fast in one direction; slow in the other direction:
See APENDIX – Joystick Potentiometer Calibration Procedures (on page 31 near
the end of this manual.)
*** BOOM UP FUNCTION TEST ***

*** BOOM DOWN FUNCTION TEST ***
Boom Function Test Procedure
This test verifies that the boom function power band is set correctly and that the joystick boom
ACTION OBSERVATION
position.
8 Move Joystick Unit right joystick to minimum RIGHT position. Boom slowly
Hold until the boom is fully raised. raises.
9 Move Joystick Unit right joystick to minimum LEFT position. Boom slowly
Hold until the boom is fully lowered. lowers.
10 Move Joystick Unit right joystick to maximum RIGHT position. Boom quickly
Hold until the boom is fully raised. raises.
11 Move Joystick Unit right joystick to maximum LEFT position. Boom quickly
Hold until the boom is fully lowered. lowers.
; *** BOOM UP FUNCTION TEST completed ***
; *** BOOM DOWN FUNCTION TEST completed ***
Troubleshooting
Steps 8 If the boom does not raise verify that:
& 10 1) The Boom Up Solenoid on the 6 bank manifold illuminates when the boom up
2) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Boom Up
function.
3) Boom Up Output (CANON-10 pin D) varies between dead band and maximum
RMS voltage for boom function
Steps 9 If the boom does not lower verify that:
& 11 1) The Boom Down Solenoid on the 6 bank manifold illuminates when the boom
down function is activated.
2) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Boom Down
function.
3) Boom Down Output (CANON-10 pin F) varies between dead band and maximum
RMS voltage for boom function.
If the LHD’s Boom moves fast in one direction; slow in the other direction:
*** BUCKET ROLL FUNCTION TEST ***

*** BUCKET DUMP FUNCTION TEST ***
Bucket Function Test Procedure
This test verifies that the bucket function power band is set correctly and that the joystick boom
ACTION OBSERVATION
position.
8 Raise the boom so that the bucket may be moved through its full
range.
9 Move Joystick Unit right joystick to minimum DOWN position. Bucket slowly rolls.
Hold until the bucket is fully rolled back. Note: Some RRC’s
are configured to roll
the bucket quickly.
10 Move Joystick Unit right joystick to minimum UP position. Bucket slowly dumps.
Hold until the bucket is fully dumped. Note: Some RRC’s
are configured to roll
the bucket quickly.
11 Move Joystick Unit right joystick to maximum DOWN position. Bucket quickly rolls.
Hold until the bucket is fully rolled back.
12 Move Joystick Unit right joystick to maximum UP position. Bucket quickly
Hold until the bucket is fully dumped. dumps.
; *** BUCKET ROLL FUNCTION TEST completed ***
; *** BUCKET DUMP FUNCTION TEST completed ***
13 Lower the boom back onto the stop blocks
Troubleshooting
Steps 9 If the bucket does not roll verify that:
& 11 1) The Bucket Roll Solenoid on the 6 bank manifold is illuminated when the bucket
roll function is activated.
2) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Bucket Roll
function.
3) Bucket Roll Output (CANON-10 pin C) varies between dead band and maximum
RMS voltage for bucket function.
Steps 10 If the bucket does not dump verify that:
& 12 1) The Bucket Dump Solenoid on the 6 bank manifold is illuminated when the
bucket dump function is activated.
2) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Bucket Dump
function.
3) Bucket Dump Output (CANON-10 Pin E) varies between dead band and
maximum RMS voltage for bucket function.
If the LHD’s Bucket moves fast in one direction; slow in the other direction:
Note: Some RRC’s are configured to roll and dump the bucket quickly.
*** FRONT LIGHT FUNCTION TEST ***

*** REAR LIGHT FUNCTION TEST ***
Headlight Function Test Procedure
This test verifies that the joystick unit front and rear light controls are functioning.
ACTION OBSERVATION
position.
7 Set Joystick Unit FRONT LIGHTS switch to “ON” position. Front lights on
8 Set Joystick Unit FRONT LIGHTS switch to “OFF” position. Front lights off
; *** FRONT IGHT FUNCTION TEST completed ***
9 Set Joystick Unit REAR LIGHTS switch to “ON” position. Rear lights on
10 Set Joystick Unit REAR LIGHTS switch to “OFF” position. Rear lights off
; *** REAR LIGHT FUNCTION TEST completed ***
Troubleshooting
Step 7 Front lights off:
1) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Front Lights
function.
2) Check that the Front Lights output (CANON-19 pin P) is not shorted to ground or
disconnected.
3) See the LHD wiring schematics for any breaks or shorts in the Front Lights circuit.
Step 8 Front lights on:
1) Verify if the Front Lights switch in the operator’s cab is not in the On position.
2) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Front Lights
function.
3) Check that the Front Lights output (CANON-19 pin P) is not tied HIGH.
4) See the LHD wiring schematics for any breaks or shorts in the Front Lights circuit.
Step 9 Rear lights off:
1) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Rear Lights
function.
2) Check that the Rear Lights output (CANON-19 pin K) is not shorted to ground or
disconnected.
3) See the LHD wiring schematics for any breaks or shorts in the Rear Lights circuit.
Step Rear lights on:
10 1) Verify if the Rear Lights switch in the operator’s cab is not in the On position.
2) Perform the Joystick Unit Switch Closure Test (Pg. 11) for the Rear Lights
function.
3) Check that the Rear Lights output (CANON-19 pin K) is not tied HIGH.
4) See the LHD wiring schematics for any breaks or shorts in the Rear Lights circuit.
APPENDIX – LHD Vehicle Unit Connector Pin Outs
19-PIN CANON CONNECTOR

# COLOR DESCRIPTION
A BLK Power
B A M B GRN/BLK Power input to vehicle unit
C P N L C GRN/WHT Ground
D R V U K D BLK/RED Power ground for vehicle unit.
E S T J Run (Output)
F G H E BLU/RED
High to keep engine running.
Fire Suppression (Output)
Pin location F ORN/RED
High to activate onboard fire suppression.
Front view Start (Output)
G WHT/RED
High to activate starter.
Service Brake (Output)
H RED/WHT
High to release service brake.
Park Brake (Output)
J BLU/WHT
High to release the park brake.
Rear Lights (Output)
K RED/BLK
High to turn on rear lights.
Throttle (Output)
100Hz PWM output will vary from dead band duty
L BLU/BLK
cycle to the maximum throttle duty cycle in both the
forward and reverse directions.
Forward (Output)
M ORN/BLK
High to set transmission to FORWARD gear.
Reverse (Output)
N WHT
High to set transmission to REVERSE gear.
Front Lights (Output)
P WHT/BLK
High to turn on front light.
RRC (Output)
R RED
High when radio control link is established.
Remote Select (Input)
S BLU
High input to put LHD in radio remote control.
Neutral Sense (Input)
T BLK/WHT
High to indicate that manual gear select is in neutral.
Park Brake Sense (Input)
U ORN
High indicates manual park brake is applied.
Spare
Note: On other systems, this output is used for the
V GRN
Brake Release Pump (output).
High to turn on pump.
10 pin CANON connector - without BRAD HARRISON Junction Box

COLOR CODE
# EXT. INT. DESCRIPTION
PUR Proportional Steer Left (Output)
A BLK
007 100 Hz PWM
b a h PUR Proportional Steer Right (Output)
B GRN/BLK
c j k g 008 100 Hz PWM
d e f PUR Proportional Bucket Roll (Output)
C GRN/WHT
005 100 Hz PWM
Pin location PUR Proportional Boom Up (Output)
Front view D BLK/RED
003 100 Hz PWM
PUR Proportional Bucket Dump (Output)
E BLU/RED
006 100 Hz PWM
PUR Proportional Boom Down (Output)
F ORN/RED
004 100 Hz PWM
REVERSE (Output)
G N/C WHT/RED
H BLK RED/WHT Ground
J N/C BLU/WHT Forward (Output)
K N/C RED/BLK Throttle (Output)
10 pin CANON connector - Some Early Systems with BRAD

HARRISON Junction Box
COLOR CODE
Proportional Steer Left (Output)
A WHT BLK
100 Hz PWM
b a h Proportional Steer Right (Output)
B GRN GRN/BLK
c j k g 100 Hz PWM
d e f Proportional Bucket Roll (Output)
C YEL GRN/WHT
100 Hz PWM
Pin location Proportional Boom Up (Output)
Front view D GRY BLK/RED
100 Hz PWM
Proportional Bucket Dump (Output)
E PNK BLU/RED
100 Hz PWM
Proportional Boom Down (Output)
F RED ORN/RED
100 Hz PWM
RRC (Output)
G BRN WHT/RED
High when radio control link is established.
H BLU RED/WHT Ground
J N/C BLU/WHT Spare output 1
K N/C RED/BLK Spare output 2
10 pin CANON connector - 10 AWG Provo Multiconductor

COLOR CODE
A BLK BLK
100 Hz PWM
B WHT GRN/BLK
c j k g 100 Hz PWM
C RED GRN/WHT
100 Hz PWM
Front view D GRN BLK/RED
100 Hz PWM
E BRN BLU/RED
100 Hz PWM
F BLU ORN/RED
100 Hz PWM
REVERSE (Output)
G ORN WHT/RED
H YEL RED/WHT Ground
J PUR BLU/WHT Forward (Output)
K GRY RED/BLK Throttle (Output)
10 pin CANON connector - without BRAD HARRISON Junction Box

COLOR CODE
A BLK BLK
100 Hz PWM
B GRN/BLK GRN/BLK
c j k g 100 Hz PWM
C GRN/WH GRN/WHT
100 Hz PWM
Front view D BLK/RED BLK/RED
100 Hz PWM
E BLU/RED BLU/RED
100 Hz PWM
F ORN/RED ORN/RED
100 Hz PWM
REVERSE (Output)
G WHT/RED WHT/RED
H RED/WHT RED/WHT Ground
J BLU/WHT BLU/WHT Forward (Output)
K RED/BLK RED/BLK Throttle (Output)
APPENDIX – LHD Joystick Unit Controls
Joystick Unit Control Operation

POWER Main power.
Toggle switch
EMERGENCY STOP Emergency shutdown. Interrupts main power by shutting
Mushroom pushbutton the Joystick unit down and terminating the control link.
DELAYED SHUTDOWN Pull down before turning off joystick unit and boarding
Momentary toggle LHD.
PARK BRAKE Up to release park brake
Toggle switch Down to apply park brake
FRONT LIGHTS Up to turn on front lights
Toggle switch Down to turn off front lights
REAR LIGHTS Up to turn on rear lights
Toggle switch Down to turn off rear lights
START Pull down to turn on starter motor.
Momentary toggle
FIRE SUPPRESSION Remove ring pin and hold down for 3 seconds to activate
Momentary toggle the Ansul fire suppression system on the LHD.
Left joystick Move joystick up for forward movement
STEER/THROTTLE Move joystick down for reverse movement
Move joystick left to steer to the left
Move joystick right to steer to the right
Right joystick Move joystick up for bucket dump
BOOM/BUCKET Move joystick down for bucket roll
Move joystick left to lower boom
Move joystick right to raise boom
Left joystick right Thumb toggle Press to bring engine to 50% of maximum throttle.
switch
HALF THROTTLE
Left joystick left Thumb toggle Press to bring engine to maximum throttle.
switch
FULL THROTTLE
Right joystick L/R Thumb toggle Press to apply service brake when the LHD is in motion.
switches
FULL SERVICE BRAKE
APPENDIX – LHD Joystick Unit Control “SAFE” positions
Joystick Unit Control SAFE SAFE SAFE

POWERUP RESTART SHUTDOWN
PARK BRAKE switch “APPLIED” “APPLIED” “APPLIED”
or “ON” or “ON” or “ON”
DELAYED SHUTDOWN switch Released Released Held down
FRONT LIGHTS switch - - -
REAR LIGHTS switch - - -
START switch Released Held down Released
FIRE SUPPRESSION switch Released - -
Right joystick Centered Centered Centered
BOOM/BUCKET
Right joystick left thumb switch Released - -
Left FULL BRAKE switch
Right joystick right thumb switch Released - -
Right FULL BRAKE switch
Left joystick Centered Centered Centered
STEER/THROTTLE
Left joystick left thumb switch Released Released Released
FULL THROTTLE switch
Left joystick right thumb switch Released Released Released
HALF THROTTLE switch
APPENDIX – Joystick Potentiometer Calibration Procedures
1. Open the Joystick Units lid.

2. Disconnect all connectors on the Auxiliary Board (Con 1, Con 2, Con 3, Con 4, Con 5, Con 6
and Con 7).
3. With an Ohmmeter, measure the resistance between the CT pin and pin two (see Fig. 1 at
the bottom of this page for the potentiometer pin-out). The resistance reading should be close
to 0 Ohms (if the reading is not close to 0 Ohms proceed to step 6; If the reading is close to 0
Ohms, proceed to step 4). Note: It is very important that the joystick is resting in its neutral
position; a slight displacement of the joystick will throw off the resistance reading.
4. With an Ohmmeter, measure the resistance between the CCW pin and pin two (see Fig. 1 at
the bottom of this page for the potentiometer pin-out). Write down this reading. Note: It is
very important that the joystick is resting in its neutral position; a slight displacement of the
joystick will throw off the resistance reading.
5. With an Ohmmeter, measure the resistance between pin 3 and pin 2 (see Fig. 1 at the bottom
of this page for the potentiometer pin-out). This reading should be very close to the reading
obtained in step 4 (if the reading is not close to the reading in step 4, proceed to step 6; if the
reading is very close to the reading in step 4, the potentiometer is calibrated and proceed to
step 7). Note: It is very important that the joystick is resting in its neutral position; a slight
displacement of the joystick will throw off the resistance reading.
6. Unscrew both potentiometer-retaining screws (on both sides of the potentiometer). Slightly
turn the potentiometer Clockwise or Counter-Clockwise. Proceed to steps 3,4 and 5. Note: If
while turning the potentiometer slightly and the resistance change is very dramatic or erratic,
send the Remote Control System to Hard-Line Solutions for servicing.
7. Tighten both Potentiometers retaining screws, reconnect all the connectors on the Auxiliary
Board (Con 1, Con 2, Con 3, Con 4, Con 5, Con 6 and Con 7) and close the lid.
Fig. 1
3 2 CT
CCW
APPENDIX – LHD Proportional Output Scaling Table
BOT. TOP MIN MID MAX

(in) (out) (in) (out) (in) (out)
Service Brake $3F60 255 0 20 255 115 255 115 255
Proportional Throttle $3F68 0 255 20 146 115 166 115 166
Proportional Boom Down $3F70 0 255 20 128 86 255 86 255
Proportional Boom Up $3F78 0 255 20 128 115 255 115 255
Proportional Bucket Dump $3F80 0 255 20 255 115 255 115 255
Proportional Bucket Roll $3F88 0 255 20 255 115 255 115 255
Proportional Steer Right $3F90 0 255 20 128 115 255 115 255
Proportional Steer Left $3F98 0 255 20 128 115 255 115 255
$3FA0 - - - - - - - -
$3FA8 - - - - - - - -
$3FB0 - - - - - - - -
$3FB8 - - - - - - - -
$3FC0 - - - - - - - -
$3FC8 - - - - - - - -
$3FD0 - - - - - - - -
$3FD8 - - - - - - - -
Common percentages converted to decimal and hexadecimal notation
Percentage Decimal Hexadecimal Percentage Decimal Hexadecimal

0% 0 00
5% 13 0D 55% 140 8C
10% 26 1A 60% 153 99
15% 39 27 65% 166 A6
20% 51 33 70% 179 B3
25% 64 40 75% 191 BF
30% 76 4C 80% 204 CC
35% 89 59 85% 217 D9
40% 102 66 90% 230 E6
45% 115 73 95% 242 F2
50% 128 80 100% 255 FF
Hexadecimal to decimal conversion table
x0 x1 x2 x3 x4 x5 x6 x7 x8 x9 xA xB xC xD xE xF
0x 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
1x 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
2x 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47
3x 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63
4x 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79
5x 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95
6x 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111
7x 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127
8x 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143
9x 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159
Ax 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175
Bx 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191
Cx 192 193 194 195 196 197 198 199 200 201 202 203 204 205 206 207
Dx 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223
Ex 224 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239
Fx 240 241 242 243 244 245 246 247 248 249 250 251 252 253 254 255
APPENDIX – LHD Proportional Control Output Measurements
Company: Mine: .
Vehicle ID: Date: .
PWM Expected Bench Field

(%) (RMS) (RMS) (RMS)
Input voltage N/A 24VDC
Forward Throttle Dead Band
Forward Throttle Full
Reverse Throttle Dead Band
Reverse Throttle Full
Full Throttle
Half Throttle
Steer Full Left
Steer Full right
Boom Full Up
Boom Full Down
Bucket Full Roll
Bucket Full Dump
APPENDIX – Revision History
1998-08-21 First printing.

Based upon: Rockbreaker Radio Remote Control Commissioning and
Troubleshooting
1998-09-29 Second printing.

Replaces pages 10, 11, 12, 15, 18, 23, and 24 in previous edition.
Corrected commissioning order p.10 and 11

Replaced references to HOIST with BOOM and TILT with BUCKET (pages 11,
12, 15, and 18)
Added missing commissioning steps for BOOM and BUCKET tests (pages 24
and 24)
1998-10-18 Third printing.

Replaces page 30 in previous edition.
Added Percentage to decimal and hexadecimal conversion table

Added Hexadecimal to decimal conversion table
APPENDIX – Problem Report Form
FAX TO: HLS HARD-LINE Solutions Inc.

53 Main Street, Dowling, Ontario, CANADA P0M 1R0
VOICE: (705) 855-1310
FAX: (705) 855-9463
FROM:
Company: Mine: .
Vehicle ID: Date: .
Technician: Position: .
Describe the problem:
Problem resolution:
( ) Radio Being Returned For Service
( ) Requesting a service call
( ) Found a work-around (Please describe below)
SECTION TWO
BILLS OF MATERIAL, DRAWINGS & SCHEMATICS

HLS HARD-LINE Solutions Inc. Parts List
Assembly Number -- ASLHDS-2 -- MUCKMASTER LHD Slave Unit Standard Assembly Version 2 -- 3098
Item Part Number Item Part Number
1 ASLHDS-2-04 11 ASLHDS-1-03
MUCKMASTER LHD Slave Unit Prepared Fiberglass MUCKMASTER LHD Slave Unit Wire Harness Power
Enclosure Switch to E.Stop
Qty: 1 Each 3781 Qty: 1 Each 1710

2 8500K9 12 ASLHDS-1-04
8500 Series SPST On-None-Off Switch MUCKMASTER LHD Slave Unit Jumpers for all
Switches

3 8500K11 13 ASLHDS-1-07
8500 Series SPST Off-None-On Momentary Switch MUCKMASTER LHD Slave Unit Wire Harness 10
Socket AMP from Con 5 to Switches

4 8492K1-MOD1 14 ASLHDS-1-08
Switch Guard for Toggle Switch - Modified MUCKMASTER LHD Slave Unit Wire Harness from E
Stop to Battery Cable

5 N1030B 15 ASA10B
Half Toggle Switch Seal PCB Assembled - Joystick Unit Antenna/LED Board
Sourcing Version with Cable Harness Version B

6 090-008-MOD1 16 MSSSFP0440-0.75
Pins Steel Zinc Hitch Clips Double Loop 9/16-13/16, MS SS Flat Head Phillips Drive 4-40 X 3/4
Modified for Fire Suppression Pin on Slave

7 10250T5 17 WFN#04
C.H. Maintained Push/Pull Operator Washer Flat Nylon #4

8 10250T51 18 NUTSSNYLOC#04
C.H. 1 N/C Contact Block Nut SS Nylon Insert Locknut (nyloc) 4-40

9 10250TC47-MOD1 19 V10-PRO-T/S-MOD1
C.H. Push/Pull Operator Red Lens modified V10 Proportional Joystick Throttle/Steering c/w
ASA14A Auxiliary Board

10 ASLHDS-1-02 20 V10-PRO-D/H
MUCKMASTER LHD Slave Unit Wire Harness 12 V10 Proportional Joystick Dump/Hoist
Socket AMP Con 3 to Joystick T/S Joystick
Printed on 10/18/2004 at 12:05:05 PM by Master repMFBOMCatalog Page 1 of 2

21 ASA01E 32 BR18-MOD2
PCB Assembled - V10-Joystick Auxiliary Board Skid plate for Rose enclosure 02163609 and wheat
Version E battery c/w screw and new handle holes

22 ASM02D 33 099-140
PCB Assembled - Microprocessor Board Version D Drop Handle Zinc Plated 4 1/8" handle size

23 A095-2 34 MSSSFP10-0.5
900MHZ High Power Radio MS SS Flat Head Phillips Drive 10-32 X 1/2

24 MSSSPP0256-0.75 35 NUTSSNYLOC#10
MS SS Pan Head Phillips Drive 2-56 X 3/4 Nut SS Nylon Insert Locknut (nyloc) 10-32

25 WLITSS#02 36 SHCS0.25/20x0.75
Lockwasher SS internal tooth no. 2, type A Socket Head Cap Screws 1/4-20 X 3/4"

26 SRA0256x0.375-0.1875 37 191-400
Spacer Round Aluminum 2-56 Hole, 3/16" Outside Joint Connector Nut 1/4-20x12mm for Skid Plate
Diameter X 3/8" Long

27 762159
Weather Pack Nylon 2 Cavity for Socket Terminals
Qty: 1 Each 194

28 ASLHDS-2-10
MUCKMASTER LHD Slave Unit Electric Accessory
Plug Assembly with Weather Pack Socket Terminal
Qty: 1 Each 5226

29 762162
Weather Pack Wire Seals for 14-16AWG
Qty: 2 Each 197

30 762153
Weather Pack Pin Terminal 14-16AWG
Qty: 2 Each 151

31 762158
Weather Pack Nylon 2 Cavity for Pin Terminals
Qty: 1 Each 193

Assembly Number -- ASLHDM-2 -- MUCKMASTER LHD Master Unit Standard Assembly Version 2 --
3081
1 ASLHDM-2-01 30 A095-2
MUCKMASTER LHD Master Unit Prepared Enclosure 900MHZ High Power Radio

2 ASLHDM-1-02 31 ASLHDM-1-05
MUCKMASTER LHD Master Unit 19 socket panel MUCKMASTER LHD Master Unit Antenna Assembly
mount connector c/w wiring harness

3 ASLHDM-1-01 41 NUTSSNYLOC#02
MUCKMASTER LHD Master Unit 10 socket panel Nut SS Nylon Insert Locknut (nyloc) 2-56
mount connector c/w wiring harness

11 ASD02C 42 NUTSSNYLOC#04
PCB Assembled - Vehicle Unit Driver - Watchdog Run Nut SS Nylon Insert Locknut (nyloc) 4-40
Monitor on board Version 3

12 ASA02B 43 MSSSPP0440-0.5
PCB Assembled - Vehicle Unit LED Board Version B MS SS Pan Head Phillips Drive 4-40 X 1/2

13 ASM02D 44 MSSSPP1032-1.25
PCB Assembled - Microprocessor Board Version D MS SS Pan Head Phillips Drive 10-32 X 1-1/4

20 25.621.1453.0 45 SRA0256x0.375-0.1875
3.81mm Terminal Plug 14 Position PCB C/W Screw Spacer Round Aluminum 2-56 Hole, 3/16" Outside
Down and Numbering Diameter X 3/8" Long

21 25.621.1053.0 46 MSSSCPM68
3.81mm Terminal Plug 10 Position PCB C/W Screw MS SS Raised Cheese Head Phillips Drive M6 X 8mm
Down and Numbering

22 25.621.0753.0 47 WLETSS#06
3.81mm Terminal Plug 7 Position PCB C/W Screw Washer Lock External Tooth SS #6
Down and Numbering

23 25.621.0353.0 48 WFN#04
3.81mm Terminal Plug 3 Position PCB C/W Screw Washer Flat Nylon #4
Down and Numbering

50 1.5KE33A
TVS 33V 1500W UNI-DIR TH/H
Qty: 1 Each 345

51 BR22-MOD1
Bracket for Master Unit Enclosure 021222209-00 c/w
Holes
Qty: 1 Each 5135

54 H18-COMM-H45
Teflon Hook Up Wire 1KV 200ºC 18AWG Blue/Red
Striped
Qty: 0.1 Meter 3423

55 83029-6
Teflon Hook Up Wire 1KV 200ºC 18AWG Blue
Qty: 0.6 meter 84

56 83029-9
Teflon Hook Up Wire 1KV 200ºC 18AWG White
Qty: 0.485 meter 87

57 83029-3
Teflon Hook Up Wire 1KV 200ºC 18AWG Orange
Qty: 0.45 meter 81

58 83029-5
Teflon Hook Up Wire 1KV 200ºC 18AWG Green
Qty: 0.6 meter 83

59 83029-4
Teflon Hook Up Wire 1KV 200ºC 18AWG Yellow
Qty: 0.265 meter 82

60 H18-COMM-H82
Teflon Hook Up Wire 1KV 200ºC 18AWG Black/Red
Striped
Qty: 0.1 Meter 3420

61 HSTT12-48-Q
Heat Shrink Thin Wall 1/8" Black
Qty: 0.03 Meter 108

Assembly Number -- KITLHDDASH1 -- Kit - LHD Dash Standard -- 1747
1 10250T3011 11 10250T1
C.H. 2 Position Selector Switch Maintained, Long C.H. 1 N/O, 1 N/C Contact Block
Lever

2 ASCH-02 12 NP-MR2
Assembled Cable Harness 19 Pin Dash Cable Name Plate Manual Remote MUCKMASTER

3 VF4-15H11 13 HSTT12-48-Q
Relay VF4 Auto. 24V Coil 40A cont. quick conn Heat Shrink Thin Wall 1/8" Black
Qty: 4 Each 1169 Qty: 0.3 Meter 108

4 VCF4-1002 14 HSTT38-48-Q
Relay Socket VF4 quick connector relay with screw Heat Shrink Thin Wall 3/8" Black
tab,

5 26A1348A 15 HSTT25-48-Q
Relay Terminal Open-Barrel Series 18-20AWG 26A Heat Shrink Thin Wall 1/4" Black
Crimp On

6 10250T3 16 HSTT75-48-5
C.H. 2 N/C Contact Block Heat Shrink Thin Wall 3/4" Black

7 10250T47 17 24-6040-0061
C.H. 1 Early Closing N/O, 1 N/C Contact Block Solder 16 gauge (0.062"/1.5mm) 60/40 "44" Rosin
Core 1Lb.
Qty: 1 Each 2927 Qty: 0.05 Each 2778

8 AGC-15 18 BVYR-100707TTT
Fuse AGC-15A Fast Acting 1/4 X 1 1/4 Glass 250V PMA Connector "Y", IP68 seal, 1 Size 10 Tube, 2 Size
07 "T" Profile Tube

9 HHB 19 BFAD-P070
Fuse HHB Series In-Line Universal Fuse Holder PMA Connector Straight, IP67 seal, 7mm to 10mm

10 1N5408 20 BFN2-07T
Rectifier Axial 1000V 1A TH/H PMA Connector Retaining Clip Size 07 "T" Profile
Tube

21 BFN2-09T 32 HSTT19-48-Q
PMA Connector Retaining Clip Size 10 "T" Profile Heat Shrink Thin Wall 3/16" Black
Tube

22 NVN3-07 33 P18-10R
PMA Sealing Caps Size 07 Terminal Non-Insulation Ring 22-18AWG #10 Stud

23 NVN3-09 34 BR08-MOD1
PMA Sealing Caps Size 09 Bracket Shoulder Harness Mounting Bracket Finished

24 BVNL-P07MT 35 MSSSFP14-1.5
PMA Connector Straight, IP67 seal, PG07 Thread, MS SS Flat Head Phillips Drive 1/4" NC x 1 1/2"
Size 07 "T" Profile Tube

25 GMM-07 36 NUTSSNYLOC0.25/20
PMA Nut PG-07 Thread Nut SS Nylon Insert Locknut (nyloc) 1/4-20 N/C

26 SFN4-07
PMA Flat Gasket PG07 Thread
Qty: 2 Each 1773

27 BVYR-101010TTT
PMA Connector "Y", IP68 seal, 3 Size 10 "T" Profile
Tube
Qty: 1 Each 1470

28 BVNL-P090T
PMA Connector Straight, IP67 seal, PG09 Thread,
Size 10 "T" Profile Tube
Qty: 1 Each 279

29 GMM-09
PMA Nut PG-09 Thread
Qty: 1 Each 281

30 SFN4-09
PMA Flat Gasket PG09 Thread
Qty: 1 Each 1325

31 P14-6R
Terminal Non-Insulation Ring 16-14AWG #6
Qty: 10 Each 1478

Assembly Number -- ASLHDS-2-11 -- MUCKMASTER LHD Slave Unit Weather Pack Electric Accessory
Power\Charger\Battery Cables -- 5247
1 ASLHDS-2-09
Plug Assembly with Weather Pack PinTerminal
Qty: 3 Each 5225

2 ASLHDS-2-10
Plug Assembly with Weather Pack Socket Terminal
Qty: 3 Each 5226

3 762158
Weather Pack Nylon 2 Cavity for Pin Terminals
Qty: 1 Each 193

4 762162
Weather Pack Wire Seals for 14-16AWG
Qty: 2 Each 197

5 762153
Weather Pack Pin Terminal 14-16AWG
Qty: 2 Each 151

Service Manual MUCKMASTER LHD Remote Control System

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SERVICE MANUAL

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\\Hlsdow02\e\HLS Manuals\PDF\Service Manual MUCKMASTER LHD Remote Control System.doc

Section One – System Information

Section Two – Bills of Material, Drawings & Schematics

Approved By: Ryan Siggelkow Printed On: 11/26/04 4:07 PM

Approved By: Ryan Siggelkow Printed On: 11/26/04 4:07 PM

HLS HARD-LINE SOLUTIONS INC.

HLS HARD-LINE SOLUTIONS INC. SHALL IN NO EVENT BE LIABLE FOR

Approved By: Ryan Siggelkow Printed On: 11/26/04 4:07 PM

MUCKMASTER control systems can be configured On/Off, proportional, or a combination

This system is made of four basic blocks:

Master Unit contains:

Approved By: Ryan Siggelkow Printed On: 11/26/04 4:07 PM

The component’s specifications following:

900 MHz Radio

• Wireless Medium: Direct Sequence Spread Spectrum Radio

• Built with Aluminum die-cast

Slave Unit contains:

Approved By: Ryan Siggelkow Printed On: 11/26/04 4:07 PM

The component’s specifications following:

900 MHz Radio

• Wireless Medium: Direct Sequence Spread Spectrum Radio

• Built with Polyester

- One Selector Switch c/w contact blocks

Approved By: Ryan Siggelkow Printed On: 11/26/04 4:07 PM

• MUCKMASTER control systems can be configured as On/Off, proportional, or a

• The “MUCKMASTER” is modular and designed for quick installation. A modular

PROGRAMMED SAFETY FEATURES:

Approved By: Ryan Siggelkow Printed On: 11/26/04 4:07 PM

• Drive the LHD to the draw point.

The LHD will shut down if:

RADIO TO MANUAL MODE:

• Bring the LHD to a complete stop near remote operator’s station.

The LHD will shut down if:

Approved By: Ryan Siggelkow Printed On: 11/26/04 4:07 PM

REMOTE CONTROL MODE FUNCTIONS:

Approved By: Ryan Siggelkow Printed On: 11/26/04 4:07 PM

SYSTEM POWER SWITCH SHUTDOWN:

• Switch the Joystick Unit SYSTEM POWER switch to “OFF” position.

JOYSTICK UNIT TILT SHUTDOWN:

FIRE SUPPRESSION SHUTDOWN:

DUAL VALVE BRAKE SYSTEM:

• The MUCKMASTER LHD Radio Remote Control System uses a Dual

PARK BRAKE VALVE:

SERVICE BRAKE VALVE:

• The operating procedures, as outlined by the manufacturers of the RRC

Approved By: Ryan Siggelkow Printed On: 11/26/04 4:07 PM

INDICATOR LIGHTS FOR THE MASTER UNIT (VEHICLE UNIT):

• Power on - Indicates that the voltage is sufficient.

INDICATOR LIGHTS FOR THE SLAVE UNIT (JOYSTICK UNIT):

• Power on - Indicates that the voltage is sufficient. Flashing or cycling lights

Approved By: Ryan Siggelkow Printed On: 11/26/04 4:07 PM

GUIDELINES TO FOLLOW FOR REMOTE CONTROL SAFETY:

a) Always work with SAFETY FIRST in mind at all times.

GUIDELINES TO FOLLOW FOR REMOTE CONTROL CARE:

Approved By: Ryan Siggelkow Printed On: 11/26/04 4:07 PM

MUCKMASTER OPERATOR TRAINING

A) All remote control components are secure

A) The safest way possible

A) Place wheel chocks under the wheel

A) The Joystick and Vehicle Units are operating correctly

A) The Vehicle Unit will only shut off the engine

6. The main purpose of the master unit is to:

* COMMISSIONING EXAMPLE *

* REMOTE SELECT SWITCH FUNCTION TEST *

* PARK BRAKE STATUS INPUT TEST *

* NEUTRAL STATUS INPUT TEST *

* UNATTENDED VEHICLE TIMEOUT TEST *

* JOYSTICK UNIT POWER SWITCH TEST *

* JOYSTICK UNIT TILT SWITCH TEST *

* JOYSTICK UNIT SWITCH CLOSURE TEST *

* CONTROL LINK TEST *

* EMERGENCY STOP TEST *

* DELAYED SHUTDOWN INTERLOCK TEST *

* DELAYED SHUTDOWN FUNCTION TEST *

* UNATTENDED REMOTE TEST *

* REMOTE ENGINE START TEST *

* FIRE SUPPRESSION FUNCTION TEST *