Hirschmann MARK 4E/2 Service Manual

HIRSCHMANN

LOAD MOMENT INDICATOR SYSTEM

MARK 4E/2

01 12.0ft 40000lb
06 35.0ft

6800lb

SERVICE MANUAL

P/N 031-300-190-075 REV D 12/19/2008

Service Manual

Mark 4E/2

NOTICE

Hirschmann, Inc. makes no warranty of any kind with regard to this material, including, but not limited
to, the implied warranties of merchantability and/or its fitness for a particular purpose.

Hirschmann, Inc. will not be liable for errors contained in this manual or for incidental or consequential
damages in connection with the furnishing, performance, or use of this manual. This document
contains proprietary information, which is protected by copyright, and all rights are reserved.

No part of this document may be photocopied, reproduced, or translated to another language without
the prior written consent of Hirschmann, Inc.

Hirschmann, Inc. reserves proprietary rights to all drawings, photos and the data contained therein.
The drawings, photos and data are confidential and cannot be used or reproduced without the written
consent of Hirschmann, Inc. The drawings and/or photos are subject to technical modification without
prior notice.

All information in this document is subject to change without notice.

MANUAL REVISIONS

REV DATE NAME DESCRIPTION

- 7/25/2002 SB Created service manual, ECN 02-205
A 9/15/2003 SB Add Console/Central Unit Connections, ECN 03-115
B 4/29/2008 SC ECN 08-071 (include PAT sensors & revise wiring)
C 10/10/2008 WG ECN 08-149 (revise wiring)
D 12/19/2008 WG ECN 08-204 (Wiring diagrams added to end of manual)

© 2008 Hirschmann Automation and Control, Chambersburg, PA 17201, USA

©Hirschmann Rev. D 12/19/08 WG/SC 190075_D

Service Manual

Mark 4E/2

TABLE OF CONTENTS

1 MECHANICAL DESCRIPTION OF THE COMPONENTS .................................................1

2 MECHANICAL AND ELECTRICAL DESCRIPTION OF THE CENTRAL UNIT................2

3 BASIC ADJUSTMENT OF THE HARDWARE .................................................................. 3

4 DEFINITIONS ....................................................................................................................4

5 DRAWINGS .......................................................................................................................5

5.1 WIRING DIAGRAM - CENTRAL UNIT SHUT OFF ............................................................................. 5

5.2 CENTRAL PROCESSOR 12/24 VDC........................................................................................ 6

5.3 ELECTRICAL DIAGRAM – CENTRAL UNIT/CONSOLE.............................................................. 7

5.4 INDICATOR PANEL/CONSOLE 1-0118417.00 SPARE PARTS LIST ................................................ 8

5.5 ELECTRICAL DIAGRAM – CABLE REEL / A2B SWITCH ....................................................... 8

5.6 CABLE REEL PARTS LIST ............................................................................................................ 9

5.7 ANTI-TWO BLOCK SWITCH (PAT)........................................................................................ 10

5.8 ANTI-TWO BLOCK SWITCH (KUEGER) ..................................................................................... 11

5.9 PRESSURE TRANSDUCER (250 BAR): 1-0108060.00 ............................................................... 12

5.10 PRESSURE TRANSDUCER CABLE ASSEMBLY ......................................................................... 12

5.11 PRESSURE TRANSDUCER (DAVS300 / 3401)........................................................................ 12

5.12 CABLE ASSEMBLY (PRESSURE TRANS), 031-300-060-693.................................................... 13

5.13 JUMPER CABLE ASSEMBLY FOR EXTENSION, 031-010-100-144 ............................................ 14

5.14 ROLLER SWITCH WIRING, 031-006-100-043.......................................................................... 14

6 LENGTH AND ANGLE SENSOR ADJUSTMENT........................................................... 15

6.1 EPROM REPLACEMENT IN CENTRAL UNIT .................................................................................. 16

6.2 PISTON & ROD PRESSURE CHANNEL ADJUSTMENT ................................................................... 17

6.2.1 Adjust pressure piston: ................................................................................................... 17

6.2.2 Adjust pressure Rod: ...................................................................................................... 17

6.3 LENGTH CABLE REPLACEMENT ................................................................................................ 18

7 TROUBLESHOOTING FLOW CHARTS.........................................................................19

7.1 GENERAL FLOWCHART ...................................................................................................... 19

7.2 LEVER LOCKOUT ACTIVATED ............................................................................................ 20

7.3 BLANK DISPLAY ................................................................................................................... 21

7.4 ANTI-TWO-BLOCK PROBLEM.............................................................................................. 23

7.5 LENGTH READING PROBLEM ............................................................................................. 26

7.6 ANGLE READING PROBLEM ............................................................................................... 27

8 ERROR CODES .............................................................................................................. 28

8.1 OPERATOR ERROR CODE TABLE...................................................................................... 28

8.2 SYSTEM ERROR CODE TABLE ........................................................................................... 30

9 TROUBLESHOOTING MOISTURE................................................................................. 32

9.1 WATER INGRESS...................................................................................................................... 32

9.2 CONDENSATION ....................................................................................................................... 33

10 LMI SYSTEM TEST PROCEDURE .................................................................................34

11 APPENDIX.......................................................................................................................35

©Hirschmann Rev. D 12/19/08 WG/SC 190075_D

Mechanical Description Of The Components

1 MECHANICAL DESCRIPTION OF THE COMPONENTS

Pressure Transducer:

The pressure transducer transforms hydraulic pressure into an electric analogue voltage signal. Two
pressure transducers are connected, one to the rod side and one to the piston side of the lift cylinder.
The pressure transducer is connected to the central unit with a four conductor, double shielded cable.

The power supply voltage is +12V.

The output signal is 4.00ma at 0 pressure to 20.00ma at maximum pressure (300bar).

Cable Reel:

The cable reel houses the length-angle transducer, slip ring disc and slip ring pick up (to feed and
return A-2-B signal). The PE cable goes through the drum and out to the tip where it is wired to the
Anti-Two-Block switch. The reel is driven by a tensioned spring and should be handled with caution.

The Length-Angle Transducer:

The length-angle sensor (LWG) is a combination of two transducers in cable reel, fitted at the base
section of the boom. It measures the length and the angle of the boom. A reeling drum drives a
potentiometer, which is the length transducer. Part of the length transducer is the length cable on the
drum, which is a two-conductor cable (shield and core). It is connected to the anti-two-block switch at
the boom head and to a slip ring body in the LWG. The angle transducer is fitted in the cable reel. A
pendulum drives the axle of the angle potentiometer.

The power supply voltage for both is +12/24 vdc

The output signal for the length transducer is: 4.00ma up to 20.00ma

The output signal for the angle transducer is: 4.00ma at 90° to 20.00ma at 0°

Anti-Two-Block Switch:

The anti-two-block switch monitors the load block and its relationship with the head of the boom. In
working condition, the switch is closed with a 4.7k ohm resistor in series. When the hook block strikes
the weight the circuit opens, disengaging a relay output to the lock out solenoid valves, where
applicable. The weight at the anti-two-block switch keeps the switch closed until the hook block
strikes it.

Console:

The console displays all geometrical information such as length and angle of main boom and working
radius. It also displays the actual load and the maximum load permitted by load chart. Furthermore, it
has an alarm horn and a warning light for overload, and a pre-warning light. The LED’s instrument
shows a percentage of the total permissible moment. The console has pushbuttons to switch the
operating modes (for selection of crane configurations and reeving of the block). It also has a warning
light for overload, anti-two-block conditions and an override push-button for anti-two-block condition.

1

©Hirschmann Rev. D 12/19/08 WG/SC 190075_D

Service Manual

2

MARK 4E/2

2 MECHANICAL AND ELECTRICAL DESCRIPTION OF THE CENTRAL

UNIT

All data of the crane are stored inside the central unit in EPROMs. The central unit gets all actual
information of the crane. This is computed against the reference data and the crane status
continually monitored.

Description of the Housing:

The MARK 4E/2 central unit has a water proof aluminum housing. It is mounted on the left side of the
turntable weldment or on the counterweight. The cables are led into the central unit via strain reliefs
and connected with fast-ons. An override switch is mounted on the housing to override the LMI
function. The system is protected by a 2-AMP fuse that is mounted on the lower right side.

Description of the Boards:

Inside the central unit there is one board. The main board that has terminal strips where power and
various components are connected with fast-ons to the terminal strip. The main board
the system. It contains the main computer and the necessary electronics to receive, evaluate, process
and direct the continuous data. There are overload and anti-two-block relays, which control the Bosch
relay for lever lockout, also mounted on this board.

A 24/12 volt converter
An analogue input part
processing.

An analogue/digital converter part
ones.

A digital part

Incoming Signals:

The signals from the transducers are connected to the terminal board. The signals of the angle-length
transducer are connected to terminal #56 (angle) and terminal #53 (length).
The signal on terminal #56 (angle) is between approximately 20.00ma to 4.00ma.
The signal on terminal #53 (length) is between 4.00ma and 20.00ma.
The signals from the pressure transducers are connected to terminal #52 (rod side) and terminal #51
(piston side). The signals on terminals #51 and #52 range between 4.00ma and 20.00ma.

The signal from the force transducer is connected to the terminals #51 and #52 range between4.00ma
and 20.00ma. The supply voltage +12vdc for the anti-two-block switch is terminal #72 and return
signal on terminal #71.

Outgoing Signal:

The outgoing signal of the terminal board is the signal for lever lockout of terminal #87 on the Bosch
relay. In normal working conditions there are 12 or 24 volts at this terminal. When there is an
overload or anti-two-block condition the signal becomes 0 volts. Furthermore, all voltages for the
transducers and console are going out via the terminal strip.

is the heart of

, (for 24 volt cranes) which converts 24 volts to 12 volts on the main board.

, which receives and prepares all the signals from the transducers for further

, which converts all the processed analogue signals into digital

, which contains the main computer and the ancillary electronics.

©Hirschmann Rev. D 12/19/08 WG/SC 190075_D

Basic Adjustment of Hardware

3 BASIC ADJUSTMENT OF THE HARDWARE

Length:

Ensure that the length cable tension is correct with fully retracted boom by turning the cable reel 2 to
check that the reel fully retracts. Then remove cover from cable reel and adjust the potentiometer till
fully counter clockwise to the soft stop.

Angle:

Set the boom to 0 degrees and set a digital level on the boom. Adjust the angle sensor to the same
angle as the boom. Check the angle at 20 degrees, 45 degrees, 70 degrees. Angle display should be
less than r .2 degrees of the value of the inclinometer.

Pressure Channel:
Rest the boom and disconnect the pressure transducers. Measure the voltage of both pressure
transducers on the terminal board. The output voltage of the pressure transducers should be 4.00ma.

Check the function of the hoist limit switch (anti-two-block)

Check function of lever lockout.

Measure and record the power supply voltages.

3

©Hirschmann Rev. D 12/19/08 WG/SC 190075_D

Service Manual

4

PRS145

4 DEFINITIONS

BOOM LENGTH The straight line thru the centerline of boom pivot pin to the centerline of the boom
point load hoist sheave pin measured along the longitudinal axis of the boom. (Indicator r 2%)

BOOM ANGLE The angle between the longitudinal centerline of the boom base section and the
horizontal plane. (Indicator 65° to 90° boom angle + 0°/2°; less than 65° boom angle + 0°/-3°)

RADIUS OF LOAD
the supporting surface, before loading, to the center of the vertical hoist line or tackle with rated load
applied. (Indicator 100% to 110%)

RATED LOAD
crane configuration, boom length, boom angle, or functions or these variables. For radii outside those
shown on the load ratings chart, the rated load is to be considered as zero.

ACTUAL LOAD
sensors, etc. Also referred to as working load. (Indicator 100% to 110%)

CRANE CONFIGURATION The physical arrangement of the crane as prepared for a particular
operation in conformance with the manufacturer’s operating instructions and load rating chart.

TWO-BLOCKING Contact of the lower load block or hook with the upper load block, boom point, or
boom point machinery.

ANALOGUE

Electrical signals that vary in proportion to the quantities they represent. (Boom length,

angle, and pressure transducer)
DIGITAL

Electrical signals of an on-and-off-state (two different voltage levels) to represent some

quantity of operation. (A2B, area definition switch)

The horizontal distance from a vertical projection of the crane’s axis of rotation to

The load value shown on the applicable load ratings chart of the crane for the particular

The weight of the load being lifted and all additional equipment such as blocks, slings,

©Hirschmann Rev. D 12/19/08 WG/SC 190075_D

Drawings

5 DRAWINGS

WIRING DIAGRAM - CENTRAL UNIT SHUT OFF

5.1

WARNING: The connection to the ground must
be as short as possible!

5

©Hirschmann Rev. D 12/19/08 WG/SC 190075_D

Service Manual

6

5.2 CENTRAL PROCESSOR 12/24 VDC

1-0116440.00 Spare Parts List

MARK4E/2

1

2

2.1

4

ITEM DESCRIPTION QTY PART NUMBER

1 Housing 1 1-0103719.00
2 P.C. Board (Central Processor) 1 1-0116073.00
3 Module (DC/DC Converter) 1 1-0028174.00
4 Key Switch 1 1-0103247.00

©Hirschmann Rev. D 12/19/08 WG/SC 190075_D

Drawings

5.3 ELECTRICAL DIAGRAM – CENTRAL UNIT/CONSOLE

7

©Hirschmann Rev. D 12/19/08 WG/SC 190075_D

Service Manual

8

MARK4E/2

5.4 INDICATOR PANEL/CONSOLE 1-0118417.00 SPARE PARTS LIST

1

SYSTEMTECHNIK

6/6.1

3

5

2

4

ITEM DESCRIPTION QTY PART NUMBER

1 Housing 1 1-0116046.00
2 Membrane Push Button 1 1-0118389.00
3 Buzzer 1 1-0012135.00
4 U-Shackle 1 1-0116059.00
5 Mounting Knob 2 1-010667800
6 P.C. Board 1 1-0115673.00

6.1 LCD-Matrix-Display 1 1-0114234.00

5.5 ELECTRICAL DIAGRAM – CABLE REEL / A2B SWITCH

Central Unit
1-0116440.00

2

CORE

SHIELD

TOP

BRN

BOTTOM

Cable Reel
068-308-060-001

RED

1

+12VDC

1

L-Sig.

L

2

4...20mA4...20mA

3

4

A

5

6

7

8

GND

A2B Power
+12VDC

A2B Signal­closed = +12V

A-Sig.

7

2

3

1

4

5

6

6 Pin Receptacal
Boom Tip

2

Core

3

Shield

1

6

5

4

3

2

2

1

6 Pin Plug - Extension

A2B Switch

031-002-060-011

6

5

4

3

2

1

Dummy Plug for
Main Boom only

6

5

4

3

2

1

(BLK) 1
not used
(RED) 3

(BRN) 2

1

A2B Switch

(BLK) 1

031-002-060-014

(BRN) 2

(RED) 3

©Hirschmann Rev. D 12/19/08 WG/SC 190075_D

(RED) 3

(BRN) 2

(BLK) 1

Drawings

5.6 CABLE REEL PARTS LIST

6

9

10

11

1

3

2

4

5

6

7

8

9

6

©Hirschmann Rev. D 12/19/08 WG/SC 190075_D

Service Manual

10

MARK4E/2

DRAWING 5.5 CABLE REEL - PARTS LIST - continued

CABLE REEL ASSEMBLY, PARTS LIST
PART NO. PAT 068-308-060-001

NO. PART NO QTY DESCRIPTION

01 068-000-300-060 1 BOARD, TERMINAL W/ EMC FILTERS
02 064-103-060-007 1 ANGLE SENSOR WG103/0007
03 068-000-300-018 1 LENGTH POTENTIOMETER UNIT

04 002-050-206-012 2 SCREW M6 X 12 HEX SOCKET CAP

05 000-207-010-064 2 WASHER M6 FLAT
06 068-000-100-152 1 HOUSING KT200
07 000-214-340-013 1 PG13.5 HOLE PLUG
08 000-673-020-002 139’ CABLE, LENGTH SINGLE CORE
09 002-148-131-013 1 STRAIN RELIEF, PG13.5 RED/WHT
10 031-300-100-206 1 CHEMICAL, CORROSION INHIBITOR
11 068-000-100-064 1 SLIP RING ASSEMBLY 2 POLE

5.7 ANTI-TWO BLOCK SWITCH (PAT)

031-002-060-011 - main boom (with 12’ cable)
031-002-060-014 - jib (with 32’ cable)

©Hirschmann Rev. D 12/19/08 WG/SC 190075_D

Drawings

5.8 ANTI-TWO BLOCK SWITCH (KUEGER)

1-0024849.00 Spare parts List

ITEM DESCRIPTION QTY PART NUMBER

1 Center Housing 1 1-0112531.00
2 Cover - Left 1 1-0010045.00
3 Cover – Right 1 1-0010044.00
4 Slotted Flat Head Screw - M5 x 8 2 1-0013391.00
5 Lever 1 1-0010041.00
6 Straight Pin 1 1-0010042.00
7 Bushing 1 1-0010104.00
8 Spring 1 1-0100326.00
9 Micro Switch 1 1-0010039.00

10 Cable Connector 1 1-0010037.00
11 Blind Plug 1 1-0010038.00
12 Shackle with Cotter Pin 1 1-0009999.00

Required for Mounting - Order Separately
DESCRIPTION QTY PART NUMBER

Weld Plate 1 1-0010046.00
Hex Head Cap screw - M8 x 50 2 1-0010083.00

Lock Washer - M8 2 1-0010097.00

11

©Hirschmann Rev. D 12/19/08 WG/SC 190075_D

Service Manual

12

MARK4E/2

5.9 PRESSURE TRANSDUCER (250 BAR): 1-0108060.00

5.10 PRESSURE TRANSDUCER CABLE ASSEMBLY

(Part Number is depends cable length)

Connector Cable - Straight x 7M. 1-0114293.00
Connector Cable - Straight x 10M. 1-0114294.00
Connector Cable - 90q Connector 1-0101758.00

5.11 PRESSURE TRANSDUCER (DAVS300 / 3401)

Part Number 031-300-060-453 (4.20mA, 300 bar, M12, 9/16-18)

©Hirschmann Rev. D 12/19/08 WG/SC 190075_D

Drawings

5.12 CABLE ASSEMBLY (PRESSURE TRANS), 031-300-060-693

Pressure Transducer and Cable Assembly connection in Central Unit:

X1.

MARK4 E/2 CENTRAL UNIT

GND

+UDC

123456

+12VDC

1178 109

41 42

12

51

52

Analog Input 2

Analog Input 1

GND

GND

+12VDC

13

GND

+12 VDC

(+24 VDC)

Crane Voltage

-refer to Crane DW G.-

1 - BRN (Piston.)

Piston Pressure

Transducer 300bar

1 - BRN (Rod)

3 - BLK (Rod Trans.)

3 - BLK (Piston Trans.)

2 - BLU (Rod Signal)

2 - BLU (Piston Signal)

3 SS

Cable assembly 031-300-060-693

3 SS

Cable assembly 031-300-060-693

031-300-060-452

GND

+12 VDC

4...20 mA

Signal

3

1

4

2 - BLU

3 - BLK

1 - BRN

not used

2

Rod Pressure

Transducer 300bar

031-300-060-452

GND

+12 VDC

4...20 mA

Signal

2

3

1

4

2 - BLU

3 - BLK

1 - BRN

not used

©Hirschmann Rev. D 12/19/08 WG/SC 190075_D

Service Manual

14

MARK4E/2

5.13 JUMPER CABLE ASSEMBLY FOR EXTENSION, 031-010-100-144

5.14 ROLLER SWITCH WIRING, 031-006-100-043

Central Unit
1-0116440.00

©Hirschmann Rev. D 12/19/08 WG/SC 190075_D

Procedures

6 LENGTH AND ANGLE SENSOR ADJUSTMENT

15

©Hirschmann Rev. D 12/19/08 WG/SC 190075_D

Service Manual

16

MARK4E/2

6.1 EPROM REPLACEMENT IN CENTRAL UNIT

1. Loosen screws and remove electronic box cover.

2. With power off to the system use small screwdriver to lift I.C. out of socket.

3. Replace I.C. with notch down and flat side to the top as shown in diagram.

WARNING: If I. C. is placed in wrong, the I.C. will be destroyed and a new I.C. will have to be ordered.

©Hirschmann Rev. D 12/19/08 WG/SC 190075_D

Procedures

17

6.2 PISTON & ROD PRESSURE CHANNEL ADJUSTMENT

6.2.1 Adjust pressure piston:

1. Turn power off to the system and wire simulator to the piston pressure channel (blue to term. # 12,
brown to term. #45, green/yellow to term. # 51). Put voltmeter ground on term. # 45 and positive to
term. # 51.

2. Go to the Calibration menu by pushing the up then P button while in the Program menu screen.

3. Push up or down button until NORM menu title is blinking, then push P button.

4. Push up or down button until PRESSURE-PIS menu title is blinking, then push P button.

5. Adjust simulator to 4.00 ma.

6. Push up or down button until MINIMUM menu title is blinking, then push P button.

7. Push P button until all digits have been verified with the proper value, which will be 000.00 bar.

8. Adjust simulator to 20.00 ma. Push up or down button until MAXIMUM menu title is blinking, then
push P button.

9. Push P button until all digits have been verified with the proper value, which will be 300.00 bar.

10. Push up or down button until ADJUST menu title is blinking then push P button.

11. Push down button until EXIT menu title is blinking then push P button.

6.2.2 Adjust pressure Rod:

12. Move positive lead of voltmeter to term. # 52.

13. Push up or down button until PRESSURE-ROD menu title is blinking then push P button.

14. Adjust simulator to 4.00 ma.

15. Push up or down button until MINIMUM menu title is blinking then push P button.

16. Push P button until all digits have been verified with the proper value, which will be 000.00 bar.

17. Adjust simulator to 20.00ma

18. .Push up or down button until MAXIMUM menu title is blinking then push P button.

19. Push P button until all digits have been verified with the proper value, which will be 300.00 bar.

20. Push up or down button until ADJUST menu title is blinking then push P button.

21. Push down button until EXIT menu title is blinking then push P button.

22. Push down button to EXIT then P button until you get to the Program menu and enter the working
display.

©Hirschmann Rev. D 12/19/08 WG/SC 190075_D

Service Manual

18

MARK4E/2

6.3 LENGTH CABLE REPLACEMENT

PROBLEM: Damaged or broken length cable.

Replace length cable using the following procedure:

1. Turn drum counter-clock wise until drum is fully tensioned.

2. Tighten locking nuts to drum to prevent recoil. Refer to Drawing 1 in Section 11 – Appendix.

3. Take reel cover off and remove screw and cable clamp.

4. Remove wire from slip ring disc cut wire ends off and remove all old length cable from reel.

5. Feed new length cable through drum. Strip wire, separate inner core from shield, insulate shield
by using heat shrink or electrical tape, put spade lugs on and wire to slip ring disc terminals 2 and

3. Put cable clamp on and tighten screw to drum.

6. Put silicone around hole where the new length cable is fed through the drum.

7. While holding cable or drum, (Warning! To prevent recoil.) loosen locking nuts and jam the nuts
together.

8. Slowly allow cable to spool onto the drum, keeping the cable tight together and layering properly,
spool until all tension is off the cable reel.

9. Re string cable through the roller guides and reconnect at the boom tip.

10. After cable replacement refer to length adjustment procedure to reset length.

11. Put cover on reel. Crane is ready to put back into service.

©Hirschmann Rev. D 12/19/08 WG/SC 190075_D

Troubleshooting Flow Charts

7 TROUBLESHOOTING FLOW CHARTS

7.1 GENERAL FLOWCHART

This section explains how to handle a problem that may arise with the PAT Load Moment Indicator
Kruger Mark 4E/2 System. The procedures are easy to follow and are given in flowcharts on the
following pages. Start with the general flowchart below that will guide you to one of the other detailed
flowcharts shown in this section.

START

What’s

Wrong?

19

Lever
Lockout
Activated

Blank
Display

Anti-Two
Block
Problem

Length
Reading
Problem

Angle
Reading
Problem

Go to Section 7.2

Go to Section 7.3

Go to Section 7.4

Go to Section 7.5

Go to Section 7.6

©Hirschmann Rev. D 12/19/08 WG/SC 190075_D

Service Manual

overload or two

play

20

7.2 LEVER LOCKOUT ACTIVATED

MARK4E/2

Problem

The lever lockout system of the crane is activated.

Crane movements “hoist up”, “telescope out”, and

“boom down” are stopped. Crane is not in

-block condition.

START

Set the override key switch in electronic box into upper
position to override LMI. Refer to Drawing 8

NO

If console display is blank fault is
located in power supply, wiring or
fuse.

Check lever lockout system in
crane.

Fixed

Does light (6)
indicate

NO

If Load Moment Limit Light (5)
displays fault is located in LMI,
cables, wiring, fuses, or console.
Read error code displayed on

console dis

. Refer to Section

Anti-Two-Block
warning?

YES

Fault in Anti-Two
Block system.
Refer to Section

7.4

©Hirschmann Rev. D 12/19/08 WG/SC 190075_D

Troubleshooting Flow Charts

7.3 BLANK DISPLAY

21

PROBLEM

Blank display.
No warning lights shown.
Crane movements stopped

YES NO

If fuse is open check for direct short to ground by using a
voltmeter checking for continuity between terminal X1.2 and
X1.11-20.

NO YES

Replace fuse with 2 amp fuse only.
If system returns
the crane is ready to be put back into
service.

to normal operation

Continuity

Fuse Open?

YES NO

Check input voltage using a
voltmeter put positive lead at
terminal X1.1 and ground at
terminal X1.2. If there is no
voltage there is a problem with
supply voltage from the crane.

Remove wires from terminals
X1.11-X1.20 (power to sensors)
and check for short circuit to
ground.

Continuity

NEXT
PAGE

©Hirschmann Rev. D 12/19/08 WG/SC 190075_D

Check for short on the wires
removed, X1.11-X1.20 when the short
is found trace out short using wiring
diagrams Refer to wiring diagram in
Section 5. After short has been
removed replace fuse with 2 amp
fuse only.

Defective electronic CPU
board.

Service Manual

22

MARK4E/2

PREVIOUS PAGE

NO

Then check output voltage to console using a
voltmeter put positive lead at terminal X1.33 and
ground at terminal X1.2.

YES NO

Replace console. Replace or repair Electronic box CPU.

Voltage?

Display working?

If system returns to normal operation the
crane is ready to be put back in service.

YES

©Hirschmann Rev. D 12/19/08 WG/SC 190075_D

Troubleshooting Flow Charts

7.4 ANTI-TWO-BLOCK PROBLEM

PROBLEM

Function of the Anti-Two-Block System is faulty.

Check to see whether the crane
is in Anti-Two-Block condition.

23

START

NO YES

Check if jumper or dummy plug (if two
winch crane) in receptacle at boom nose is
plugged in. Refer to Drawing 2, “Anti-Two­Block Junction”, In Section 11 – Appendix.

YES NO

Plug appropriate plug into
socket of the receptacle.

Correct?

Two-Blocked?

Lower hook down into
safe position.

Remove jumper/dummy plug and check
the function of the Two-Block switch by
using /ohmmeter between terminals 2
and 4 of the receptacle. Safe condition
(switch pulled down) = 0 ohm
Two-Blocked (switch up) = open.

Remove cover from cable reel.
Check with ohmmeter between
terminals 2 and 3 on the slip ring disc
with Two-Block switch down = 0
ohm.

NEXT PAGE

©Hirschmann Rev. D 12/19/08 WG/SC 190075_D

NO

Correct?

Replace Anti-Two-Block switch

YES

Service Manual

24

MARK4E/2

PREVIOUS PAGE

YES NO

Correct?

Check with ohmmeter between terminals 2 and
3 on the terminal strip with Two-Block switch
down = 0 ohm.

YES NO

Correct?

Check with ohmmeter between terminals
6 and 7 in the receptacle a boom pivot point
with Two-Block switch down = 0 ohm.

Replace length cable, refer to Section

Clean or replace slip ring disc or terminal
strip p.c. board with plungers.

YES NO

Correct?

Check with ohmmeter between terminals X1.71
and X1.72 in the electronic box with Two-Block
switch down = 0 ohm.

YES NO

Correct?

Use a voltmeter with ground lead on X1.41-50
and positive lead on X1.72 check for 12 vdc.

Replace defective cable from cable reel to
receptacle.

Replace cable from plug at boom pivot
point to electronic box.

©Hirschmann Rev. D 12/19/08 WG/SC 190075_D

Troubleshooting Flow Charts

PREVIOUS PAGE

25

YES NO

Correct?

With 12vdc on terminal X1.72 and all checks have been
completed you should have 12 vdc on terminal X1.71. If you
have the correct voltages the Electronic Box P.C. Board is
defective. Send to PAT America, Inc. for repair or
replacement.

Electronic Box P.C. Board is defective. Send
to PAT America, Inc. for repair or
replacement.

©Hirschmann Rev. D 12/19/08 WG/SC 190075_D

Service Manual

y

26

MARK4E/2

7.5 LENGTH READING PROBLEM

PROBLEM
Length reading is incorrect. Crane
Is not “out of load chart” condition?

START

Check mechanical adjustment of
the length Potentiometer with
boom full

retracted

NO YES

If indication is correct at short boom
and has bad indication the problem my
be a defective length potentiometer.
Refer to Section?

Correct?

If indication is off by approximately 3 ft.
(1m) add or remove 1 rap from cable reel.
If this does not repair problem refer to
Length Adjustment Procedure section?

©Hirschmann Rev. D 12/19/08 WG/SC 190075_D

Troubleshooting Flow Charts

7.6 ANGLE READING PROBLEM

PROBLEM
Angle reading incorrect. Crane is not
“out of load chart” condition.

Check mechanical adjustment of the angle
Potentiometer with boom at 0 degrees Indication
should match load chart.
Indication should match load chart.

NO YES

27

START

Correct?

If indication is correct at 0 degrees and
has bad indication the problem my be
defective length potentiometer.
Refer to Section 7.

If indication is off check the mechanical
adjustment of the angle bracket.
Refer to Section 7.

©Hirschmann Rev. D 12/19/08 WG/SC 190075_D

Service Manual

28

MARK4E/2

8 ERROR CODES

8.1 OPERATOR ERROR CODE TABLE

Operation errors
information will be shown on the second line of the display with an error message or description. The
error will be automatically reset when user corrects error.

ERROR
DISPLAYED

A2B CONDITION Anti-2-Block circuit

A2B BYPASS The hoist limit switch

LOAD > MAX
LOAD

SHUT OFF
BYPASS

LENGTH < CHART The length of the main

LENGTH > CHART The length of the main

RADIUS < CHART The Radius is shorter

RADIUS > CHART The Radius is longer

are measurement errors, i.e.; the actual radius is lower than in the load chart. The

ERROR CAUSE ACTION

Lower the hook. Check all
cables and connection to
hoist limit switch.
Error occurs when bypass
button on the panel is
pushed.
Lower load or move load into
safe working condition.

has been activated.

has been by-passed.

The actual load is
greater than the max

The hoist limit switch has
been activated or open in A­2-B circuit.
The hoist limit by-pass
button has been pushed or
is defective.
The crane is at maximum

lifting capacity.
load.
The shut-off system is
currently by-passed.

The shut-off contact has

been by-passed by the user

Remove key from electronic

box.
with the aid of the key
operated switch installed on
the electronic box.

Select proper configuration.

Check length indication with

boom fully retracted, if

incorrect length is indicated

Refer to Section 7.5

Select proper configuration.

Check length indication with

boom fully extended, if

incorrect length is indicated

Refer to Section 7.5.

Lower or extend boom to

return to a working radius in

the load chart. Check radius

indication to actual radius.

boom is shorter than
the lowest value in the
Load Chart for the
configuration selected.

boom is longer than
the highest value in
the Load Chart for the
configuration selected.

than the lowest value
in the Load Chart for
the configuration

The incorrect configuration
has been selected. The
length indication is
incorrect.

The incorrect configuration
has been selected. The
length indication is
incorrect.

The crane has exceeded
the shortest radius for the
configuration that has been
selected.

selected.

Raise or retract boom to

return to a working radius in

the load chart. Check radius

indication to actual radius.

than the highest value
in the Load Chart for
the configuration

The crane has exceeded
the longest radius for the
configuration that has been
selected.

selected.

©Hirschmann Rev. D 12/19/08 WG/SC 190075_D

Error Codes

ERROR

ERROR CAUSE ACTION

DISPLAYED

ANGLE < CHART The Angle of the main

boom is lower than the
lowest value in he
Load Chart for the
configuration selected.

ANGLE > CHART The Angle of the main

boom is higher than
the highest value in
the Load Chart for the
configuration selected.

SWING AREA The crane has swung

into a non-working
area unacceptable to
the Load Chart for the
configuration selected.

The crane has exceeded
the lowest angle for the
configuration that has been
selected.

The crane has exceeded
the highest angle for the
configuration that has been
selected.

The crane has swung into
the wrong working range.
May have defective roller
switch or open wire to the
roller switch.

29

Raise the boom to return to
a working angle in the load
chart.

Lower the boom to return to
a working angle in the load
chart..

Swing to return to a working
rang. Replace defective
roller switch. Replace wire
from electronic box to roller
switch.

©Hirschmann Rev. D 12/19/08 WG/SC 190075_D

Service Manual

30

MARK4E/2

8.2 SYSTEM ERROR CODE TABLE

System errors

will occur if a system component has failed or been damaged and must be corrected.

The system has to be reset after error has been corrected.

ERROR

ERROR CAUSE ACTION
DISPLAYED
CH: 1 SHORT Piston Pressure

Transducer output

Defective pressure
transducer or cable.

Replace pressure
transducer or cable.

voltage to low.
CH: 1 OPEN Piston Pressure

Transducer output

Defective pressure
transducer or cable.

Replace pressure
transducer or cable.

voltage to high.
CH: 2 SHORT Rod Pressure

Transducer output

Defective pressure
transducer or cable.

Replace pressure
transducer or cable.

voltage to low.
CH: 2 OPEN Rod Pressure

Transducer output

Defective pressure
transducer or cable.

Replace pressure
transducer or cable.

voltage to high.
CH: 3 SHORT Length Transducer

output voltage to low.
CH: 3 OPEN Length Transducer

output voltage to high.
CH: 6 SHORT Angle Transducer

output voltage to low.
CH: 6 OPEN Angle Transducer

output voltage to high.
E: 0001 - 0042 LMB Error Codes Errors occur from improper

E: 1040 Error of division. The system has tried to

Defective length transducer
or cable.
Defective length transducer
or cable.
Defective angle transducer
or cable.
Defective angle transducer
or cable.

programming of data I.C.’s.

divide by zero.

Replace length transducer
or cable.
Replace length transducer
or cable.
Replace angle transducer
or cable.
Replace angle transducer
or cable.
If problem recurs contact
PAT America, Inc.
Reset system by turning
power off then on. If
problem recurs contact PAT
America, Inc.

E: 1041 Invalid interrupt

vector.

The system has attempted
to execute an interrupt that
is in valid.

Reset system by turning
power off then on. If
problem recurs contact PAT
America, Inc.

E: 1042 Incorrect CHECKSUM

of EPROM 1.
E: 1043 No real-time clock. A EPROM 1 program for

Loss of data or invalid
modification of EPROM 1.

using data logger has been
installed and pc board has
no real-time clock or

Install new EPROM 1 with
valid control program.
Replace EPROM 1 with
proper programming or
replace pc board with real­time clock.

defective real-time clock.

E: 1080 – 108D Range Check Errors. Errors occur from improper

E: 10C0 – 10CE Data Programming

Errors EPROM 1.

©Hirschmann Rev. D 12/19/08 WG/SC 190075_D

programming of data I.
C.’s.
Programming errors in
EPROM 1.

If problem reoccurs contact
PAT America, Inc.

If problem recurs contact
PAT America, Inc.

Error Codes

ERROR

ERROR CAUSE ACTION

DISPLAYED

E: 1100 Invalid EEPROM

identification.

E: 1101 Incorrect

“CHECKSUM”
EEPROM (EPROM2)

Incorrect EEPROM inserted
in EEPROM 2 slot.
Information has been
changed in EPROM 2 and
not checksum before
turning power off to system.

E: 1102 – 110E Data Programming

Errors.

E: F000 Error in shut-off

circuit.

Invalid programming of
EPROM 2.
Fault on electronic box P.C.
board.

E: F001 12 Volt DC fault. The 12 Volt DC power

supply voltage has dropped
below 12 Volt DC –20%.

E: F002 ADC timeout. Malfunction of A/D

converter.

E: F040 – FE43 Hardware Error. The system has a hardware

failure.

31

Replace the EEPROM with
valid programming.
With error message
displayed push down
button. Enter ACCESS
code and CHECKSUM EEP
then RESET.
If problem reoccurs contact
PAT America, Inc.
Replace electronic box P.C.
board.
If crane is 12 volt check
supply voltage of crane. If
crane is 24 volt check for
fault of 12/24 volt converter
on electronic box P.C.
board.
Replace electronic box P.C.
board.
Contact PAT America, Inc.
or replace electronic box
P.C. board.

©Hirschmann Rev. D 12/19/08 WG/SC 190075_D

Service Manual

32

MARK4E/2

9 TROUBLESHOOTING MOISTURE

The MARK4/E2 contains electronic components in various locations, such as central unit, sensors,
junction boxes etc. These internal components cannot be designed to withstand exposure to moisture
over a longer period of time. For this reason, the housings of the components are water protected
according to IP 65. If you find water or moisture inside any of the housings, the source for the water
ingress has to be detected and corrected to ensure proper operation.

There are two major possibilities for the occurrence of excessive moisture inside an enclosure:

1) Water ingress

2) Condensation

This outline gives instructions for detecting the cause for excessive moisture by using simple
troubleshooting methods and how to prevent the moisture ingress from happening again.

9.1 WATER INGRESS

There are 6 possibilities for water to enter an enclosure:

1) Spray Cleaning

2) Missing / Loose Screws

3) Bent Lid

4) Defective Gasket

5) Loose Strain Relieves

6) Water Entry through External Cabling

It is possible to find out the source of water ingress by going through the following steps and ruling out
one possibility after the other until the cause is identified:

1) Spray Cleaning

The enclosures used for the MARK4/E2 are water protected to IP 65. This means protection
against the environment, such as rain. However, through the use of spray cleaner at short
distances, it is possible to force water through the gasket or strain relieves. For this reason, avoid
spraying any components from short distances with spray cleaners. Convey this fact to any member
of a maintenance crew.

2) Missing / Loose Screws

All screws have to be present and to be equally tight to ensure water protection of the enclosure. If
there are screws missing, replace them. If no screw is missing, check the tightness. If any were
loose, then open all screws and then re-tighten them equally.

3) Bent Lid

An enclosure will only seal correctly if the lid is not bent. To check this, loosen all screws of the lid,
take the lid off the box and visually inspect it for deflection. If the lid is bent or damaged, it needs to
be replaced. Try to determine what has caused the lid to be bent and eliminate the reason for that.
Order a new lid through your Hirschmann representative.

©Hirschmann Rev. D 12/19/08 WG/SC 190075_D

33

4) Defective Gasket

The gasket underneath the lid seals the unit. The gasket needs to be in good condition in order to
seal correctly. If the gasket is torn, brittle or severely bent, it needs to be replaced. Order a new
gasket through your Hirschmann representative.

5) Loose Strain Relieves

The strain relieves allow cabling to enter the box without allowing water to enter it. The strain
relieves have to be correctly tightened in order to do this. Check the tightness by taking the external
cable into one hand and carefully trying to turn it. If the internal wires turn with the outer cable, the
strain relief is loose. Get a new grommet (insert) through your Hirschmann representative and
replace the existing one with the new one. Tighten the strain relief correctly. Note: Whenever a
strain relief is opened, i.e. to replace a cable, a new grommet needs to be used. Never re-use any
grommet or the strain relief will not seal properly!

6) Water Entry through External Cabling

Even with a tight strain relief, water may still enter the box through the inside of the cable. In this
case, you have to find out why and where water enters the cable. Look for damages to the cable
itself and inspect the opposite side of the cable. In example, if the cable comes from a connector
that is full of water, the water will run through the inside of the cable and fill up the central unit, too.

9.2 CONDENSATION

In a climate with high humidity and rapidly changing temperatures, condensation can happen inside
any enclosure, usually the larger the volume of the box, the more likely. In this case, water drops build
up on the inner components when humid air is trapped inside the box. With condensation, water
tightness is not a problem – the box is sealed just fine, which is what prevents the trapped air from
exiting the box. There are two ways to deal with condensation:

1. If the volume is very small, a desiccant bag might be able to soak up the air’s humidity.

2. If the effect is more severe, the only way to get rid of this effect is then to give the box the
ability to breath without sacrificing its water tightness. Contact your Hirschmann representative
for breathing elements to than can be added to the box and will help to reduce the effects of
humid climates.

©Hirschmann Rev. D 12/19/08 WG/SC 190075_D

Service Manual

34

MARK4E/2

10 LMI SYSTEM TEST PROCEDURE

WARNING

Do not operate the crane out side the permissible operating range for the

type of crane / capacity chart being tested.

1) Most crane manufacturer calibrate the cranes with the jib removed it is recommended that this is done to carry out
the following test. How ever on some cranes this might not be the case, if in doubt contact the manufacturer.

2) For calibration verification a test load is to be employed for each of the following configuration;

NOTE: For safety reasons first measure the allowable radius for the load being used have a spotter to
ensure the system stops the functions at or before this point.

3) Maximum Boom Length and Middle Radius (select a load that will lock out the functions about the middle of the load
chart in the long boom length step)

4) The following test should be recorded signed and dated. A copy of this test sheet should be available at all times.

5) Test load to be applied by suspending known weights accurate to +/-1%. Weights of all additional equipment such
as blocks, slings, sensors, etc., are included in the test load. The total load is to be known to an accuracy of +/-1%.

With extended boom and the load suspended, move the load smoothly from the short radius to overload lock out, measure
and record radius, calculate cut off % see section 6. Ensure the appropriate functions are disabled.

6) Computations:
For each radius measured in the above tests refer to the applicable load rating chart and determine the rated load.
At radii intermediate to those on the load chart, rated load shall be determined by linear interpolation unless
otherwise specified by the crane manufacturer.

The system accuracy is to be determined from the following formula:

TEST LOAD
RATED LOAD at cut off radius/angle

7) The actual load which activates the overload lock out is not less than 90% of the rated load or more than 100% of

the rated load for the corresponding actual load radius or boom angle.

Note: This is a general standard and variations may exist, if in doubt contact the crane manufacturer.

CALIBRATION TEST

CRANE S/N:_____________

x 100 = % OF RATED LOAD

Op/

Mode

Parts of

Line

Main / B

Length

Main / B

Angle

Jib / Ext

Length

Jib

Offset

Actual

Load

Indicated

Load

Actual

Radius

Indicated

Radius

Cutoff

©Hirschmann Rev. D 12/19/08 WG/SC 190075_D

%

11 APPENDIX

MARK4E/2 CENTRAL UNIT

30

86

87a

85

87

K5

Cut off Device (Crane Component)

Crane Voltage

BLK (Piston Trans.)

BLK (Rod Trans.)

#3 (C-reel GND)

By-pass relay (GND)

BLU (Piston Signal)

BLU (Rod Signal)

#2 (C-Reel Length)

#4 (C-Reel Angle)

BLU (Console)

RED (Console)

BLU/2 (S1 Signal)

BLU/2 (S2 Signal)

BRN/2 (S3 Optional)

BRN/2 (S4 Optional)

BRN/2 (S5 Optional)

GRA/ PNK (Console)

VIO (Console)

BLK (Console)

#6 C-Reel(A2B sign.)

#5 C-Reel(A2B 12V)

RED/ BLU (Console)

By-Pass switch

11

21 22

X1.

41 42

43

44

45 46

47

48 50

5149

5352 54 55

56 57 58 59

60 61 62 63

64

6665 67

68

69 70

71 72

73

74

75 76

12

7977 78 80

GND

GND

GND

GND

GND

GND

GND

GND

GND

GND

Analog Input 1

Analog Input 2

Analog Input 3

Analog Input 4

Analog Input 5

Analog Input 6

Analog Input 7

Analog Input 8

RS422 LOAD+

RS422 LOAD-

Roller Switch 1

Roller Switch 2

Roller Switch 3

Roller Switch 4

Roller Switch 5

ANGLE / LENGTH

PROGR./ BUZZER

UP / TARE

GND

A2B Switch Signal

A2B Switch +12VDC

A-2-B BYPASS

A-2-B BYPASS

Not used

Not used

By-pass +

By-pass +

By-pass out

By-pass out

35

slow blow

-refer to Crane DWG.-

Crane Voltage

+12 VDC

(+24 VDC)

Rollerswitch S2: on outriggers

Rollerswitch S3 to S5: optional

Rollerswitch S1: on Tires

Note:

BRN (Piston.)

BRN (Rod)

BRN/1 (S 1)

BRN/1 (S2)

BRN/1 (S3)

BRN/1 (S4)

BRN/1 (S5)

#1 (C-Reel)

GRN(Cons.)

YEL(Cons.)

GRA(Cons.)

PNK (Cons.)

BRN(Cons.)

WHT(Cons.)

To GND

30VDC/ 5A

GND

X1.

12

+UDC

GND

3

Ref 3.8 VDC

4

Ref 3.8 VDC

56

Ref 1.0 VDC

Ref 1.0 VDC

78

RS232 TXD

RS232 RXD

RS232 CTS

10913

RS232 DTR

11

+12VDC

12

+12VDC

+12VDC

14

+12VDC

15

+12VDC

16

+12VDC

17

+12VDC

18 19

+12VDC

+12VDC

20

+12VDC

21 22

+VREF 5VDC ANALOG

+VREF 5VDC ANALOG

23

+VREF 5VDC ANALOG

24

+VREF 5VDC ANALOG

+VREF 5VDC ANALOG

2625

+VREF 5VDC ANALOG

27

Console RS422 CLK+

28

Console RS422 CLK-

29 30

Console RS422 DATA+

Console RS422 DATA-

31 32

Console Power 24/12V

Console GND

33 34 35 36

Console +12VDC

Console Shutoff

Console RS422 RXD+

Console RS422 RXD-

Console RS422 TXD+

Console RS422 TXD-

3937 38 40

Console Heating GND

Console Heating 24/12V

Fuse 2A

F1

©Hirschmann Rev. D 12/19/08 WG/SC 190075_D

To Console 118418

To P-Transd. piston

To P-Transd. rod

To Roller Switch 1

To Roller Switch 2

To Roller Switch 3

To Roller Switch 4

To Roller Switch 5

To Cable reel

A

E

H

K

G

D

F

B

C

Service Manual

36

MARK4E/2

©Hirschmann Rev. D 12/19/08 WG/SC 190075_D

37

©Hirschmann Rev. D 12/19/08 WG/SC 190075_D

Service Manual

38

MARK4E/2

©Hirschmann Rev. D 12/19/08 WG/SC 190075_D