Black Tip Operation Manual
Contents
1. 9 Maximum Fim Molise qud 9 Using the PC to Set the Maximum Voltage 9 Upload and Store the Trim and Settings tere MS PARS 10 Downloading Trim and Settings Backup Copy 10 Using Stored Trims and Settings Restore Settings 10 Optional Hoist Limit with optional override or lockout seen 10 System Self Diagnostics and Troubleshooting enne 11 POY SUCK Check durne Start uot tuba dtu used dad 11 Joystick failure during operation SafeStik Blinks Slow 11 Shorted or Open Circuit on Output channels Blinks 11 Trouble Shooting Guide 52 ee ee Ae t t e tere dece CR ae e Ede 12 Appendix A Spare parts list ei e etia sert ta iion e qa tous 12 Appendix B Glossary of Plow Control Terms 13 Appendix C Standard and Optional System Drawings2. PLOW LEFT LT WING OUT PLOW LEFT SLIDE IN AUGER REV GRAY J4 HOIST UP HOIST UP HOIST UP BLADE UP PRE WET RED J6 GND GND GND GND GND GREEN YELLOW AUGER RT WING OUT TOE UP BLADE LEFT NOT USED VIOLET J8 Ci ru S 9200 Wyoming Ave N Suite 320 Brooklyn Park MN 55445 Tel 763 493 9380 C on t ro Fax 763 493 9340 Rev Date DESCRIPTION BLACK TIP CABLES 12 30 09 THIS DRAWING IS THE PROPERTY OF CIRUS CONTROLS l THIS IS TO BE CONSIDERED CONFIDENTIAL AND NO VALVE JUNCTION BOX 8 PORT REPRODUCTION IN WHOLE OR PART WITH OUT ee L E S gt 2 0 3 1 PERMISSION IS ALLOWED DESIGN DRAWN AS BUILT PROJECT NUMBER pare 4 16 08 JTM JTM TS 2031 smior B B O M EuroFast 4 SIG Female Pins Female Threads PART NUMBER 8MB12Z 4P2 5 39 01 2100 39 00 0039 39 01 2020 10 PIN MOLEX PIN 10 5 4 3 2 2 PIN MOLEX PIN 2 2 PIN MOLEX PIN 2 NOTES DESCRIPTION BACK VIEW SIDE PINS ARE INSERTED FROM BT110 210 STD BT108HOOK 108 V PLOW PLOW DOWN PLOW DOWN PLOW DOWN PLOW RIGHT PLOW RIGHT LT WINGIN HOIST DOWN HOIST DOWN HOIST DOWN GND GND GND PLOW UP
3. THIS IS TO BE CONSIDERED CONFIDENTIAL AND NO TRUCK WIRING REPRODUCTION IN WHOLE OR PART WITH OUT PERMISSION IS ALLOWED JM DRAWN iS x 5 SCA
4. 13 Rev F Page 2 1 21 2010 Copyright 2010 by Cirus Controls LLC All Rights Reserved No part of this material may be reproduced without the express written permission of Cirus Controls LLC for each reproduction Limited Warranty Cirus Controls LLC What and who is covered This warranty covers all defects in materials or workmanship in your Cirus Controls system under normal use maintenance and service This warranty coverage applies only to the original owner and is not transferable How long is the warranty period This warranty coverage runs for a period of 1 year from the date of initial installation or 13 months from date of shipment from Cirus Controls whichever occurs first Replacement parts are warranted for the remaining portion of the original warranty period or thirty 30 days from date of shipment from our factory whichever is greater How can you get service Cirus Controls obligation under this warranty is limited to repairing and or replacing at Cirus Controls option any part or parts that are determined by Cirus Controls to be defective To be eligible for any claim under this warranty the owner or Cirus authorized dealer must return any defective part s to the factory within the applicable warranty period as set out above What will we do Cirus Controls may at its option elect to grant adjustments in the field through an authorized representative and may thereby elect to waive the
5. FLY LEADS PLACE SPLIT LOOM AS 1 CLOSE TO WAGO CONNECTOR AS POSSIBLE NOTES 1 LABEL WIRE WITH SIGNAL NAME EVERY 12 INCHES i rus 0 Wyoming Ave N Sulte 320 pone Controls Fax 763 493 9340 BLACK TIP ONE TON THIS DRAWING IS THE PROPERTY OF CIRUS THIS IS TO BE CONSIDERED CONFIDENTIAL EXTERNAL SWITCH WIRING REPRODUCTION IN WHOLE OR PARTWITHOUT inasre PERMISSION IS ALLOWED pss OF 58 PROJE x B O M Female Pins PART NUMBER DESCRIPTION Female Threads or Coupling Nut 5 GND 8MB12Z 4P2 5 8 TERMINAL TURCK BOX 15 CABLE 39 01 2100 MOLEX RECEPTACLE 10 PIN Digi Key WM3704 ND 39 00 0039 MOLEX TERMINALS FEMALE 18 24 AWG Digi Key WM2501 ND 3 GND BACK VIEW SIDE PINS ARE INSERTED FROM MOLEX PIN 108 HYD 210 HYD II HYDA MAKO II HYD B SPREADER COLOR PORT 10 PLOW DOWN PLOW DOWN PLOW DOWN HEEL DOWN SPINNER FWD WHITE J1 9 PLOW RIGHT LT WING IN PLOW RIGHT SLIDE OUT SPINNER REV YELLOW 06 NER TO MAIN CAES 8 HOIST DOWN HOIST DOWN HOIST DOWN BLADE DOWN PINK J5 7 GND GND GND GND GND BLUE SPINNER RT WING IN TOE DOWN BLADE RIGHT NOT USED BLACK J7 PLOW UP PLOW UP PLOW UP HEEL UP AUGER FWD GREEN J2
6. PLOW LEFT HOIST UP GND PLOW UP PLOW UP PLOW LEFT LT WING OUT HOIST UP HOIST UP GND GND SPINNER HOIST RIGHT RT WING IN AUGER HOIST LEFT RT WING OUT or Coupling Nut 8 TERMINAL TURCK BOX 15 CABLE MOLEX RECEPTACLE 10 PIN MOLEX TERMINALS FEMALE 18 24 AWG MOLEX RECEPTACLE 2 PIN BACK VIEW SIDE PINS ARE INSERTED FROM COLOR PORT WHITE 1 YELLOW J3 PINK J5 BLUE GREEN J2 GRAY J4 RED J6 GREEN YELLOW BLACK J7 VIOLET or ORANGE J8 1 WIRE COLORS MAY CHANGE SO ALWAYS GO OFF OF MOLEX PIN NUMBERS AND J PORT NUMBERS CABLE TS 2032 THIS DRAWING IS THE PROPERTY OF CIRUS CONTROLS THIS IS TO BE CONSIDERED CONFIDENTIAL AND NO REPRODUCTION IN WHOLE OR PART WITH OUT PERMISSION IS ALLOWED 3 GN 1 5 GND 2 5 WIRES USED SHOULD TRIMED BACK AND HEAT SHRUNK TO MAIN CABLE LABEL CABLE TS 2032 9200 Wyoming Ave N Suite 320 Brooklyn Park MN 55445 Cirus Tel 763 493 9380 C on t ro Fax 763 493 9340 R amp V T DE 1 BLACK TIP CABLES e gt gt added spinner and auger 2pm opion j j VALVE JUNCTION BOX 8 PORT DESIGN DRAWN AS BUILT PROJECT NUMBER pare 9 28 08 REV UM VM E P mz EE Tor WIRING DIAGRAM B O M PART NUMBER DESCRIPTION WS 4T 5 M12 90 degree connector and cable 38043
7. Irus ONTROLS Black Tip BT 108 BT 210 BT 310 Operation Manual Rev F Page 1 1 21 2010 Copyright 2010 by Cirus Controls LLC All Rights Reserved No part of this material may be reproduced without the express written permission of Cirus Controls LLC for each reproduction Limited Warranty zx tree a esee ama reete 3 Revision level of thiszanual oe S ehe s ene er vee 4 Package Contents ua eee tere eee ete o 4 Functional ec Ee HERREN HAERES EE 4 Pre Delivery System Setup Checklist 5 Step ls Installing the control unit eiie tte eed 5 Connecting the Cabling aig cities seas S D 5 Step 2 Testing the signal outputs uu u u n 6 5tep 3 Configure the JoystiCk iu oie ead e RR re hie e oe Per AM 6 Joystick Protection and Failure Diagnos s 6 SYSTEMIC OMTMSUTATION 6 Step 4 Set Up for Operation Trimming 7 Instructions Tor Sette l S an SS l S SASS a u SG 7 Glebal Trims Dabiy n la RR Orestes i gte 8 Test and Set Trims for Each 8 61 5 l a Di tasa aus nns 9 Using the PC to Identify the Minimum Voltage
8. BLACK WIRE FROM TS 2100 AUGER REV OR HOIST LIMIT MOLEX PIN SIGNAL NOT USED B O M PART NUMBER DESCRIPTION Bi10 M30 VP4X H1141 PROX SENSOR FOR MONITORING HOIST LIMIT TS 2101 20FT CABLE FROM CAB TO SENSOR TS 2100 10 FT IN CAB CABLE 595 2 2 PIN MOLEX PLUG WITH LOCK 39 01 2060 OR WM3702 ND 6 PIN MOLEX PLUG WITH LOCK 39 00 0039 OR WM2501 ND MOLEX SOCKETS FOR PLUGS METAL SENSING PLATE AS TRUCK BODY MOVES UP THE PLATE GOES WITH IT UNTIL MAX ANGLE IS ACHIEVED PROX SENSOR MOUNTED AT BACK OF TRUCK 0 394 CONNECT ORANGE WIRE TO THE 2 PIN MOLEX ADD DIELECTRIC GREASE TO ALL THREADED FITTINGS SENSOR HAS A MAX SENSING RANGE OF 394 INCHES IF PLATE IS FURTHER THEN THAT AWAY FROM THE SENSOR IT WILL NOT SEE IT TYPICAL SETUP THIS CIRCUIT WILL ALLOW THE HOIST TO GO UP AND DOWN AS LONG AS THE SENSOR SIGNAL WIRE IS 12 VDC AS SOON AS THE SIGNAL WIRE GOES TO GROUND THE HOIST WILL NO LONGER BE ABLE TO GO UP BUT STILL WILL BE ABLE TO BE LOWERED IF A KEY SWITCH IS ADDED AND THE SIGNAL LINE IS BROKEN HOIST OVERRIDE DISABLED POSITION THE HOIST WILL REMAIN ENABLED AT ALL TIMES SIGNAL ORANGE WIRE FROM TS 2100 HOIST LIMIT SENSOR CIRCUIT C i TUS Ave N Suite 200 p Park MN 55445 493 9380 Co ntro 5 493 9340 LIMIT OVERRIDE CIRCUIT BLACK TIP THIS DRAWING IS THE PROPERTY OF CIRUS CONTROLS THIS IS TO BE CONSIDERED CONFIDENTIAL AND NO
9. 15pt font M12 MATES TO SENSOR BOX 4MB12 4P2 ru S 9200 Wyoming Ave N Suite 320 Brooklyn Park MN 55445 Tel 763 493 9380 Co n t ro Fox 763 493 9340 REV DATE DESCRIPTION ROSES HEAT SHRINK NOTE SPREADER CABLE SYSTEM a THIS DRAWING IS THE PROPERTY OF CIRUS CONTROLS THIS IS TO BE CONSIDERED CONFIDENTIAL AND NO M12 TO AMP JR Timer REPRODUCTION IN WHOLE OR PART WITH OUT PERMISSION IS ALLOWED Em AS BUILT PROJECT NUMBER DATE 3 16 05 3 16 05 oare 3 16 08 177 JIM B O M PART NUMBER DESCRIPTION M12 90 degree connector and cable 282080 1 AMP Superseal 1 5 RECEPTACLE 183025 1 FEMALE TERMINAL for Superseal 1 5 281934 2 18 AWG SEAL for Superseal 1 5 WIRING DIAGRAM ADD DIELECTRIC TO BACK OF CONNECTOR AND HEAT SHRINK USING DUAL WALL POLYOLEFIN Label Placement Notes 18 AWG 2 Conductor cable Label to be white w black printing and located on cable per drawing mylar w clear cover all caps 15pt font MI2 MATES TO SENSOR BOX 4MB12 4P2 ru S 9200 Wyoming Ave N Suite 320 Brooklyn Park MN 55445 Tel 763 493 9380 Co n t ro 5 Fax 763 493 9340 REV DATE DEscRPTION sess mae ERT saei None SPREADER CABLE SYSTEM i THIS DRAWING IS THE PROPERTY OF CIRUS CONTROLS THIS IS TO BE CONSIDERED CONFIDENTIAL AND NO M12 TO AMP PLUG REPRODUCTION IN
10. SIGNAL C2 CONNECTOR PIN 2 DRIVE BLACK 18 AWG 1 RETURN WHITE 18AWG THIS DRAWING IS THE PROPERTY OF CIRUS CONTROLS THIS IS TO BE CONSIDERED CONFIDENTIAL AND DESCRIPTION MOLEX RECEPTACLE 2 PIN MOLEX TERMINALS FEMALE 18 24 AWG 18 AWG 2 COND SVO CABLE or SIMILAR SURESEAL BOOT SURESEAL RECEPTACLE SURESEAL TIN SOCKET SURESEAL TIN PIN CIRUS 5 55 CONTROLS LLC 9200 WYOMING AVE N SUITE 320 BROOKLYN PARK MN 55445 REV 7 SWORDFISH SPREADER CABLE SYSTEM fT EZ SPREAD HYDRAULIC CABLE poera ay PROPRIETARY NO REPRODUCTION IN WHOLE OR PART DESIGN DRAWN AS BUILT PROJECT NUMBER 12 20 04 WITH OUT PERMISSION IS ALLOWED er 5521002 SHT 1 OF 1 E B O M QTY PARTNUMBER DESCRIPTION 1 39 01 2020 MOLEX RECEPTACLE 2 PIN 2 39 00 0039 MOLEX TERMINALS FEMALE 18 24 AWG 18 FT 777 18 AWG 2 COND SVO CABLE or SIMILAR 1 38043 WAYTEK WEATHERPAK 2 PIN TOWER HALF 2 30035 WAYTEK TOWER TERMINALS 20 18 AWG 2 39000 WAYTEK WEATHERPAK WIRE SEALS MOLEX PIN SIGNAL AMP CONNECTOR PIN 1 RETURN WHITE 18AWG 2 DRIVE BLACK 18 AWG BACK VIEW SIDE PINS ARE INSERTED FROM C IRUS Pror 63 405030 9200 WYOMING AVE N SUITE 320 BROOKLYN PARK MN 55445 P L J SWORDFISH SPREADER CABLE SYSTEM THIS DRAWING IS THE PROPERTY OF CIRUS CONTROLS THIS IS TO BE CONSIDERED CONFIDENTIAL AND EZ SPREAD HYDRAULIC
11. waytek weatherpack 2 pin tower half 30035 waytek tower terminals 20 18 awg 39000 waytek weatherpack seals ADD DIELECTRIC TO BACK OF CONNECTOR AND HEAT SHRINK USING DUAL WALL POLYOLEFIN THEN ZIP TIE Label Placement Notes 18 AWG 2 Conductor cable Label to be white w black printing and located on cable per drawing mylar w clear cover all caps 15pt font MI2 MATES TO SENSOR BOX 4MB12 4P2 Ci ru s 9200 Wyoming Ave N Suite 320 Brooklyn Park MN 55445 Tel 763 493 9380 Co n t ro Fox 763 493 9340 Rev DATE DESCRIPTION 3 16 05 ADDED HEAT SHRINK AND DIELECTRIC NOTE SPREADER CABLE SYSTEM 2 THIS DRAWING IS THE PROPERTY OF CIRUS CONTROLS THIS IS TO BE CONSIDERED CONFIDENTIAL AND NO M12 TO WEATHERPACK REPRODUCTION IN WHOLE OR PART WITH OUT TS 2 0 1 PERMISSION IS ALLOWED esn AS BUILT PROJECT NUMBER DATE 3 16 05 3 16 05 PE JTM 15 2010 MP TUE WIRING DIAGRAM B O M PART NUMBER DESCRIPTION 222 M12 90 degree connector and cable 282189 1 AMP Junior Timer RECEPTACLE 929930 3 FEMALE TERMINAL for AMP Junior Timer 828905 1 18 AWG SEAL for AMP Junior Timer ADD DIELECTRIC TO BACK OF CONNECTOR AND HEAT SHRINK USING DUAL WALL POLYOLEFIN Label Placement Notes 18 AWG 2 Conductor cable Label to be white w black printing and located on cable per drawing mylar w clear cover all caps
12. Black Tip plow control The red bar that says waiting for link will turn green At this point the PC has uploaded the current configuration in the Black Tip and now controls the Black Tip plow control Global Trims Tab 1 1 File View Datalink Help Plow Hoist Hook System Mode r Global Trims Frequency 5 All Hydraulics a gt Min Enable Saftey Triggers Joystick 1 Hoist Hook Joystick 2 Plow Joystick 3 Wing Valve types x Enable Plow Float Enable Hoist Limit Set All Trims Cartridge valve control for open center systems Henke V plow with attitude control toggle V plow modes of running lift or wings NOTE Once enabled the hoist up will only operate if 12v is applied to the Hoist limit input no voltage is applied the hoist will not go up mee M emen em Rev F Page 8 1 21 2010 Copyright 2010 by Cirus Controls LLC Rights Reserved No part of this material may be reproduced without the express written permission of Cirus Controls LLC for each reproduction This screen is used for setting the coil type coil frequency and setting all the trims to be the same with the global trim sliders Use the slider to select the voltage desired and then selects set all trims to apply those values to all channels on the system Test and Set Trims for Each Channel If wish to set trims i
13. Controls LLC Rights Reserved No part of this material may be reproduced without the express written permission of Cirus Controls LLC for each reproduction 3 Final setting will depend on the desired maximum speed you seek Observe the speed at several Max settings and choose the speed that meets your needs 4 To set the next channel independently select the tab for the next implement and repeat Upload and Store the Trim and Settings Once all the trims are set to the users liking they must be uploaded to the Black Tip box by clicking the Send Cal button NOTE TRIMS ARE NOT UPDATED OR SAVED IN THE SYSTEM UNTIL THE SEND CAL BUTTON IS PRESSED This file can also be saved on the PC by clicking the file menu and saving the configuration When the PC is connected to a printer the numerical values can be printed for your records Downloading Trim and Settings Backup Copy In the event you wish to download the trim setting from a Black Tip box Connect the PC as before and simply press Get Cal button Save the new file on your PC Using Stored Trims and Settings Restore Settings You may use a settings file on your PC to upload an existing configuration to Black Tip Connect the PC to the Black Tip plow control as before and click on Send Cal The Black Tip plow control now is configured with the settings from the stored file Optional Hoist Limit with optional override or lockout Black
14. EXTERNAL WIRING REPRODUCTION IN WHOLE OR PART WITH OUT PERMISSION IS ALLOWED DRAWN Ss BU NUUBEI 428 07 n B O M PART NUMBER DESCRIPTION HYD10001 LOW OIL SHUTOFF MANIFOLD WITH E COIL METRI PACK CONNECTOR 625 2 POSITION FEMALE METRI PACK 150 CONNECTOR ASSEMBLY 6251 TPA LOCKING PART FOR METRI PACK 150 6252 FEMALE TERMINALS FOR METRI PACK 150 6253 SEALS FOR METRI PACK 150 1018 INDICATOR PANEL FOR LENS 1032 LOW OIL LENS 1020 MOMENTARY OFF SWITCH O N gt LOW OIL INDICATOR MOUNTED IN CAB OPTIONAL HYDRAULIC PUMP HYDRAULIC LINES LOW OIL SHUTOFF FROM TANK MANIFOLD BOLTED TO TO PUMP PUMP MOMENTARY CONNECT TO HER in COIL COIL 12VDC SOURCE EE GND 12VDC OPTIONAL HYDRAULIC TANK SWITCH OUT LOW LEVEL SWITCH N O SWITCH IN THIS CIRCUIT WILL SHUT DOWN THE FLOW OF HYDRAULIC FLUID WHEN ITS LEVEL REACHES THE LOW SETTING IN THE TANK WHEN THE LOW LEVEL IS REACHED A LIGHT WILL COME ON INDICATING LOW OIL AND AT THE SAME TIME ENGAGE THE LOW OIL MANIFOLD TO PROTECT THE PUMP A MOMENTARY OFF SWITCH CAN BE ADDED TO THE SYSTEM TO ALLOW THE DRIVER TO TEMPORARILY DISABLE THE Cirus Sute 200 Brooklyn Park MN 55445 PROTECTION TO MOVE AN IMPLEMENT 763 493 9380 Controls Fax 763 493 9340 ev LOW OIL SHUTOFF WITH OVERRIDE OPTION E THIS DRAWING IS THE PROPERTY OF CIRUS CONTROLS
15. HOLDER SWITCH 3 POWER YELLOW 18 AWG 20 ft SWITCH 3 OUTPUT RED 18 AWG 208 WAYTEK 46026 10 AMP IN LINE FUSE HOLDER COVER WAYTEK 46256 10 AMP FUSE SWITCH 4 POWER BLUE 18 AWG 20 ft SWITCH 4 OUTPUT RED 18 AWG 20 ft SWITCH 5 POWER WHITE 18 AWG 20 ft SWITCH 5 OUTPUT RED 18 AWG 20 ft SWITCH 6 POWER GREY 18 AWG 20 ft SWITCH 6 OUTPUT RED 18 AWG 20 ft GROUND BLACK 18 AWG 20 ft O O4 QN 2 oO TOP VIEW WIRES INSERTED FROM 3 4 5 2 FLY LEADS LABEL CABLE WITH PM 1001 ON SPLIT LOOM N N Co N PLACE SPLIT LOOM AS CLOSE TO WAGO CONNECTOR AS POSSIBLE 1 NOTES 1 LABEL WIRE WITH SIGNAL NAME EVERY 12 INCHES Cirus Tx Tel 763 493 9380 Co nt ro 6 763 493 9340 PEDESTAL MOUNT THIS DRAWING IS THE PROPERTY OF CIRUS CONTROLS Rev ow THIS IS TO BE CONSIDERED CONFIDENTIAL AND NO EXTERNAL SWITCH WIRING REPRODUCTION IN WHOLE OR PART WITH OUT PERMISSION IS ALLOWED DESIGN DRAWN lt BU NUMBEI SCALE PIN SIGNAL LENGTH B M Y INDICATOR 1 BROWN 18 AWG 10 PART NUMBER DESCRIPTION INDICATOR 2 PINK 18 AWG 10 1 231 605 019 000 5 PIN WAGO BULKHEAD RECEPTACLE INDICATOR S ORANGE 18 AWG 10 8 5 2004 FEMALE SPADES FOR SPRAGUE PLUGS INDICATOR 4 BLUE 18 AWG 10 40 4 SP913 328 SPRAGU
16. WHOLE OR PART WITH OUT PERMISSION IS ALLOWED Em AS BUILT PROJECT NUMBER DATE 3 16 05 3 16 05 05 16 05174 JIM 19 le B O M PART NUMBER DESCRIPTION 222 M12 connector and cable 317 1398 000 SURESEAL BOOT 120 1804 000 SURESEAL RECEPTACLE 031 1267 001 SURESEAL TIN SOCKET 030 2196 001 SURESEAL TIN PIN WIRING DIAGRAM ADD DIELECTRIC TO BACK OF CONNECTOR AND HEAT SHRINK USING DUAL WALL POLYOLEFIN Label Placement 24 Notes 18 AWG 2 Conductor cable Label to be white w black printing and located on cable per drawing mylar w clear cover all caps 15pt font MI2 MATES TO SENSOR BOX 4MB12 4P2 ru S 9200 Wyoming Ave N Suite 320 Brooklyn Park MN 55445 Tel 763 493 9380 Co n t ro 5 Fax 763 493 9340 REV DATE DEscRPTION sess mae ERT saei None SPREADER CABLE SYSTEM i THIS DRAWING IS THE PROPERTY OF CIRUS CONTROLS THIS IS TO BE CONSIDERED CONFIDENTIAL AND NO M12 TO ITT CANNON PLUG REPRODUCTION IN WHOLE OR PART WITH OUT PERMISSION IS ALLOWED Em AS BUILT PROJECT NUMBER DATE 3 16 05 3 16 05 oare 5 16 06 4 JIM 19 2015 DIN 43650 FEMALE WIRING DIAGRAM NOTES 1 INDICATES CABLE LENGTH IN METERS CONTACT TURCK TO ORDER SPECIFIC LENGTHS FX DRAWING RELEASE MALE END VIEW SKETCH ONLY SPECIFICATIONS CONTACT MATERIAL PLATING EU
17. included with system Double Acting Float 2 pin Molex connector used for controlling dump valve for plow lift Cables ordered separately Cartridge Valve 2 pin Molex connectors used for controlling system unloader valve Cables ordered separately Auger Spinner Pre wet 2 pin Molex connectors for hydraulic outputs for spreader auger reverse and pre wet Cables ordered separately Aux Input input port for hoist limit and other sensors optional cable required Speedo Port 4 pin Molex connector for TS 2004 cable for use with Ground Speed Oriented controllers optional Sensor Port 6 pin Molex connector for use with TS 2000 sensor input cable system or Hoist lockout key switch Optional cable required Pre Delivery System Setup Checklist Description Completed By Date Step 1 Install System and connect cables Step 2 Test the Signal Outputs Step 3 Configure the Joystick Step 4 Trim hydraulics for all axes of motion Step 1 Installing the control unit The Black Tip control unit may be mounted on a pedestal using the PEM nuts provided on the base of the unit or inserted into the optional padded console for a bench seat Do not mount the control unit with the cable end facing up Connecting the cabling Note Modification of any factory wiring in the joystick pod arm unit Black Tip unit or drilling holes in any of the sheet metal housings voids the product warranty 1 Verify that power s
18. 12 VDC RED 18AWG MOLEX PIN SIGNAL AUGER REV GREEN 18AWG AUGER BLUE 18AWG PRE WET WHITE 18AWG SPINNER ORANGE 18AWG NOT USED NOT USED MOLEX PIN SIGNAL GROUND WHITE 18AWG REMOTE PASS BLUE 18AWG SPEEDO IN GREEN 18AWG REMOTE BLAST ORANGE 18AWG MOLEX PIN SIGNAL GROUND BLACK 18AWG NOT USED SPINNER SENSOR GREEN 20AWG POWER BROWN 18 AWG PREWET SENSOR YELLOW 20 AWG AUGER SENSOR WHITE 20AWG LE E ZIP TIE ALL 4 TOGETHER IN CENTER AND LABEL BT 2003 9210 Wyoming Ave N Suite 200 Brooklyn Park MN 55445 Cirus Controls Fax 053 439340 BLACK TIP ONE TON THIS DRAWING IS THE PROPERTY OF CIRUS CONTROLS THIS IS TO BE CONSIDERED CONFIDENTIAL AND NO EZ DS amp SPREAD DR INTERNAL JUMPER REPRODUCTION IN WHOLE OR PART WITH OUT PERMISSION IS ALLOWED 12 10 09 Ee B O M PIN SIGNAL LENGTH PARTNUMBER DESCRIPTION 231 640 019 000 10 PIN WAGO BULKHEAD RECEPTACLE CH AW S SPC 2004 FEMALE SPADES FOR SPRAGUE PLUGS SWITCH 2 POWER GREEN 18 AWG SP596 289 SPRAGUE PLUG FOR SWITCH _ SP913 328 SPRAGUE PLUG FOR LIGHT SWITCH 3 POWER NEL 18 AW LCP 413 SPLIT LOOM SWITCH 3 OUTPUT RED 18 AWG GROUND BLACK 18 AWG NOT USED SWITCH 4 OUTPUT RED 18 AWG SWITCH 4 POWER PURPLE 18 AWG O Q N 3 LABEL SWITCH 1 TOP VIEW WIRES INSERTED FROM
19. 46256 10 AMP FUSE PIN SIGNAL LENGTH SWITCH 1 POWER ORANGE 18 AWG 20 ft SWITCH 1 OUTPUT RED 18 AWG 20 ft SWITCH 2 POWER GREEN 18 AWG 20 ft SWITCH 2 OUTPUT RED 18 AWG 20 ft SWITCH 3 POWER YELLOW 18 AWG 20 ft SWITCH 3 OUTPUT RED 18 AWG 20 ft GROUND BLACK 18 AWG 20 ft INDICATOR 1 BLUE 18 AWG 20 ft INDICATOR 2 PURPLE 18 AWG 20 ft INDICATOR 12 VDC RED 18 AWG 20 ft SFOONODOARWN 0 N o TOP VIEW WIRES INSERTED FROM L 2 N N FLY LEADS LABEL CABLE WITH BT 1001 ON SPLIT LOOM PLACE SPLIT LOOM AS 1 CLOSE TO WAGO CONNECTOR AS POSSIBLE NOTES 1 LABEL WIRE WITH SIGNAL NAME EVERY 12 INCHES i rus 0 Wyoming Ave N Sulte 320 posten Controls Fax 763 493 9340 3 CA ADDED CABLE NUMBER To CABLE BLACK TIP ONE TON THIS DRAWING IS THE PROPERTY OF CIRUS Lc THIS IS TO BE CONSIDERED CONFIDENTIAL A 5 TERNAL INDICATOR AND SWITCH WIRING jin m B DATE 7 15 05 oq EAE NUBE 87 1001 PART NUMBER 39 01 2040 OR WM3701 ND 39 01 2020 OR WM3700 ND DESCRIPTION 4 PIN MOLEX PLUG WITH LOCK 2 PIN MOLEX WITH LOCK BACK VIEW SIDE PINS ARE INSERTED FROM BACK VIEW SIDE PINS ARE INSERTED FROM MOLEX PIN SIGNAL GROUND BLACK 18AWG 12 VDC RED 18AWG GROUND BLACK 18AWG 12 VDC RED 18AWG a LAB
20. CABLE PROPRIETARY NO REPRODUCTION IN WHOLE OR PART g 888 Tas AS BUILT PROJECT NUMBER 01 07 05 WIRING DIAGRAM B O M ITEM QTY PART NUMBER DESCRIPTION 1 WS 4T 5 M12 90 degree connector and cable 38201 waytek FEMALE METRI PACK 150 2 pin 31077 waytek FEMALE TERMINALS 16 18 AWG 38202 waytek TPA LOCK 39006 waytek CABLE SEALS ADD DIELECTRIC TO BACK OF CONNECTOR AND HEAT SHRINK USING DUAL WALL POLYOLEFIN THEN ZIP TIE Label Placement Notes 18 AWG 2 Conductor cable Label to be white w black printing and located on cable per drawing mylar w clear cover all caps 15pt font M12 MATES TO SENSOR BOX 4MB12 4P2 C i r u S 9200 Wyoming Ave N Suite 320 Brooklyn Park MN 55445 Tel 763 493 9380 Co ntro 763 493 9340 RV DAE DESCRIPTION SPREADER CABLE SYSTEM THIS DRAWING IS THE PROPERTY OF CIRUS CONTROLS THIS IS TO BE CONSIDERED CONFIDENTIAL AND NO M12 TO METRI PACK 150 REPRODUCTION IN WHOLE OR PART WITH OUT TS 2 0 1 T PERMISSION IS ALLOWED 566 E AS BUILT PROJECT NUMBER pare 8 2 06 JIM 15 2017 PIN SIGNAL LENGTH B M QTY 13 SWITCH 1 POWER ORANGE 18 AWG 10 QTY PARTNUMBER DESCRIPTION 12 SWITCH 1 OUTPUT RED 18 AWG 10 1 231 643 019 000 13 PIN WAGO BULKHEAD RECEPTACLE 11 SWIICH So WER GREEN 18 AWG 10 24 5 2004 FEMALE SPADES FOR SPRAGUE PLUGS 10 SWITCH 2 OUTPUT EM 10 6 SP596 289 SPRAGUE PLU
21. E PLUG FOR LIGHT GROUND OR POWER RED 18 AWG LCP Aiz SPLITLOOM TOP VIEW WIRES INSERTED FROM LABEL INDICATOR 1 LABEL INDICATOR 2 LABEL INDICATOR 3 LABEL INDICATOR 4 LABEL SPLIT LOOM WITH PM 1002 PLACE 6 OF SPLIT LOOM AS CLOSE TO WAGO CONNECTOR AS POSSIBLE Ci rus 9200 Wyoming Ave N Suite 320 Brooklyn Park MN 55445 3 493 9380 Tel 763 Co n t ro Fax 763 493 9340 PEDESTAL MOUNT THIS DRAWING IS THE PROPERTY OF CIRUS CONTROLS Rev par THIS IS TO BE CONSIDERED CONFIDENTIAL AND NO INDICATOR WIRING uS REPRODUCTION IN WHOLE OR PART WITH OUT PERMISSION IS ALLOWED DESIGN DRAWN S BU PROJECT NUMBET SCALE B O M QT PART NUMBER DESCRIPTION 231 305 037 000 5 PIN WAGO PLUG WITH LOCKING TABS LCP 413 SPLIT LOOM WAYTEK 46025 10 AMP IN LINE FUSE HOLDER WAYTEK 46026 10 AMP IN LINE FUSE HOLDER COVER WAYTEK 46256 10 AMP FUSE PIN SIGNAL LENGTH O4 QN 2 INDICATOR 1 BROWN 18 AWG 20 ft INDICATOR 2 PINK 18 AWG 20 ft INDICATOR 3 ORANGE 18 AWG 20 ft INDICATOR 4 BLUE 18 AWG 20 ft GROUND OR POWER RED 18 AWG 20 ft TOP VIEW WIRES INSERTED FROM 2 FLY LEADS LABEL CABLE WITH PM 1003 ON SPLIT LOOM PLACE SPLIT LOOM AS CLOSE TO WAGO CONNECTOR AS POSSIBLE NOTES 1 LABEL WIRE WITH SIGNAL NAME EVERY 12 INCHES Cirus cin Co ntrols Fax 763 493 9340 PEDESTAL MOUNT THIS DRAWING IS THE PROPERTY OF CIRUS CONTROLS oW CEJ THIS I
22. ED CONFIDENTIAL AND NO REPRODUCTION IN WHOLE OR PART WITH OUT DS amp SPREAD DR INTERNAL JUMPER PROJECT NUM BACK VIEW SIDE PINS ARE INSERTED FROM BACK VIEW SIDE PINS ARE INSERTED FROM MOLEX PIN SIGNAL GROUND BLACK 18AWG 12 VDC RED 18AWG GROUND BLACK 18AWG 12 VDC RED 18AWG MOLEX PIN SIGNAL AUGER REV GREEN 18AWG AUGER BLUE 18AWG PRE WET WHITE 18AWG SPINNER ORANGE 18AWG MOLEX SIGNAL GROUND WHITE 18AWG REMOTE PASS BLUE 18 AWG SPEEDO IN GREEN 18AWG REMOTE BLAST ORANGE 18 AWG BACK VIEW SIDE PINS ARE INSERTED FROM MOLEX PIN SIGNAL GROUND BLACK 18AWG NOT USED SPINNER SENSOR GREEN 20AWG POWER BROWN 18 AWG PREWET SENSOR YELLOW 20 AWG AUGER SENSOR WHITE 20AWG BACK VIEW SIDE PINS ARE INSERTED FROM CABLE BT 2003 IN LABEL SPDR PWR LABEL SPDR HYD LABEL SPDR GND SPD LABEL SPDR SENSOR 18 long between molex connectors E 3 PART NUMBER 39 01 2040 OR WM3701 ND 39 01 2060 OR WM3702 ND 39 00 0039 OR WM2501 ND 39 01 2041 OR WM3601 ND 39 01 2061 OR WM3602 ND 39 00 0041 OR WM2500 ND DESCRIPTION 4 PIN MOLEX PLUG WITH LOCK 6 PIN MOLEX PLUG WITH LOCK MOLEX SOCKETS FOR PLUGS 4 PIN MOLEX RECEPTICAL 6 PIN MOLEX RECEPTICAL MOLEX PINS FOR RECEPTICAL MOLEX SIGNAL GROUND BLACK 18AWG 12 VDC RED 18AWG GROUND BLACK 18AWG
23. EL SPDR HYD MOLEX PIN SIGNAL 1 NOT USED 2 AUGER BLUE 18AWG 3 PRE WET WHITE 18AWG 4 SPINNER ORANGE 18AWG MOLEX PIN SIGNAL GROUND BLACK 18AWG NOT USED SPEEDO IN GREEN 18AWG NOT USED CABLE BT 1002 39 00 0039 OR WM2501 ND MOLEX SOCKETS FOR PLUGS LABEL SPDR PWR MOLEX PIN SIGNAL GROUND BLACK 18AWG 12 VDC RED 18AWG GROUND BLACK 18AWG 12 VDC RED 18AWG LABEL AUGER MOLEX PIN SIGNAL 2 AUGER BLUE 18 AWG 1 NOT USED LABEL PREWET MOLEX PIN SIGNAL 2 PREWET WHITE 18 AWG 1 NOT USED MOLEX PIN SIGNAL 2 SPINNER ORANGE 18 AWG m i 1 NOT USED LABEL SPINNER LABEL SPDR GND SPD MOLEX PIN SIGNAL GROUND BLACK 18AWG NOT USED SPEEDO IN GREEN 18AWG NOT USED ZIP TIE ALL 3 TOGETHER IN CENTER AND LABEL BT 1002 8 long between molex connectors Cirus uen Controls Fax 763 495 9940 BLACK TIP ONE TON THIS DRAWING IS THE PROPERTY OF CIRUS CONTROLS THIS IS TO BE CONSIDERED CONFIDENTIAL AND NO REPRODUCTION IN WHOLE OR PART WITH OUT EZ SPREAD INTERNAL JUMPER PERMISSION IS ALLOWED NUM BT 1002 BACK VIEW SIDE PINS ARE INSERTED FROM MOLEX PIN MOLEX PIN MOLEX PIN MOLEX PIN CABLE BT 1003 SIGNAL PART NUMBER 39 01 2040 OR WM3701 ND 39 01 2060 OR WM3702 ND 39 00 0039 OR WM2501 ND BACK VIEW SIDE PINS ARE INSERTED FROM LABEL SPDR PWR MOLEX PIN GROUND BLACK
24. G FOR SWITCH 9 SWITCH 3 POWER YELLOW 18 AWG 10 6 5 913 328 SPRAGUE PLUG FOR LIGHT SWITCH 3 OUTPUT RED 18 AWG 10 LO SLIT LOOM SWITCH 4 POWER BLUE 18 AWG 10 SWITCH 4 OUTPUT RED 18 AWG 10 SWITCH 5 POWER WHITE 18 AWG 10 SWITCH 5 OUTPUT RED 18 AWG 10 SWITCH 6 POWER GREY 18 AWG 10 SWITCH 6 OUTPUT RED 18 AWG 10 GROUND BLACK 18 AWG 10 3 LABEL SWITCH 1 TOP VIEW WIRES INSERTED FROM JUMPER BETWEEN PIN 5 AND PIN B SHOULD BE 1 25 INCHES LABEL SWITCH 2 COPY DETAIL FOR SWITCH 4 DETAIL FOR SWITCH 5 COPY DETAIL FOR SWITCH 6 LABEL SWITCH 3 COPY SWITCH WIRING DETAIL LABEL SPLIT LOOM WITH PM 1000 FOR SWITCHES 4 5 6 PLACE 6 OF SPLIT LOOM AS CLOSE TO WAGO CONNECTOR AS POSSIBLE Ci rus 9200 Wyoming Ave N Suite 320 Brooklyn Park MN 55445 Tel 763 493 9380 Co n tro 763 493 9340 PEDESTAL MOUNT THIS DRAWING IS THE PROPERTY OF CIRUS CONTROLS tare DESCRIPTION THIS IS TO CONSIDERED CONFIDENTIAL AND NO SWITCH WIRING REPRODUCTION IN WHOLE OR PART WITH OUT PERMISSION IS ALLOWED DESIGN DRAWN 5 80 PROJECT NUMBE SCALE PIN SIGNAL LENGTH B M QTY SWITCH 1 POWER ORANGE 18 AWG 20 ft PART NUMBER DESCRIPTION SWITCH 1 OUTPUT RED 18 AWG 20 ft SWITCH 2 POWER GREEN 18 AWG 20 ft 231 313 037 000 13 PIN WAGO PLUG WITH LOCKING TABS SWITCH 2 OUTPUT RED 18 AWG 20 ft LCP 413 SPLIT LOOM WAYTEK 46025 10 AMP IN LINE FUSE
25. ISAWG n 12 VDC RED 18AWG lt GROUND BLACK 18AWG i 12 VDC RED 18AWG AUGER REV GREEN 18AWG A AUGER BLUE PRE WET WHITE 18AWG SPINNER ORANGE 18AWG LABEL SPDR HYD SIGNAL MOLEX PIN LABEL SPDR GND SPD SIGNAL GROUND BLACK 18AWG NOT USED SPEEDO IN GREEN 18AWG NOT USED LABEL SPDR SENSOR SIGNAL GROUND BLACK 18AWG NOT USED SPINNER SENSOR GREEN 20AWG POWER BROWN 18 AWG PREWET SENSOR YELLOW 20 AWG AUGER SENSOR WHITE 20AWG MOLEX PIN MOLEX PIN DESCRIPTION 4 PIN MOLEX PLUG WITH LOCK 6 PIN MOLEX PLUG WITH LOCK MOLEX SOCKETS FOR PLUGS SIGNAL GROUND BLACK 18AWG 12 VDC RED 18AWG GROUND BLACK 18AWG 12 VDC RED 18AWG SIGNAL AUGER REV GREEN 18AWG AUGER BLUE 18AWG PRE WET WHITE 18AWG SPINNER ORANGE 18AWG NOT USED NOT USED SIGNAL GROUND BLACK 18AWG NOT USED SPEEDO IN GREEN 18AWG NOT USED SIGNAL GROUND BLACK 18AWG NOT USED SPINNER SENSOR GREEN 20AWG POWER BROWN 18 AWG PREWET SENSOR YELLOW 20 AWG AUGER SENSOR WHITE 20AWG ZIP TIE ALL 4 TOGETHER IN CENTER AND LABEL BT 1003 8 long between molex connectors 9200 Wyoming Ave N Sulte 320 Brooklyn Park MN 55445 Cirus Co ntro S 299 4959340 BLACK ONE TON THIS DRAWING IS THE PROPERTY OF CIRUS CONTROLS PERMISSION IS ALLOWED THIS IS TO BE CONSIDER
26. JUMPER BETWEEN PIN 5 AND PIN B SHOULD BE 1 25 INCHES LABEL SWITCH 2 JUMPER BETWEEN PIN A s SHOULD BE 3 INCHES N A N LABEL SPLIT LOOM WITH 8 1004 PLACE 4 OF SPLIT LOOM AS I CLOSE TO WAGO CONNECTOR LABEL SWITCH 3 AS POSSIBLE LABEL SWITCH 4 Ci irus 9200 Wyoming Ave N Suite 320 Park MN 55445 Tel 763 493 9380 Co n t ro 1 rex 763 493 0340 BLACK TIP ONE TON HIS DRAWING IS THE PROPERTY OF CIRUS CONTROLS T T THIS IS BE CONSIDERED CONFIDENTIAL AND NO SWITCH WIRING REPRODUCTION IN WHOLE OR PART WITH OUT mam ES zy PERMISSION IS ALLOWED 5 55 OF SB PROJECT NUMBER P B O M PART NUMBER DESCRIPTION 231 310 037 000 10 PIN WAGO PLUG WITH LOCKING TABS LCP 413 SPLIT LOOM WAYTEK 46025 10 AMP IN LINE FUSE HOLDER WAYTEK 46026 10 AMP IN LINE FUSE HOLDER COVER WAYTEK 46256 10 AMP FUSE PIN SIGNAL LENGTH SWITCH 1 POWER ORANGE 18 AWG 20 ft SWITCH 1 OUTPUT RED 18 AWG 20 ft SWITCH 2 POWER GREEN 18 AWG 20 ft SWITCH 2 OUTPUT RED 18 AWG 20 ft SWITCH 3 POWER YELLOW 18 AWG 20 ft SWITCH 3 OUTPUT RED 18 AWG 20 ft GROUND BLACK 18 AWG 20 ft NOT USED SWITCH 4 OUTPUT RED 18 AWG 20 ft SWITCH 4 POWER PURPLE 18 AWG 20 ft O OQ Q N 0 N gt TOP VIEW WIRES INSERTED FROM LABEL CABLE WITH BT 1005 ON SPLIT LOOM L N N
27. R DESCRIPTION 231 640 019 000 10 PIN WAGO BULKHEAD RECEPTACLE SWITCH 1 OUTPUT RED 18 SPC 2004 FEMALE SPADES FOR SPRAGUE PLUGS SWITCH 2 OUTPUT RED 18 AWG SP913 328 SPRAGUE PLUG FOR LIGHT SWITCH 3 POWER YELLOW 18 AWG LCP 413 SPLIT LOOM SWITCH 3 OUTPUT RED 18 AWG GROUND BLACK 18 AWG INDICATOR 1 BLUE 18 AWG INDICATOR 2 PURPLE 18 AWG INDICATOR 12 VDC RED 18 AWG O Q N 3 LABEL SWITCH 1 TOP VIEW WIRES INSERTED FROM JUMPER BETWEEN PIN 5 AND PIN B SHOULD BE 1 25 INCHES LABEL SWITCH 2 N A N LABEL SPLIT LOOM WITH BT 1000 LABEL SWITCH 3 PLACE 4 OF SPLIT LOOM AS CLOSE TO WAGO CONNECTOR AS POSSIBLE Ci irus 9200 Wyoming Ave N Suite 320 Park MN 55445 Tel 763 493 9380 Co n t ro 1 rex 763 493 0340 Pee nso ADDED CABLE NAME To CABLE BLACK TIP ONE TON HIS DRAWING IS THE PROPERTY OF CIRUS CONTROLS TH THIS IS TO BE CONSIDERED CONFIDENTIAL AND NO INDICATOR AND SWITCH WIRING REPRODUCTION WHOLE OR PART WITH OUT PERMISSION IS ALLOWED DES bg SB PROD R ETA B O M PART NUMBER DESCRIPTION 231 310 037 000 10 PIN WAGO PLUG WITH LOCKING TABS LCP 413 SPLIT LOOM WAYTEK 46025 10 AMP IN LINE FUSE HOLDER WAYTEK 46026 10 AMP IN LINE FUSE HOLDER COVER WAYTEK
28. ROFAST MOLDED HEAD MATERIAL COUPLING NUT MATERIAL RATED CURRENT NUMBER OF CONDUCTORS CONDUCTOR INSULATION TEMPERATURE RATING PROTECTION CLASS CIRUS CABLE NOT OFFICIAL TURCK DRAWING MATERIAL TS 2014 SOURCE DRAWING FOR REFERENCE ONLY ANGLE 2668 TOLERANCES UNLESS DRFT OTHERWISE SPECIFIED UNIT OF MEASUREMENT VAS 22 653 0 6 5 5 5 Was DO NOT SCALE THIS DRAWING B O M QTY PARTNUMBER DESCRIPTION 1 39 01 2020 MOLEX RECEPTACLE 2 PIN 2 39 00 0039 MOLEX TERMINALS FEMALE 18 24 AWG 18 FT 222 18 AWG 2 COND SVO CABLE or SIMILAR 1 43650 DIN CONNECTOR WITH INTEGRAL LED MOLEX PIN SIGNAL DIN CONNECTOR PIN 2 DRIVE BLACK 18 AWG 1 RETURN WHITE 18AWG BACK VIEW SIDE PINS ARE INSERTED FROM CIRUS CONTROLS LLC 9200 WYOMING AVE N SUITE 320 BROOKLYN PARK MN 55445 Rev DESCRIPTION 1 SWORDFISH SPREADER CABLE SYSTEM THIS DRAWING IS THE PROPERTY OF CIRUS CONTROLS THIS IS TO BE CONSIDERED CONFIDENTIAL AND EZ SPREAD HYDRAULIC CABLE PROPRIETARY NO REPRODUCTION IN WHOLE OR PART su AS BUILT PROJECT NUMBER DATE 04 07 04 04 07 04 WITH OUT PERMISSION IS ALLOWED MVM MVM SF 1000 52228 SHT 1 OF 1 BACK VIEW SIDE PINS ARE INSERTED FROM B O M QTY PARTNUMBER 1 39 01 2020 2 39 00 0039 18FT 777 1 317 1398 000 120 1804 000 031 1267 001 2196 001 MOLEX PIN
29. S 2017 24 pigtail w Metripak terminations TS 2020 24 pigtail w Deutsch terminations Appendix B Glossary of Plow Control Terms Black Tip Multiple joystick system for controlling plowing systems Mako Trim Windows compatible software for configuration of plow control system Proportional Control the ability to control motion of a plow in a smooth feathering manner from slowest to fastest speed of motion possible for a given hydraulic set up The closer the joystick is to center neutral the slower the implement will move the further from center the faster the implement will move Bang Bang Control the ability to control motion of a plow as either fully on or fully off resulting in a single speed of motion determined by the hydraulic system no operator control Minimum Trim the minimum signal voltage delivered to the coil necessary to result in enough flow of hydraulic fluid to begin to move the implement selected Maximum Trim the maximum signal voltage delivered to the coil necessary to result in enough flow of hydraulic fluid to reach the maximum speed of motion of the implement intended Appendix C Standard and Optional System Drawings Joystick Interconnection Use this image of the Joystick board and the table below to verify joysticks are plugged into correct ports uM NUN Rev F Page 13 1 21 2010 Copyright 2010 by Cirus Controls LLC All Rights Reserved No part of this materi
30. S TO BE CONSIDERED CONFIDENTIAL AND NO 5 EXTERNAL INDICATOR WIRING REPRODUCTION WHOLE OR PART WITH OUT PERMISSION IS ALLOWED DESIGN DRAWN 5 BU 1555 EV B O M PART NUMBER DESCRIPTION QTY 1 39 01 2060 OR WM3702 ND 6 PIN MOLEX PLUG WITH LOCK BACK VIEW 2 39 00 0039 OR WM2501 ND MOLEX SOCKETS FOR PLUGS SIDE PINS ARE INSERTED FROM 2 634 RING CONNECTOR 2 24 AWG WIRE SENSOR ON CPU MOLEX PIN SIGNAL RETURN WIRE FROM KEY GREEN 18 LONG TO NOT USED NOT USED L9 WIRE TO KEY GREEN 18 LONG NOT USED NOT USED KEY SWITCH H 9200 Wyoming Ave N Suite 320 BACK VIEW Ci rus Brooks Park MN 55445 SIDE PINS ARE INSERTED FROM Tel 763 493 9380 Controls Fax 16 499 0940 HOIST KEYSWITCH WIRIN BLACK TIP THIS DRAWING IS THE PROPERTY OF CIRUS CONTROLS EV T oe DECRETO SS 1 H Q S KEYSWI gt W RI N THIS IS TO BE CONSIDERED CONFIDENTIAL AND INTERNAL WIRING REPRODUCTION IN WHOLE OR PART WITH OUT FOR HOIST ON OFF LIMIT LOCKOUT amp LIMIT OVERRIDE PERMISSION IS ALLOWED mm P P abe E SAU BACK VIEW BACK VIEW SIDE PINS ARE INSERTED FROM SIDE PINS ARE INSERTED FROM CONNECT BROWN or black WIRE TO GROUND 6 pin molex CONNECT BLUE or red WIRE TO 12VDC 6 pin molex WHITE or white WIRE NOT USED TAPE OFF SENSOR MOLEX PIN SIGNAL NOT USED NOT USED NOT USED POWER RED WIRE FROM TS 2100 NOT USED GND
31. Tip offers the option to limit the hoist circuit using an optional proximity sensor and cabling With the sensor installed and the hoist limit enabled in Mako Trim TM the Black will not allow the hoist to be raised above the position of the sensor unless it receives a true signal back from sensor The sensor will only report true when the following conditions are met the sensor and cable are intact and functional the hoist position is below the chosen limit position and the optional key switch is in the hoist enable position Using the optional key switch the hoist limit circuit can be over ridden or the hoist can be completely locked out for seasonal or safety reasons Use of these features requires purchase and installation of the sensor cable and key switch See wiring diagram and BOM in the attached drawings Note LAE the hoist limit is enabled by checking above and a sensor is not installed the Black 1 cannot raise the hoist even though all systems are functional Mako Configuration Tool c x File View Datalink Help 16 81 Plow Hoist Hook Syste Mode Global Tim Frechen Al saute T gt Max Enable Saftey Triggers Joystick 1 Hoist Hook LI Joystick 2 Plow sve Wee Joystick 3 Wing Enable Plow Float TOV Enable Hoist Limit Set All Trims Cartridge valve control for open center systems Henke Violon vit
32. ability of Cirus Controls of any nature whatsoever by reason of the manufacture sale lease or use of such products and Cirus Controls neither assumes not authorizes anyone to assume for it any other obligation or liability in connection with such products Rev F Page 3 1 21 2010 Copyright 2010 by Cirus Controls LLC Rights Reserved No part of this material may be reproduced without the express written permission of Cirus Controls LLC for each reproduction Revision level of this manual Rev Letter Date Detail A 7 6 05 Initial Release B 10 11 05 SafeStik Channel Safe details added C 8 14 06 Hoist limit function D 4 27 07 Hoist lockout and over ride capability added E 3 9 09 BT210 added F 1 19 10 BT310 added Cirus Controls reserves the right to make revisions to this manual without notice Package Contents A complete Black Tip control system contains the following items 1 Black Tip control unit 2 Mako program for the PC on a CD 3 This manual 4 Power cable 5 Hydraulic control cables ordered 6 Switches and Indicator wiring harness If any of these items are missing please contact your distributor for replacement parts Functional Overview The Black Tip control system is a 10 channel proportional hydraulic controller It translates movements from a joystick s to movements of truck implements such as plows hoists and hook lifts The closer the joystick is to center neutral the
33. al may be reproduced without the express written permission of Cirus Controls LLC for each reproduction JOYSTICK OPTIONS SF SERIES CABLE OPTIONS 848 DUAL AXIS HFX JOYSTICK SF 1000 MOLEX TO DIN 846 SINGLE AXIS HFX JOYSTICK SF 1002 MOLEX TO ITT CANNON SF 1003 MOLEX TO WEATHERPACK MK 2000 AUX INPUT CABLE FOR MAKO 2 AND BLACK TIP e AUX INPUTS AUGER SPINNER PREWET PORTS LE SEE ABOVE CHART EXTRA OUTPUT LE SEE ABOVE CHART DA FLOAT OUTPUT MAIN HYD OUT HOIST RIGHT MOIST LEFT VALVE PIGTAIL OPTIONS POWER 75 2010 M12 TO WEATHERPACK 75 2011 M12 TO AMP JUNIOR TIMER 75 2012 M12 TO AMP USS 5 2013 M12 TO ITT CANNON DEPORT TS 2014 M12 TO DIN SWITCH PORT WAGO BELOW BLACK TIP SHEETMETAL PN 978 TOP VIEW R S Phone 763 493 9380 07 2 INDICATOR AND 3 SWITCH WIRING BT 1002 JUMPER CABLE FROM EZ SPREAD TO BLACK TIP CONTROLS LLC BT 1003 JUMPER CABLE FROM SPREAD DR OR DUAL SPREAD TO BLACK TIP 9210 WYOMING AVE N SUITE 200 BT 1004 INTERNAL 4 SWITCH WIRING BROOKLYN PARK MN 55445 REV DATE 2 BLACK TIP CONTROL SYSTEM THIS DRAWING IS THE PROPERTY OF CIRUS CONTROLS THIS IS TO BE CONSIDERED CONFIDENTIAL AND CABLE OVERVIEW PROPRIETARY NO REPRODUCTION IN WHOLE OR PART WITH OUT PERMISSION IS ABLOWED Forse Tem AS BUILT PROJECT NUMBER SCALE DATE 7 26 05 7 26 05 par 7 26 05 REV JTM BLACK TIP OV NONE B O M PIN SIGNAL LENGTH PARTNUMBE
34. figure the Joystick Joystick Protection and Failure Diagnosis All Black Tip joysticks are true Hall Effect magnetic joysticks When handled properly these joysticks will give long service since there are no contact parts inside Joystick Damage Prevention Joysticks can by damaged by incorrect wiring Joysticks are installed wired and tested at the factory and must not be touched in the field by anyone other than a qualified technician See Appendix C for plug in locations Do not plug in or un plug either joystick harness with power on or joystick will be damaged and warranty will be voided System Configuration 1 To adjust trims or system parameters plug a standard serial cable into the PC port on the Black plow control Use the latest version of Mako TM Current versions are posted on Cirus Controls website Verify that the COM port on the PC is available Open the Mako Trim configuration utility The program opens on the Joysticks screen 2 After the Mako Trim program is opened turn on the Black Tip plow control The red bar that says waiting for link will turn green At this point the PC has uploaded the current configuration in the Black Tip and now controls the Black Tip plow control Note that the current joystick s screen changes to display the current configuration of the Black Tip Mako Configuration Tool 215 File View Datalink Help i Plow Hoi
35. h attitude control toggle V plow modes of running lift or wings NOTE Once enabled the hoist up will only operate if 12v is applied to the BERE DAS 8525 J J sess Reset Rev Page 10 1 21 2010 Copyright 2010 by Cirus Controls LLC All Rights Reserved No part of this material may be reproduced without the express written permission of Cirus Controls LLC for each reproduction System Self Diagnostics and Troubleshooting Joystick Check during Startup During each system power up the Black Tip tests each joystick for proper electrical function This test takes approximately 5 seconds after power is turned on Should the Black Tip identify a bad joystick during power up it will automatically cancel all of the joystick outputs to protect the hydraulic system until the joystick problem is corrected Joystick failure or system disable Green hoist LED blinks slowly Joystick failure during operation SafeStik Blinks Slow In the event that a joystick axis fails during operation the Black Tip system automatically recognizes the failure and disables the failed axis In this event single axis failure all other joystick axis will function properly To confirm the diagnosis shut off the system power for 5 seconds and then re start the system Upon power up the system self test will recognize the failed axis and cause the 0151 LED t
36. his will tell the Black Tip box to move the hoist at the set level It is not necessary to move the joystick 3 If the hoist doesn t move move the slider and repeat the process until the hoist just starts to move Ideal min voltage is the point at which hoist barely moves with test min 4 To set the next channel independently select the tab for the next implement and repeat Maximum Trim Voltage The maximum voltage setting is pre set at the factory to match the valve coil in use on this system The max trim can be reduced below the pre set level to from full on to barely moving by moving the max slider downward This type of lowered maximum is used to balance the speed of a lighter implement to keep it from banging when run at top speed Increasing the maximum voltage will only increase speed of motion up to the maximum capacity of the hydraulic system increasing max voltage above that point will not increase the speed Using the PC to Set the Maximum Voltage Caution the hoist will move keep all personnel clear before beginning 1 With the truck running move the hoist up max slider down in 0 1 volt increments Each mouse click will move the value down 0 1 and the displayed value will change 2 After each increase press and hold the TEST MAX button This will tell the Black Tip to move the hoist at the set level Do not move the joystick Rev F Page 9 1 21 2010 Copyright 2010 by Cirus
37. implement intended This voltage value will vary based on the valve coil in use the size of the hydraulic system the size of the hydraulic cylinder and the weight of the implement in use dump body plow wing etc and is normally pre set at the factory Typical Settings largest difference between min and max settings choosing these settings results in the largest amount of proportional control available for that hydraulic system The operator will be able to make large and small adjustments to speed of motion by moving the control joystick a corresponding amount Bang Bang Control On Off Set the minimum and maximum trim voltage levels at 12V Zero proportional control of speed is available at this setting Other Setting Combinations because each implement has performance characteristics setting trims uniquely for each one will create the best sense of control for both safety and efficiency Instructions for Setting Trims In order for a Black Tip plow control system to proportionally move implements the system may have to be trimmed The unit comes factory set for a variety of different coils which allows the unit to run without changes However if some of the implements don t move as desired they can be adjusted by setting new min and max trim settings via the Mako Trim configuration program which can be found on the CD accompanying the system user manual Mako Trim is Rev F Page 7 1 21 2010 Copyright 2010 by Cirus C
38. it C Joystick was damaged by incorrect wiring and must be replaced a Replace joystick b Shorted or open circuit external to the Black Tip Investigate the wiring and coil in the device controlled by the axis of motion that causes the flashing LED Le LED flashes when moving joystick for hoist up Troubleshoot wiring and Hydraulic coil for hoist up function 000848 HFX Dual Axis Joystick Standard joystick for BT 108 system 000845 HFX Single Axis Joystick MK 1003 Black Tip Power Cable TS 2004 Black Tip Speedometer cable optional with spreader 001032 Printed Lens for Sprague Switch and Sprague Indicators BT 1000 Black Tip indicator amp Switch cable internal harness BT 1001 Black Tip indicator amp Switch cable external cable fly lead termination IP 68 Valve Junction Box Parts TS 2031 8 active Port Junction Box SF 100x Hydraulic Connection for single wired connections TS 2010 24 Pigtail with AMP Jr termination 2 pin TS 2011 24 Pigtail with Weatherpak termination 2 pin tower half Rev F Page 12 1 21 2010 Copyright 2010 by Cirus Controls LLC All Rights Reserved No part of this material may be reproduced without the express written permission of Cirus Controls LLC for each reproduction TS 2012 24 Pigtail with AMP termination 2 pin TS 2013 24 Pigtail with C2 ITT Canon Termination TS 2014 24 Pigtail with DIN Terminations T
39. ndividually for each implement use the next 2 tabs to do so for all the axes of motion To set the hoist trims simply click the hoist hook tab 1 13 nk File View Help File View Datalink Help Global 1 Hois Hock AER Host ig Plow Up Plow Down Plow Left Right RT Wing in RT Wing out Global Plow Hoist Up Min Min Max Min Max Min Mi Max Min Min Min 38 33 TTI gt lt d 120 120 1204 120V 120 120 120v 120v 120 12 120v 120V 120v 120V 120v 120v 120v120V 120v 120v TestMin TestMin Test Min Test Min Test Min Test Min Test Min Test Min Test Min Test Min TestMax TestMax TestMax TestMax Test Max Test Test Max Test Max Test Max Test k Ai 4 HE 5 565 8 1 1 SendCal Get Cal Reset Progress 0 Using the PC to Identify the Minimum Voltage Caution the hoist will move keep all personnel clear before beginning 1 With the truck running move the hoist up slider up in 0 1 volt increments Each mouse click will move the value up 0 1V and the displayed value will change 2 After each increase press and hold the TEST MIN button T
40. ne tuning of the range of proportional control available to the operator Proportional control of motion allows the operator to move the control joystick a small amount to control low speed movement and a large amount to control high speed movement When properly set the operator can feather the control joystick and move the implement plow dump body at the rate of speed that is appropriate to the task at hand for best safety and efficiency Trims can be set at the outer limits of the electro hydraulic system s capability for proportional control of motion or they can be narrowed to a tighter range of control The larger the difference in voltage between the minimum and maximum settings the larger the range of movement of the control joystick and the finer degree of proportional control of motion is available to the operator Minimum Trim the minimum signal voltage delivered to the coil necessary to result in enough flow of hydraulic fluid to begin to move the implement selected This voltage value will vary based on the valve coil in use the size of the hydraulic system the size of the hydraulic cylinder and the weight of the implement dump body plow wing etc Minimum settings can only be determined at operating engine rpm s with hydraulic fluid warmed to its operating temperature Maximum Trim the maximum signal voltage delivered to the coil necessary to result in enough flow of hydraulic fluid to reach the maximum speed of motion of the
41. o blink slowly confirming the failure and then you can replace the joystick or return the unit for service Shorted or Open Circuit on Output channels Blinks Fast The Black Tip system is designed to recognize when an output channel is connected to a shorted or open circuit This protection ensures that the system stops sending an output signal to the affected device until the problem is resolved The failure indication is a flashing green Hoist LED adjacent to the joystick The LED will flash slowly while the operator attempts to actuate the damaged circuit by moving the joystick toward the damaged function If only one output channel controlled by one direction of joystick motion is damaged only that output channel is shut off by the Black Tip system until repairs can be made Rev F Page 11 1 21 2010 Copyright 2010 by Cirus Controls LLC Rights Reserved No part of this material may be reproduced without the express written permission of Cirus Controls LLC for each reproduction Trouble Shooting Guide Complaint Power Isn t On Black Tip cuts out or acts strange Plow or Hoist Doesn t Move System doesn t respond to joystick initial setup Implement plow or hoist moves without actuating joystick Hoist LED Flashes fast or slow Note system has one LED and it will flash if either Hoist or Plow circuits have defect Cause s a Master Power Off b Fuse is blown c Bad Power or Ground connecti
42. on Low power supply voltage from truck battery alternator a PTO not engaged b Hydraulics not functioning c Electrical connection failure d Black Tip power off e Joystick malfunction f Hoist limit is enabled a Black Tip not configured to match the joystick system in truck b One or more joysticks have failed and Black Tip has canceled the output signal to protect the hydraulic system a Output signal on at all times a Flashes slowly joystick failed b Flashes rapidly only when joystick is moved in a particular direction stops flashing when stick returns to neutral Appendix A Spare parts list Black Tip 108 amp 208 Correction s a Turn on power b Replace Fuse c Verify power ground connections Minimum truck voltage must be gt 12 0 volts a Engage PTO b Verify Hydraulics actuate plow or hoist manually operate using manual over ride on valve c Check LED at coil connection and at valve junction box Repair cable d Check wiring and switch 6 Power up joystick self test Repair replace indicated joystick f Correct hoist limit conditions a Use Black Tip Trim to configure the system to match the joystick installed in the truck b See Joystick Safety section in this manual to diagnose which joystick has failed a Verify joystick cable is plugged in properly on both ends b Verify that individual joysticks are plugged into joystick PCB in arm un
43. ontrols LLC All Rights Reserved No part of this material may be reproduced without the express written permission of Cirus Controls LLC for each reproduction compatible with personal computers PC or laptops running Windows 2000 XP or Vista operating system 1 To adjust trims or system parameters plug a standard serial cable into the PC port on the Black plow control Validate that you are using the latest version of Mako Trim Current versions are posted on Cirus Controls website Verify that the COM port on the PC is available Open the Mako Trim configuration utility The program opens on the Joysticks screen Mako Configuration Tool 1 File View Datalink Help Plow Hoist Hock System Mode Global Trims Frequency 5 Hydraulics 2 Min Max Enable Saftey Triggers Joystick 1 Hoist Hook Joystick 2 Plow Joystick 3 wing S Valve types v v Enable Plow Float 1 Enable Hoist Limit Set All Trims Cartridge valve control for open center systems Henke V plow with attitude control toggle V plow modes of running lift or wings NOTE Once enabled the hoist up will only operate if 12v is applied to the Hoist limit input If no voltage is applied the hoist will not go up m 7 Reset Progress 0 2 After the Mako Trim program is opened turn on the blue
44. requirement that parts be returned to Cirus Controls factory The repair or replacement of defective parts under this warranty will be made without charge to the owner except for transportation of the part to our authorized repair location What is not covered under this warranty Cirus Controls will not assume any expense or liability for repairs made outside our plant without our prior written consent We are not responsible for damage to any associated equipment or product and will not be liable for loss of profit or other special damages The provisions of this warranty do not apply to any product or parts which have been subject to misuse negligence or accident or which have been repaired or altered outside of Cirus Controls factory in any way in the judgment of Cirus Controls so as to affect adversely its performance or reliability Neither does this warranty apply to normal maintenance service and parts or to normal deterioration due to wear and exposure This warranty is expressly in lieu of other warranties expressed or implied in fact or by law including any implied warranty of merchantability of fitness for a particular purpose The remedies of repair or replacement as set forth are the only remedies under this warranty Cirus Controls disclaims any obligations or liability for loss of time inconvenience commercial loss or direct consequential special or incidental damages This warranty is in lieu of any other obligation or li
45. slower the implement will move the further from center the faster the implement will move The Black Tip system is field configurable using a PC connection This allows the end user to tailor the speed of each individual function or to turn on and off certain functions For example set the speed of the plow down different from the plow up speed Black Tip Top View Shown with optional Dual Spread spreader control Backlighting indicates power is on to the system Rev F Page 4 1 21 2010 Copyright 2010 by Cirus Controls LLC All Rights Reserved No part of this material may be reproduced without the express written permission of Cirus Controls LLC for each reproduction Black Tip Cable Connections see drawing for detail at end of manual Connections BT 1001 10 pin Wago orange connector used for inputs and outputs to switches and indicators PC Port standard PC serial connection used for field setting trims and other configuration options Optional cable PWR GND 4 pin Molex used for connecting power and ground to system Standard cable Hook Two 2 pin Molex connector for hydraulics output for hook lift optional cable Hook Left Right 2 pin Molex connector used for hydraulic outputs for hook in out or wide out plow cylinders Cables sold separately BT HYD 10 pin Molex connector used for controlling a Hoist Plow Auger and Spinner for EZ Spread Spread DR and Dual Spread TS 2031
46. st Hook System Mode Glebe Trim Frequency All Hydraulics 4111 gt Min Enable Saftey Triggers Joystick 1 Hoist Hook Joystick 2 Plow Joystick 3 wing 12 0 12 0 Enable Plow Float Enable Hoist Limit Set All Trims Cartridge valve control for open center systems Henke V plow with attitude control toggle V plow modes of running lift or wings NOTE Once enabled the hoist up will only operate if 12v is applied to the Hoist limit input If no voltage is applied the hoist will not go up 0 Send Cal Get Cal Reset Rev F Page 6 1 21 2010 Copyright 2010 by Cirus Controls LLC Rights Reserved No part of this material may be reproduced without the express written permission of Cirus Controls LLC for each reproduction 3 From the system mode menu use the other pull down menus to assign each joystick to the hydraulic function desired and use the check boxes to assign top switches as desired 4 Once joysticks are configured follow instructions in the trimming section to trim each device 5 Click send cal to send new configuration to Black Tip controller and save the file Step 4 Set Up for Operation Trimming Overview of Trims for Proportional Control of Motion Feathering Setting trims is the process of setting minimum and maximum signal voltages for the valve coil that result in a fi
47. witch is off Connect the hydraulic cables to the labeled ports Cable is labeled on the sleeve with TS 2031 2 Connect the orange Wago input plug and wire it to the systems on truck using BT 1001 3 Finally connect the power cable MK 1003 to the unit Check to make sure that the power switch is off before connecting the power leads and then connect power and ground to the cable The ground source must be direct to the battery A chassis ground is not adequate The power cable can be connected either directly to the battery as the unit is fused or to a power circuit capable of delivering a minimum of 10 amps Rev F Page 5 1 21 2010 Copyright 2010 by Cirus Controls LLC Rights Reserved No part of this material may be reproduced without the express written permission of Cirus Controls LLC for each reproduction Step 2 Testing the signal outputs WARNING KEEP ALL PERSONNEL CLEAR OF MOVING PARTS With the truck off turn on the system and wait 5 seconds for self test to complete Move a joystick on the Black Tip Move the joystick up and check for the correct LED lighting up on the valve junction box out by the valve body Repeat this for every function on the truck Once that is complete start the truck and repeat The implements should now move when each function is selected The speeds of the functions can be tailored using the Mako Trim configuration tool which is described in the Trimming step Step 3 Con
Download Pdf Manuals
Related Search