Angle sensor

replacement instructions
HLE1054260
 Due to unavailability of the currently used angle sensor Holland Lift is forced to switch to an alternative. In this
replacment instruction we will explain how your machine can be converted to use this new sensor

Prior to preforming any work on the machine, read the manual and make sure you are aware of safe operation of
the machine as well as all safety precausions that need to be taken prior to conversion.

The overload protection system is an important safety feature of the machine, if a instruction is unclear or the
discription is not applicable to the machine, don’t continue the replacement.
If you don ‘t fully understand the information that is given in these replacment instructions, please contact
Holland Lift at:

Holland Lift International B.V.

Service department
+31 229 285556
Service@HollandLift.com
Whatsapp text only +31 6 271 197 53
Available 08:00-16:30 CET

Order number conversion kit HLE1053747

containing:

1x HLE1054260 conversion manual 2x HLE0003551 hex socket bolt

2x HLE0006208 ring

1x HLE1053740 angle sensor 1x HLE1004256 starlock

1x HLE1053743 bracket 1x HLE1054263 cable clamp

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 Replacement of the angle sensor
• Locate the lower control box, use the manual for reference

• Using the toggle switch on the side of the control box, raise the platform until end stroke of cylinder.
This is different per model, please see the angle calibration procedure on page 16

• Now you can see the complete angle sensor assembly

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 • Remove the angle assembly

• Some models
have the angle • Remove the
sensor cable angle sensor
going through bracket by
the control cable loosening the
clamp, if so take it two hex socket
off by loosening bolts
2x M6 bolts

• Loosen 2x hex socket bolts to remove the slider

• Disconnect angle sensor plug

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 • The green slider and aluminum rod will be reused

• Remove the slider assembly by loosening the hex socket bolts

• When the aluminum rod is reused you don’t need to take off the starlock

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 • The replacement angle sensor will have a new bracket. In some cases, depending on the model and
age, the bracket will need to be adjusted to fit the holes on the scissor arm.

• Take the old bracket and align the top with the new bracket and mark the holes. The new holes will
need to be drilled Ø 5 mm

• Below the result, now the bracket should fit correctly on the scissor arm

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 • Mounting the bracket to the scissor arm is machine type specific

• When fitting the bracket make sure the axle of the angle sensor is always as close as possible to the
frame see following examples:

Wrong Wrong

Frame side Frame side

Angle sensor correct, bracket wrong direction Angle sensor wrong direction

Correct, closest to the frame

Frame side

Angle sensor and bracket correct way

axle closest to the frame

• Mount the bracket to the scissor arm with 2x M4 hex bolt

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 • Put the angle sensor in place, tightening it just slightly so the bolts kan easly be removed when the
sensor needs to be adjusted.

• Fix the aluminum rod to the angle sensor. The hex socket bolt in the aluminum rod needs to be fitted
on the flat surface of the angle sensor rod

• Check the position of the green slider. In some cases the aluminum rod needs to be bent so the slider
reaches the frame again.
! Important, when fitting the green slider and/or bending the aluminum rod, make sure that with the up
and down movement of the scissor the rod doesn’t move out of the sliders range

• If a new aluminum rod is provided, it needs to be fixed to the green slider. This is done with a starlock
locking ring. (Use a hex socket that matches the starlock to fix it to the rod)

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 • When fixing the starlock make sure the rod doesn’t stick out the back of the slider

• Fix the slider to the frame

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 Taking out the resistor in angle sensor cable*
cable*
* For machine models without resistor, models fitted with FP7 PLC unit, see page 11
For hybrid models HL 160/190 H20 and HL 190/220 H25 see page 11

• In order for the new angle sensor to reach the correct values a resistor in the cable line needs to be
removed

• Use the isolator and the emergency stop in order to remove the control voltage

• Locate the lower control box, use the manual for reference

• Remove the lower cable tray cover

• Locate the orange cable connected to V0 I0 from the A21 module, this is the angle sensor cable. Inside
the black heat shrink tube is the resistor that needs to be taken out

* See page 14/15 first for alternative adjustment

• Cut out both clamps and reconnect the 2 ends with a cable clamp

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 • No in-line resistor is used in FP7 PLC

FP7 type PLC:

• Hybrid models HL 160/190 H20 and HL 190/220 H25

• These models have the resistor is located on control print Hy001

• Bridge connector 9 and 10 on control print Hy001 as shown below

Bridge wire

HLE1054260 11
 Adjusting the angle alignment
• Within 360° rotation, the angle sensor goes from 0% to 100% back to 0% value as shown in the diagram
below

• The correct setting will be between 95 - 98 % (at the end of the stoke of the lifting cylinder)

• The angle sensor value can be measured in 3 different ways:

- With the HLI monitor program (page 13)
- Voltage output (page14)
- Amperage output (page 15)

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 Angle alignment with HLI monitor program
• Connect the Holland Lift monitor program using the USB port on the PLC unit.

• Raise platform till end of stroke of the lifting cylinder (see page 16)

• Connect preferably with a long cable, so the laptop can be used close to the angle sensor

• Open the tab monitor so the angle value is shown

• Take the retaining bolt out of the angle sensor and turn the sensor upwards (as if lifting) to find the
highest ABS value. Slightly turn the sensor downwards so the ABS value will be just a little less then
the highest value

• Fix the angle sensor in place. Press lower on the controls and check if the ABS angle value lowers
directly*, if not repeat the previous step

• If the previous steps are succesful, proceed with the angle calibration as stated in the ‘‘Angle
sensor calibration’’ document

* If the value starts rising instead of lowering nearing the stowed position the angle sensor is out of
range and the maximum point should be re-adjusted

HLE1054260 13
 Angle alignment with voltage

• Use the same procedure as with the monitor program, instead of finding the 100% mark with the ABS
value, use the voltage to find the 100% mark

• For voltage connect the meter as followed:

+ to V1 cable (orange/black) - to the ground rail (under PLC unit)

• Use the meter in voltage configuration to find the highest value, Slightly turn the sensor downwards so
the voltage value will be just a little less then the highest value

• Fix the angle sensor in place. Press lower on the controls

and check if the voltage value lowers directly*, if not
repeat the previous step

• If the previous steps are succesful, proceed with

the angle calibration as stated in the ‘‘Angle sensor
calibration’’ document

* If the value starts rising instead of lowering nearing the

stowed position the angle sensor is out of range and the
maximum point should be re-adjusted

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 Angle alignment with amperage

• Use the same procedure as with the monitor program, instead of finding the 100% mark with the ABS
value, use the amperage to find the 100% mark

• For amperage connect the meter as followed:

Red lead to the black cable Black lead to the orange cable

• Use the meter in DC mili Amp configuration to find the highest value, Slightly turn the sensor downwards
so the amperage value will be just a little less then the highest value

• Fix the angle sensor in place. Press lower on the controls

and check if the amperage value lowers directly*, if not
repeat the previous step

• If the previous steps are succesful, proceed with

the angle calibration as stated in the ‘‘Angle sensor
calibration’’ document

* If the value starts rising instead of lowering nearing the

stowed position the angle sensor is out of range and the
maximum point should be re-adjusted

HLE1054260 15
 Angle sensor calibration

4.1. Adjusting the angle sensor

► 2,5 – 4 meter switch

Always make sure that this switch is properly adjusted before you start,
this means measuring from the top of the wood board to the ground and
adjust if necessary

HL-160/190/220 E12+N: HL-160 between _,_ and _,_ meter

HL-190 between 3,50 en 3,55 meter
HL-220 between 4 en 4,05 meter
HL-160/190 D/E/H20 : HL-160 on 14%
HL-190 on 12%
HL-190/220 D25: on 4 meter
HL-190/220 E25 : HL-190 between 4 en 4,05 meter
HL-220 between 4,1 en 4,15 meter
HL-190/220 H25 : HL-190 between _,_ en _,_ meter
HL-220 between 4,2 en 4,3 meter

► Bypass the maximum height limit switch

HL-160/190/220 E12 : On the ground control hold the lifting button for 2 minutes
HL-190/220 D25 : Connect +24 volt on input X2 of the PLC unit
HL-190/220 E/H25 : On the ground control hold the lifting button for 2 minutes
HL-160/190 E20 : On the ground control hold the lifting button for 2 minutes
► Set up angle sensor
Lift to maximum height ( max. stroke of the lifting cilinder)
Turn the overload key to off
Turn the angle sensor till you start to hear a sound.
The angle sensor should be tightened between the 2 sounds.
Secure here Sound signal

Bottem Top

► Calibrating angle sensor

Stay at max height and press the store button for 10 seconds(Green)
Lower to fully stowed and press save for 10 seconds (Red)

► Turn the overload key to on.

17-12-2020

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