ROTOTILT Komatsu PC210

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Overview

Function Description
Important Technical Specifications
Usage Features
Maintenance Features

This document describes the Rototilt® Control System - ICS, designed for Komatsu excavators including models PC210, PC228, PC240, PC290, and PC360. The system integrates control of the tiltrotator and base machine functions, offering enhanced precision and versatility for various applications.

Function Description

The ICS control system comprises several key components working in conjunction:

Harness, boom: Connects the system, including SecureLock and machine coupler contacts, with safety plugs.
Display: Serves as the primary interface for settings, calibration, and activation of functions. It includes a buzzer to alert the operator to quick coupler locking issues or faults.
Handles with controls: Ergonomically designed handles with switches and rollers to operate both Rototilt® and base machine functions. These are ordered separately and configured according to a sticker on the handle.
Locking cylinder sensor (ICS SecureLock): Monitors the quick coupler's locking status, often accompanied by LED lighting.
Valve block: Manages hydraulic flow, incorporating an electric swivel.
Rototilt® control unit (TCU): Receives signals from the cab control unit and Rototilt® sensors (zero-position and frequency sensors). It sends signals to valves and LED lamps, and includes a sensor for tilt angle detection.
Connection to the base machine control unit: Integrates the ICS with the excavator's main control system.

The system is activated when the base machine is in the ignition position. It allows for proportional and parallel use of tilt, rotation, grapple, and an extra function. ICS operates in parallel with any pedals on the base machine, but it's crucial not to use the base machine's pedals to further increase oil flow when using the Rototilt®, as this can cause serious damage.

Control Unit (CCU and TCU): Both control units have similar appearances but different internal content, making them non-interchangeable. They feature three LEDs (green, orange, red) to indicate status:

PWR (green): Indicates power supply.
CAN (orange): Shows CAN bus communication status.
SYS (red): Confirms correct internal component operation. All LEDs light up without flashing during correct operation; flashing indicates a malfunction. The Cab Control Unit (CCU) receives signals from handles and switches, sending signals to the valve block shunt and tiltrotator via CAN bus. The Rototilt® Control Unit (TCU) receives signals from the CCU and Rototilt® sensors, sending signals to valves and LED lamps. It also detects the tilt angle.

Machine Control: Regulates oil flow to the hydraulic circuit for extra equipment. Roller movements on the handles affect oil flow to the machine's main valve via the control unit.

Rototilt® control: When the 8-pole connector on the stick is connected, flow is regulated parallel to Rototilt® valves, and hydraulic flow is adjusted accordingly, running in one direction only.
Regulation of extra hydraulics: When the base machine operates without Rototilt®, the control can regulate oil flow in the machine circuit for extra hydraulics in both directions.

Quick Coupler Locking Function: This interlocked switch prevents accidental activation. Pressurizing the Rototilt® hydraulic system pressurizes the quick coupler locking function. A connected safety plug prevents accidental opening of the base machine's quick coupler during tiltrotator use. The display shows the quick coupler locking function icon above the green function key. To open, press and release the green function key, then move the switch to the open position within 10 seconds. The lock remains open as long as the switch is held, but pressurization occurs only for a preset time (3-12 seconds). The switch must be toggled off and on again to repressurize the hydraulic cylinder.

Quick Coupler with SecureLock: Operates similarly to the standard quick coupler. A warning is displayed when the locking cylinder is retracted (open position) and a message indicates secure locking when extended. If the tool is not coupled correctly, a warning text appears. Acknowledge the warning by pressing the green function key, then the OK key to stop the buzzer. A visual warning appears every 30 seconds if the Rototilt® runs without a tool.

Quick Coupler QuickChange™: Features three inductive sensors (one per pin, one for locking pistons) that are continuously monitored. Sensors must engage in a specific order; any deviation indicates a sensor fault. If the lock switch is returned to the closed position before the system verifies the tool is in place, a sensor fault is indicated. When closing, pin (1) engages, then pin (2), and finally locking pistons (3). All sensors appear green on the display when a tool is correctly coupled.

Pulse Function: The ICS system can create a pulsating, shaking function, useful for spreading material from a tilting bucket. Activate by pressing the Pulse switch and adjusting speed with the tilt function roller.

Hold Function (Non-variable hydraulic flow, Extra 2): Locks hydraulic flow at a desired level using the Hold switch and the Extra 2 roller. Press and hold the switch for 0.5 seconds. Pressing it again stops the function and flow.

On/Off Function (without tiltrotator):

Pulse function: Starts and closes full flow in one direction.
Hold function: Starts and closes full flow in the other direction. Activated via the Angles menu, requiring confirmation of "On/off Double Feeder" with OK. Only active in this view.

Detach Rototilt®: Park the tiltrotator on a stable, flat surface without tools to prevent tipping. Disconnect hydraulic hoses and harness. If the machine coupler is open while the tiltrotator harness is connected, a warning is shown.

Safety Plug: Locks the machine coupler when the tiltrotator is mounted, preventing accidental opening. Disconnect the Rototilt® contact, remove the safety plug, and connect it to the boom harness contact. Machine coupler control then resumes normal operation.

Operating Extra Hydraulics (without tiltrotator): After detaching the Rototilt®, select "regulation of extra hydraulics" on the display by activating the double valve block shunt and confirming with OK. To return to Rototilt® control, reconnect the tiltrotator, then select "Rototilt® operation" and confirm. Oil flow in the base machine's extra hydraulics circuit can be controlled using a roller or switch, working in parallel with base machine pedals. The tilt function roller regulates flow in both directions.

Hydraulic Thumb: If the excavator has a hydraulic thumb, the ICS system can prevent simultaneous use of the tiltrotator and thumb. The display shows options in the Angles menu; grey text indicates the function cannot be activated. To activate, the tiltrotator's rotation position must be at zero (within <5° margin of error). Visually confirm the angle is 0° relative to the stick. A warning text appears as long as the thumb is activated. Disabling is manual; the thumb must be in its parked position, then confirm with OK.

Automatic Grade Control (AGC): Available with activated RPS and established communication with the excavator system. Controls automatic tilt and rotation functions. Select the Angles menu icon, confirm, then select AGC using arrow keys and confirm. Activate by pressing and holding the button on the right handle (check handle sticker). Only active in this view.

Important Technical Specifications

Control Units: Not interchangeable.
Quick Coupler Pressurization: 3-12 seconds preset time.
Sensor Monitoring (QuickChange™): 3 inductive sensors, continuously monitored for specific engagement order.
Hydraulic Thumb Activation: Requires tiltrotator rotation at 0° (±5° margin).
Harnesses: Specific harnesses for R2-R8 models, including options for oilquick and shunt. Connection T2 must be connected to a separate, non-pressurized return line directly to the tank for X and X HF models.
Electrical Swivel: Max 2 Amp per wire for optional connections in Secure Lock models.

Usage Features

Display Interface: Settings, calibration, and function activation are performed via the display and its keys.
Operator Profiles: Up to 4 profiles (1-4) are available for users, allowing customization of speed, roller direction, and tilt/rotation position. Profile 0 is reserved for installers and cannot be modified by other users.
Speed Adjustment: The speed of all functions can be adjusted generally or individually via the Display's "Speed settings" menu. General speed is not adjustable in profile 0.
Handle Functions: Configurable switches and rollers on the handles control Rototilt® and base machine functions. Roller direction can be changed and confirmed via the menu. A dash above a function indicates inverted direction. The user can toggle tilt and rotation positions, but this should be done as seldom as possible. A warning is displayed upon activation and system start-up if positions are swapped.
System Information: The display provides serial number, software version for each unit (display, CCI, TCU), supply voltage, current time and date (editable), and hours counters for total operation and individual functions (Power on, Rotor, Tilt, Grapple, Extra2).
Double Feeder Mode: Activated after Rototilt® disengagement, controlled by the tilt function roller or pulse/hold switches. Activated via the Angles menu and confirmed with "On/off Double Feeder."

Maintenance Features

Reminder Service: The system displays reminders for maintenance at 8, 40, 160, and 500 hours of operation. The 8-hour reminder is automatically switched off if the ILS option is specified.
Brightness Adjustment: Display brightness can be adjusted using arrow keys and confirmed with OK.
Troubleshooting Menu: Provides three levels of alarm information: Current alarm, Historical alarm, and Alarm log.
- Active Alarms: Shown on the display as a picture or text on the upper bar. Detailed information is available in the Troubleshooting menu.
- Historical Alarms: Previous alarms can be viewed and deleted by the operator.
- Alarm Log: All alarms are saved in a log and cannot be deleted.
Input Signals: The menu shows information about input signals to rollers, shut-off levers, and switches. Non-calibrated rollers are red and show voltage (V) instead of percent (%).
Output Signals: The menu shows the current for each output signal.
Calibrate Angles: To ensure correct angle display, the system must be calibrated with the correct bucket. Rotate the bucket to zero position, flatten the bucket bottom against the surface, then highlight the save icon and confirm. This calibration is performed by an authorized installation engineer if RPS is installed.