Hirschmann Electronics, 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 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.
Hirschmann 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. The drawings and/or photos are subject to technical modification without
prior notice.
All information in this document is subject to change without notice.
This service manual is designed to assist a service or maintenance person in identifying system
problem areas or malfunctions. A digital voltmeter with the capability to measure current will be
required, along with standard maintenance and service tools. NOTE: Knowledge of how to use a
voltmeter to measure both voltage and current is assumed.
REFERENCE:
For system operation, refer to the consoles operator’s manual 031-300-190-147.
2 WARNINGS
The LMI is an operational aid that warns a crane operator of approaching overload conditions and
over hoist conditions that could cause damage to equipment and personnel.
The device is not, and shall not be, a substitute for good operator judgment, experience and use of
accepted safe crane operating procedures.
The responsibility for the safe crane operation shall remain with the crane operator who shall ensure
that all warnings and instructions supplied are fully understood and observed.
Prior to operating the crane, the operator must carefully and thoroughly read and understand the
information in this manual to ensure that he knows the operation and limitations of indicator and
crane.
Proper functioning depends upon proper daily inspection and observance of the operating
instructions set forth in this manual. Refer to Section 6. Pre-Operation Inspection and Calibration Verificationof the operator’s manual.
The LMI can only work correctly, if all adjustments have been properly set. For correct
adjustment, the operator has to answer thoroughly and correctly all questions asked during
the setup procedure in accordance with the real rigging state of the crane. To prevent
material damage and serious or even fatal accidents, the correct adjustment of the LMI has
to be ensured before starting the crane operation.
The iFLEX5 system is a CAN bus system made up of a central microprocessor unit, operating
console, length/angle sensor, pressure transducers, and anti-two block switches. All components and
sensors are equipped with CAN bus controllers.
The PAT Load Moment Indicator system operates on the principle of reference/real comparison. The
real value, resulting from the pressure measurement is compared with the reference data, stored in
the central processor memory and evaluated in the microprocessor. When limits are reached, an
overload warning signal is generated at the operator’s console. At the same time, the aggravating
crane movements, such as hoist up, telescope out and boom down, will be stopped.
The fixed data regarding the crane, such as capacity charts, boom weights, centers of gravity and
dimensions are stored in memory chips in the central processor unit. This data is the reference
information used to calculate the operating conditions.
Boom length and boom angle are registered by the length/angle sensor, mounted inside the cable
reel, which is mounted on the boom. The boom length is measured by the cable reel cable, which also
serves as an electrical conductor for the anti two-block switches.
The crane load is measured by pressure transducer block attached to the piston and rod side of the
hoist cylinders.
The interactive user guidance considerably simplifies the input of operating modes as well as the
setting of geometry limit values.
3.2 DESCRIPTION OF A CAN BUS SYSTEM
CAN stands for “Controller Area Network”. Its intended use is as a serial bus system for a network of
controllers. Each controller connected through a CAN chip is called a "node" and is mostly used to
acquire data from a sensor. All nodes are connected to a common bus and all nodes are able to
simultaneously read the data on that bus. Also, all nodes are able to transmit data on that bus
however only one node at a given time has write access to the bus. If the message is relevant, it will
be processed; otherwise it is ignored. The unique identifier also determines the priority of the
message. The lower the numerical value of the identifier, the higher the priority.
The cable bus is a twisted pair of shielded wire. Data can be transmitted in blocks from 0-8
bytes at a maximum transfer rate of 1 Mbit/s for networks up to 40 meters. For longer network
distances the maximum transfer rate must be reduced to 50 Kbit/s for a 1 km network distance.
CAN will operate in extremely harsh environments and the extensive error checking
mechanisms ensure that any transmission errors are detected.
Pressure Transducer: The pressure transducer converts hydraulic pressure into an electric signal.
A pressure transducer block houses two transducers, CAN bus converter board, and two bus
connectors. One pressure transducer is connected to the piston side of the lift cylinder and the other
to the rod side.
The Length-Angle Transducer: The length-angle sensor (LWG), often referred to as the “cable reel”,
is a combination of two transducers in one box, installed on 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
circuit is the length cable on the drum, which is a multi-conductor cable. It is connected to the antitwo-block switch at the boom head and to a slip ring body in the LWG.
The angle transducer is a potentiometer driven by a weighted pendulum that is oil damped. Both
length and angle transducer are connected to a CAN bus controller board, which is connected to the
bus system.
Anti-Two-Block Switch: The anti-two-block switch monitors the load block and it’s relationship with
the head of the boom. In working condition the switch is closed. When the load block strikes the
weight the circuit opens, disengaging a relay output to the lock out solenoid valves, where applicable.
To check the cable for damage, (short circuit to ground) there is a 4.7k resistor between ground and
the contact of the switch, to give a signal back to the central unit. The weight at the anti-two-block
switch keeps the switch closed until the load block strikes it.
Console: The graphic console displays all geometrical information such as length and angle of main
boom, working radius and head height of the boom. It also displays the actual load and the maximum
load permitted by load chart. Furthermore, it has an alarm horn, a warning light for overload, and a
pre-warning light. The graphic display allows for a simple interactive configuration setup, as well as
sensor calibration (zero adjustment), and troubleshooting sensor output screen. The console has a
warning light for anti-two-block conditions and an override switch for overload or anti-block condition.
Refer to Operator’s Handbook for detailed operation of the console.
Central Unit: Inside the central unit there is a CPU and connection board. The board has a hard
mounted connector for power, ground, bus controller, and slew indication. The board has a green
LED, indicating relay energized and a communication LED that flashes through red, yellow, and green
colors.
Slew Potentiometer: This component is not supplied by PAT/Hirschmann. It is part of the electrical
swivel (slip ring assembly). The potentiometer has two wipers which are used to determine the
slewing angle (rotational positioning) of the super structure in relation to the carrier. The slew input to
the central unit is not a CAN signal, but rather two 4..20mA analog signals.
So, what’s wrong? Assuming you are reading these pages because of some kind of problem with the
PAT system, let us try to guide you quickly to solving the problem. In most cases, your problem will
fall under the following categories:
4.1 I HAVE AN ERROR CODE INDICATED ON THE CONSOLE
Please go to section Error Codes!
4.2 THE DISPLAYED ANGLE DOES NOT MATCH THE ACTUAL BOOM ANGLE
Start in section Angle Sensing to check the indicated angle.
4.3 THE DISPLAYED LENGTH DOES NOT MATCH THE ACTUAL BOOM LENGTH
Start in section Length Sensing to check the indicated length.
4.4 THE DISPLAYED SLEWING DOES NOT MATCH THE ACTUAL SLEWING ANGLE
Refer to section Slewing Sensing to check the slew sensor.
4.5 THE DISPLAYED LOAD DOES NOT MATCH THE ACTUAL LOAD
Please note that the indicated load is calculated by the system from the geometry information in the
computer, the operator’s selections, and all the sensor inputs. If the load display is off, it can therefore
be due to an error in any or several of these inputs! Refer to section Load sensing to narrow down the
source of your problem.
4.6 THE CONSOLE DISPLAY IS BLANK
If the console does not show any sign at all (no lights, no buzzer, no display), the problem is either in
the wiring between console and central unit, or the console itself. Refer to section No console display
for further troubleshooting.
4.7 I HAVE AN A2B PROBLEM
Please go to sectionA2B PROBLEM
4.8 I HAVE A CAN-BUS PROBLEM
Please go to section CAN-Bus Communication!
4.9 I NEED TO IDENTIFY A SPARE PART
Please go to the Spare Part Listings!
4.10 I HAVE NOTICED WATER IN SOME PART OF THE SYSTEM
The System measures the angle of the main boom of the machine with an angle sensor. The angle
sensor is contained within the cable reel, located on the left side of the main boom.
Block Diagram
The signal runs from the angle sensor to the Can-Bus converter board, both located in the cable reel.
From there, it travels as digital information on the CAN-Bus to the pressure transducer, which acts as
a T-connector to the main CAN-Bus running to the central unit.
So, what do you do when you are having a problem with your angle read-out?
Start by verifying the angle display. Refer to the section “Troubleshooting A Sensor Problem Using
The Display” to call up the sensor signal on your console display. The CAN-Bus is digital and as such
will either transmit the signal correctly or not at all. If your readings are off, you have to determine
what is causing the problem (reference the following flow charts).
CAN-Bus electronics in cable reel.
The angle sensor has a potentiometer built in that is driven by a pendulum. As the angle changes, so
will the pendulum and with it the potentiometer’s axle. The converter board supplies a constant
voltage of 5V to the angle sensor and in return monitors the voltage of the potentiometer. The terminal
used is X21. The angle sensor is connected as follows:
The system measures the length of the main boom of the machine with a length sensor. The length
sensor is contained within the cable reel, located on the left side of the main boom.
Block Diagram
The signal runs from the length sensor to the CAN-Bus converter board, both
located in the cable reel. From there, it travels as digital information on the
CAN-Bus to the pressure transducer, which acts as a T-connector to the main
CAN-Bus running to the central unit.
So, what do you do when you are having a problem with your length read-out?
Start by verifying the length display. Refer to the section “Troubleshooting A Sensor Problem Using
The Display” to call up the sensor signal on your console display. The CAN-Bus is digital and as such
will either transmit the signal correctly or not at all. If your readings are off, you have to determine
what is causing the problem (reference the following flow charts).
CAN-Bus electronics in cable reel.
The length sensor has a potentiometer built in that is driven by a gear drive from the cable drum. As
the length changes, the cable drum will turn and with it the potentiometer’s axle. The converter board
supplies a voltage of about 4.7V to the length potentiometer and in return monitors the output voltage
of the potentiometer. The terminal used is X20. The length sensor is connected as follows:
Fully retract the boom and turn the
screw of the length potentiometer
with a small screwdriver counterclockwise to a soft stop, bringing the
sensor voltage to 0V (+/- 0.1 Volt).
Measure voltage between
Pin 5 (-) and Pin 3 (signal)
of terminal X20 and compare.
Return to the indication screen and again
compare the indicated and actual length.
The length sensor returns a voltage between 0.16V at 0 turns of the length pot (= fully retracted) and
4.84V at 10 turns. How many turns you get at full extension depends on the gear ratio, the boom
length, the length cable used and the spooling pattern, so we cannot provide a standard table for it.
What we can give you for trouble-shooting, however is the following table that shows the expected
output voltage (measured between X20-5 and X20-3 Signal) for each complete turn of the length
potentiometer. Note that this does not sync to the number of turns of the cable reel, though:
Note: Actual voltages will vary slightly.
For the boom control system, the length sensors are the same as described above with the exception
of cable reel internals (location of hardware, wiring, and gear wheels). Refer to the LWG520 and
LG152 spare part list for these differences.
If the reading is slightly off, small variations can be adjusted;
see section Service Screen For Sensor Calibration.
NO
Ensure that the pressure lines
are drained and disconnected.
Replace pressure transducers.
YES
7 PRESSURE SENSING
The System measures the pressure of the boom lift cylinder for both rod- and piston-side. Both
sensors are contained within one box that also contains the electronics needed for amplification and
creation of the CAN-Bus signal.
Block Diagram:
7.1 PRESSURE SENSING ERROR - FLOW CHART
Note: After exchanging the pressure transducer block, BOTH transducer channels need to be zeroed,
see procedure Zero-Setting The Transducer Inputs.
The signal runs from the pressure transducer as
digital information on the CAN-Bus to the central
unit.
Page 18
Service Manual iFLEX5
12
0
500
1000
1500
2000
2500
3000
3500
4000
04590135180225270315360
SLEW ANGLE
MILLIVOLTS
Potentiometer 1
Potentiometer 2
0 45 90 135 180 -135 -90 -45 0
ANGLE
(deg)
SL ANG 1
(mv)
SL ANG 2
(mv)
0
717
2161
30.3
1174
2645
60
1680
3150
89.9
2158
3595
120.1
2641
3141
150.1
3144
2639
180
3595
2161
-150.1
3144
1681
-120.1
2642
1180
-90
2160
718
-60.1
1681
1168
-30
1172
1680
0
718
2161
iFLEX5
CU
Slip Ring Assembly
Slew
Potentiomet
er with (2)
outputs
Current
Converter
Modular Slew Pot - Voltage on Service Screen
Display screen
for sensor inputs
8 SLEWING SENSING
The system measures the slewing (rotational position) of the crane’s upper with a slewing sensor. The
slewing sensor is contained within the slip ring assembly.
Block Diagram
The slew potentiometer has two potentiometers built in that are driven by the slip ring axle. As the
slewing angle changes, so will the axle and with it the potentiometer’s outputs. Use the display screen
by pressing ‘i’ (info) twice to show all sensor inputs.
The table to the right show measured millivolt reading for
the slew potentiotmeter.
The slew unit output can be found on pins 8 and 9. In order to
measure current, however, you must disconnect a pin and
measure in line (between the cable from the slew unit and the
central unit). *The two outputs will vary as shown in chart below.
NO
YES
Ensure that the slew pot unit
is supplied with crane voltage.
Pin 7 must carry crane
voltage and Pin 2 is GND.
You can also leave the wires connected as use your meter in
Voltage-mode to measure the output signals. In this case, you
will see the 4…20mA range as a 1.1 to 5.5 Volt range.
If the voltage or currents do not fall in line with the
charts and tables shown below, and no system errors
are present, the problem may be mechanical.
Open the slip ring unit and determine if the slew potentiometer is set correctly.
The converter board is supplied with 12V from the central unit. The potentiometer and the board
output two signals between 4 and 20mA that go to the central unit. You can measure them at the 12pin crane interface connector.
8.1 SLEW SENSING ERROR - FLOW CHART
(When the crane is over front, you should
see about 4mA in one channel (wire #2) and
12mA in the other channel (wire #3)).
Please note that the load displayed by the LMI is not a direct measurement, but a calculated value
that is based on a lot of factors. Outside of the measured values (sensors), those include:
Operator settings such as:
o Operating mode/configuration
o Parts of Line/Reeving
Rigging parts such as:
Hookblock weight
Sling weights, etc.
Tip height (length of load line used)
Boom weights
Boom attachments such as
Stowed jibs
Auxiliary boom nose, etc.
Pin 1 Shield
Pin 2 + Ub
Pin 3 Ground
Pin 4 CAN High
Pin 5 CAN Low
Pressure Transducer
E63
iFLEX5
CU
Cable Reel
CAN-Bus
Converter
E65
E64
E61
E62
12 CANN-BUS COMMUNICATION
The System measures the length of the main boom, the angle of the main boom, the pressures of the
lift cylinder, and the A2B state of the machine via a CAN-Bus connection. Since this is a digital bus
connection, it is not possible to measure the signals on the bus with a multimeter. Instead, the LMI
provides you with error codes that give you an indication of the bus state.
The error codes are one of the following:
E61 Error in the CAN bus data transfer for all CAN units
E62 Error in the can bus data transfer of the pressure transducer sensor unit
E63 Error in the can bus pressure transducer sensor unit
E64 Error in the can bus data transfer of the length/angle sensor unit
E65 Error in the can bus length/angle sensor unit
Block Diagram
The block diagram tries to clarify that: If the CU does not see any CAN-Bus component, it will report
an E61. If it sees only the cable reel, it will report an E62 (pressure transducer missing). If it sees only
the pressure transducer, it will report an E64 (cable reel missing). E63 means that the pressure
transducer is available, but is reporting an internal error. E65 means that the cable reel unit is
available, but is reporting an internal error.
So, what do you do when you are having a problem with one of those codes?
12.1 E61
In case of an E61, start by connecting the two cables on the transducer block together. If an E62
appears, the transducer block must be replaced. If an E61 appears, reconnect the cable from the
from the central unit to the transducer block. At this point, if an E61 still appears check your cabling.
You can verify that power is being supplied to the sensor by testing the CAN connectors per this
layout:
Connect the two cables on the
Transducer block together
E61
Yes
Disconnect cables and connect cable
from c/u to transducer block
E61
Yes
No
Ohm cable from c/u to the
transducer block. If cable checks
good replace c/u
Connect the cable reel can bus cable to
the transducer block. Remove can bus
connector at cable reel
E61
Yes
Replace can bus cable between
Cable reel and transducer block
No
Ohm out connector in cable reel. If connector
Checks good replace can bus converter board.
E62
Replace Transducer Block
E64
E64
Measure between pins 3 and 2 for crane voltage. If you see voltage, check all pins for continuity.
The central unit must be replaced if this cable is functioning correctly. If the E61 error code has
become an E64, connect the cable reel can bus cable to the transducer block and remove the can
bus connector at the cable reel. If this causes an E61 to appear, the can bus cable between the cable
reel and transducer block must be replaced. If an E64 remains, use the Ohm-meter to check the
connector in the cable reel. Either the connector has failed or the can bus converter boards must be
replaced.
In case of an E62 the CU is reporting no signal from the pressure transducer. Start by checking your
cabling between CU and pressure transducer, even though it is not very likely that there is a problem
with it since the same cable carries also the signals from the cable reel and those appear to be fine.
You can verify that power is being supplied to the sensor by testing the CAN connectors per the
above pin layout. If you are sure that the sensor is being supplied, you have to replace the pressure
transducer.
12.3 E63
In case of an E63, the pressure transducer is reporting an internal problem. You cannot troubleshoot
any further, but need to replace the pressure transducer.
12.4 E64
In case of an E64, the CU is reporting no signal from the cable reel unit. Start by connecting the two
cables on the transducer block together. If an E62 occurs, the transducer block must be replaced. If
an E61 occurs, measure the cable from the transducer block to the cable reel with an Ohm-meter.
Check all pins of the CAN bus cable for continuity and cross-check for short circuits. If the continuity
check fails, the cable must be replaced. If the cable appears to be fine, next check the connector at
the cable reel. You can verify that power is being supplied to the sensor by testing the CAN
connectors per the pin layout (see E61). Replace the connector if this check fails. If the connector
checks properly, the board in the cable reel might be defective.
Connect the two cables on the
Transducer block together
E61
Yes
Ohm cable from the transducer
block to cable reel.
Cable
checks good
No
Yes
Replace
cable
Check connector
at cable reel
Connector
checks good
No
Yes
Replace
connector
Replace can bus board in cable reel
E62
Replace transducer
block
Service Manual iFLEX5
12.5 E65
In case of an E65, the cable reel is reporting an internal problem. In most cases, this will be an angle
sensor, length potentiometer or A2B wiring. Go to those chapters (Angle Sensing, Length Sensing,
Troubleshooting a sensor problem using the display
21
To access the sensor output screen, press
the “INFO” button twice
10
.
10
to review software version information, press
the “INFO” button once
.
10
To EXIT the sensor output screen, press the
“INFO” button once from the software version
screen to return to the operating screen
.
10
10
Press “INFO”
To review
software
version
information
13 TROUBLESHOOTING A SENSOR PROBLEM USING THE DISPLAY
To determine whether there is a problem with a sensor, the iFLEX5 system has “sensor output
screen” built in to make trouble-shooting easier. This is the right place to start if you are suspecting a
problem with a sensor (and you don’t have an error code displayed).
The screen will show all sensor inputs as in the example below. For each sensor, an equivalent
voltage is shown in millivolts, along with the physical sensor value that that voltage refers to.
Pressure sensors are shown with physical values of [bar], angle sensors and slew sensors in degrees
and length sensors in feet (or meter for metric charts). At the bottom of the screen, the console
software version is shown.
The values shown in the screen here are just examples of actual values. Refer to the table listed
below for actual value ranges.
If you suspect a sensor error or problem with a sensor, compare the indicated physical value of the
sensor on the display screen with the real value, i.e. length, angle, etc.
The voltages given are internal calculation values only; you will not be able to actually measure them
anywhere on the electronics! Typical values to be expected are:
Pressure transducers (piston and rod), 500mV @ 0 PSI; 4500mV @ maximum PSI
Length sensor, 500mV @ retracted boom length; voltage extended depends on the various
boom lengths.
Angle sensor, 4500mV at 0; 2500mV at 45; or 500mV at 90
Please refer to table below for more values.
If the displayed value does differ from the actual value, please refer to the following sections to find
the cause of the problem:
If the displayed angle is incorrect, please go to section Angle Sensing.
If the displayed length is incorrect, please go to section Length Sensing
If the displayed pressures are incorrect, please go to section Pressure Sensing
Troubleshooting a sensor problem using the display
23
Reference Angle
Sig 1 (mA)
0.03mA
Sig 2 (mA)
0.03mA
0°
4.00
12.00
45°
8.00
16.00
90°
12.00
20.00
135°
16.00
16.00
180°
20.00
12.00
-135°
16.00
8.00
-90°
12.00
4.00
-45°
8.00
8.00
SLEW POT SIGNALS:
If the displayed angle is incorrect, please go to section Slewing Sensing
LED Colour Codes
The bicolor LED on the central unit is used as a raw diagnostic information about the system status. It
can be useful in the case that the iflex refuses terminal communication - otherwise the terminal is a
much more powerful diagnostic tool.
During initialization (after reset) the LED shows some of the initialization steps, so if the reset
procedure hangs, it is easier to find out where. The cycle is:
RESET: red+small red (for approx 5 us)
Wait for RAM: green (for approx 200 ms)
Clear RAM: yellow (for approx 1 s)
CRC-Check System program: light yellow (2.5 s)
Init RS232/RS485 : yellow (1 s)
Start RTOS: green (0.5 s)
After start of RTOS the LED toggles all 1 sec between dark/green/yellow/red.
So you can detect
- is the power supply ok?
- is the iflex in the reset procedure, hanging somewhere or is the Operating system running?
You cannot be sure if the LED shows running Operating system that all necessary tasks of the
System program are running correct, too. That has to be made sure via terminal commands.
BCS = boom control system
IM = innermid boom section
CM = center-mid boom section
OM/Fly = outer-mid and fly boom section
DI = digital input, refer to table 3 for definitions
DO = digital output, refer to table 4 for definitions
PWM = pulse width modulation
0 = off with regard to digital inputs and outputs
1 = on with regard to digital inputs and outputs
The BCS controls the boom telescoping sequence by controlling the current supplied to the
proportional solenoids on the 4-way directional control valves. These valves provide oil to the
telescoping cylinders. Here are the basic components, inputs, outputs, and logical functions
to make this happen.
14.1.2 Components:
iFLEX5 control system (central unit), located in the cab.
BCS relay junction box assy, located on rear exterior of cab.
Cable reel to measure overall length, located on boom base section.
Cable reel to measure inner-mid length, located on boom base section.
Proximity switch to sense inner-mid fully retracted, located on boom base section.
Proximity switch to sense center-mid fully retracted, located on boom inner-mid section.
Auto/Manual switch, located on the right hand arm rest in the cab.
Section selector switch, located on the right hand arm rest in the cab.
Boom out of sequence light, located on the front console in the cab.
Extend pressure switch, located on superstructure.
Retract pressure switch, located on superstructure.
Inner-mid pilot operated 4-way directional control valve with extend and retract
proportional solenoids, located on the superstructure.
Center-mid pilot operated 4-way directional control valve with extend and retract
proportional solenoids, located on the superstructure.
Tele two stage relief valve, located on the superstructure.
14.1.3 Manual / Auto Mode:
There are two modes of operation, manual or automatic mode. This is selectable by a switch
in the right hand arm rest in the cab, and is seen by the BCS as digital input 17. DI1 17=0 is
manual mode. And DI 17=1 is auto mode.
Primarily used for boom maintenance and function the boom in an unlikely event of a BCS
failure. In manual mode the boom is controlled by the section selector switch in the right
hand arm rest in the cab. When IM selected, crane electric provides full power to the extend
and retract proportional solenoids on the IM pilot operated 4-way directional control valve.
This means the telescoping action is controlled directly by moving the joystick or foot
operated treadle valve. The BCS does not control movement. Likewise when CM is selected,
crane electric provides full power to the extend and retract proportional solenoids on the CM
pilot operated 4-way directional control valve.
Note: In the event of an LMI error, overload, or A2B condition the proportional valves will be
not be energized unless the LMI bypass is activated, either from the central unit or console.
14.1.3.B Auto Mode Operation:
An extend or retract action is initiated by moving the joystick or foot operated treadle valve
causing hydraulic pilot pressure to activate an extend or retract pressure switch. The
pressure switch signals are seen as digital inputs to the BCS. As an example of extend from
fully retracted, the BCS realizes DI 19=1 (extend pressure switch on) and simultaneously
activates DO2 9 (IM extend) and DO 3 (PWM 2, IM proportional solenoid). DO 9 energizes a
relay in the BCS relay junction box assy to direct DO 3 to the IM pilot operated 4-way
directional control extend proportional solenoid. Figure 1 illustrates how DO 3 is directed to
the solenoid valve. DO 3 is a PWM output and ramps the output according to variables in the
data software. Ramp-up output is time based. When the IM section approaches a change
over point (change in sequence), DO 3 is ramped down according to variables in the data
software. Ramp-down output is percentage based. See table 1 and table 2 for sequencing
information. At the specified change over point, the BCS turns off DO 9 (IM extend) and
simultaneously turns on DO 6 (CM extend) and DO 1 (PWM 1, CM proportional solenoid).
DO 6 energizes a relay in the BCS relay junction box assy to direct DO 1 to the CM pilot
operated 4-way directional control extend proportional solenoid. DO 1 is a PWM output and
ramps the output according to variables in the data software. When the CM section
approaches a change over point DO 1 ouput is ramped down according to variables in the
data software. And so on. When retracting, the BCS realizes DO 18=1 (retract pressure
switch) and does not activate DO 6 or DO 9. DO 1 or DO 3 are activated based on the
current boom position.
*C.U. = Central Unit
**MP = Measuring Point; i.e. R89 designates resistor number; see sketches below for specific location; Notes:
must measure on bottom leg of the resistor.
DO 1 = PWM 1
DO 3 = PWM 2
DO 5 = PWM 3
DO 7 = PWM 4
A convenient method to monitor digital inputs (DI) and digital outputs (DO) is utilizing the
iTOOL5 or iFLASH terminal function. At the flashing command prompt press and hold “Ctrl”
and “A” to enter the RTOS (an asterisk will display). Type “digshow” and press “Enter”. The
result should be the screen shown below. The inputs and outputs are counted from right to
left and top to bottom as illustrated below.
*digshow (RTOS command to display digital inputs and outputs)
T E S T D E R D I G I T A L - E I N - U N D A U S G A E N G E
=======================================================================
Baugr. | Port | Modus | IN-Wert | IN-Wert | OUT-Wert | OUT-Wert | Status
| :Taste | | (Hex) | (Bin) | (Hex) | (Bin) | =NoLoad
Other methods to determine digital input and output states is by probing the junction box
mounted on the rear of the cab, the C.U. 70-pass connector pins (X2), or specific resistors on
the main board, or terminal strip in the. See table above and sketches below. Be cautious
not to short the probe across connector pins.
Junction Box Assy – located on rear exterior of cab
T E S T D E R A N A L O G E I N G A E N G E
===============================================
Ch | MUX | Error | Kanal+ | Value | Value | UADC | Special
| | | Valid | (Hex) | (Dec) | [mV] |
---+-----+-------+--------+-------+-------+------+----------------0 | | ok | 0008 | 0310 | 784 | 784 | I_Kanal 1 = 4.356 mA
1 | | ok | 0009 | 0816 | 2070 | 2070 | I_Kanal 2 = 11.500 mA
2 | | ok | 000A | 0000 | 0 | 0 | I_Kanal 3 = 0.000 mA
3 | | ok | 000B | 0000 | 0 | 0 | I_Kanal 4 = 0.000 mA
4 | | ok | 000C | 0307 | 775 | 775 | Temperature = +27°C
5 | 0 | ok | 000D | 0B90 | 2960 | 2960 | I_Kanal 5 = 16.444 mA
5 | 1 | ok | 000D | 0000 | 0 | 0 | I_Kanal 6 = 0.000 mA
5 | 2 | ok | 000D | 0000 | 0 | 0 | I_Kanal 7 = 0.000 mA
5 | 3 | ok | 000D | 0000 | 0 | 0 | I_Kanal 8 = 0.000 mA
5 | 4 | ok | 000D | 0098 | 152 | 152 | I_PWM 1 = 0 mA
5 | 5 | ok | 000D | 0014 | 20 | 20 | I_PWM 2 = 10 mA
5 | 6 | ok | 000D | 0000 | 0 | 0 | I_PWM 3 = 0 mA
5 | 7 | ok | 000D | 0000 | 0 | 0 | I_PWM 4 = 0 mA
OPERATINGMODE
X: Exit Blank: Redraw S: Slow F: Fast P: PWM-Settings
T: Test mode O: Operating mode C: ADC-Clock set E: Extension module T
E S T D E R A N A L O G E I N G A E N G E
Manual Mode retract at overload, A2B, error condition
110
Mode A, Out of Sequence
112
Mode B, Out of Sequence
127
Mode A or B, neutral position
200 - 202
Luffing jib raise
210 - 212
Luffing jib lower
14.6 IFLEX5 BCS TEST DISPLAY:
To view additional information on the console display, push buttons “F1” and “F4”
simultaneously. To return to the normal screen push button “F1” or “F4”.
Digital Output 14 boom out of sequence is lamp, located on the front crane console, is
activated when the sections become greater than 3.5% out of sequence. Refer to sequence
charts in the manufacturers’ load capacity charts. Another indication for out of sequence are
the flashing section percentages located at the bottom of the console display.
14.8 TELE ROD DRAIN VALVE:
The tele rod drain valve is a normally closed valve that when energized opens to allow oil in the rod
side of the tele cylinders a path to tank. The valve is de-energized to prevent flow to tank. The Boom
Control System energizes this valve at all times unless the boom is fully retracted, or the retract
pressure switch is activated. See the logic chart below. Digital Output 13 is on unless:
14.9 TELE TWO STAGE RELIEF VALVE:
The two stage tele relief valve is a normally closed valve that when energized increases the tele
extend relief pressure from 2500 psi to 3000 psi. The Boom Control System energizes this valve
when the retract pressure switch is activated, or when the OM/Fly section is greater than 4% while
extending. See the logic chart below.
Hydraulic control of the extension consists of a four-way, three position directional control valve, a
hose reel, a proportional control valve and a double acting cylinder. The four-way, three position
directional control valve is mounted on the turntable. There are two solenoids for directing the flow for
extension or retraction of the cylinder. The hose reel is mounted on the boom and conveys the
hydraulic fluid to the cylinder on the boom extension. The proportional control valve is mounted to the
cylinder on the boom extension.
The offset angle is measured directly by a potentiometer located on the base adapter. The opposite
end of a lever arm mounted on the potentiometer shaft rests on and follows the structure which
offsets. PAT does not supply the potentiometer.
There are two ways to offset the luffing extension. The first is two switches located in the left hand
armrest. One switch is a luffing system ON/OFF switch. The other is a RAISE/LOWER switch. This
switch has momentary positions on either side, and a return to center position. It raises or lowers the
extension by controlling the raise and lower solenoids on the four–way three position directional valve.
This switch also sends an actuation signals to the LMI. DI 8=1 (raise) DI 9=1 (lower). The
proportional solenoid on the luffing cylinder is energized by DO 5 & 7 (PWM 3 & 4) if DI 8=1. The
proportional valve on the luffing cylinder is not be energized for luffer lower. Hydraulically the
proportional valve is bypassed for luffer lower.
Raise and lower can also be activated form remote switches located on the extension. Remote raise
is DI 10 and remote lower is DI 11. The raise and lower solenoids on the turntable are energized by
DO 9 & 11 respectively. If DI 10=1, then DO 5, 7, & 9=1. If DI 11=1, then DO 11=1. The proportional
valve on the luffing cylinder is not be energized for luffer lower. Hydraulically the proportional valve is
bypassed for luffer lower. See sketch below.
Hirschmann Electronics, Inc. reserves proprietary rights to this drawing and to the data shown there on. The
drawing and data are confidential and are not to be used or reproduced without the written consent of
Hirschmann. This drawing is subject to technical modification without prior notice.
Hirschmann Electronics, Inc. reserves proprietary rights to this drawing and to the data
shown there on. The drawing and data are confidential and are not to be used or
reproduced without the written consent of Hirschmann. This drawing is subject to
technical modification without prior notice.
15.3.1 Central Unit to Crane and Console Wiring Diagram
Hirschmann Electronics, Inc. reserves proprietary rights to this drawing and to the data
shown there on. The drawing and data are confidential and are not to be used or
reproduced without the written consent of Hirschmann. This drawing is subject to
technical modification without prior notice.
Hirschmann Electronics, Inc. reserves proprietary rights to this
drawing and to the data shown there on. The drawing and data are
confidential and are not to be used or reproduced without the written
consent of Hirschmann. This drawing is subject to technical
modification without prior notice.
BOOM BASE CONNECTION
TO LG152/0056
REFER TO CABLE REEL
(LG152/0056) WIRING DIAGRAM
TO LWG520/0002
REFER TO CABLE REEL
(LWG520/0002) WIRING DIAGRAM
Hirschmann Electronics, Inc. reserves proprietary rights to this drawing and to
the data shown there on. The drawing and data are confidential and are not to
be used or reproduced without the written consent of Hirschmann. This
drawing is subject to technical modification without prior notice.
TO BOOM BASE CONNECTOR
REFER TO CONSOLE AND SENSOR
WIRING DIAGRAM
TO LWG520/0002
REFER TO CABLE REEL LWG520/0002
WIRING DIAGRAM
Hirschmann Electronics, Inc. reserves proprietary rights to this drawing and to the
data shown there on. The drawing and data are confidential and are not to be used
or reproduced without the written consent of Hirschmann. This drawing is subject to
technical modification without prior notice.
LED BOARDS
4 050-150-300-068 1 CONNECTION BOARD WITH BUZZER
5 031-300-050-223 1 FUSE, 2 AMP AUTO
6 050-150-290-061 1 CABLE, 4 POL COMPUTER BRD X1 TO CONN BRD X6,X11
7 050-150-290-063 1 CABLE, 10 POL COMPUTER BRD X2 TO CONN BRD X7
8 050-150-290-064 1 CABLE, 6 POL COMPUTER BRD X10 TO CONN BRD X23
9 050-150-300-072 1 5 LED BOARD, LMI/A2B ALARM LITE
10 050-150-300-073 1 8 LED BOARD, LED’S BY SELECTION BUTTONS
Hirschmann reserves proprietary rights to this drawing and to the data shown there on. The drawing and data are
confidential and are not to be used or reproduced without the written consent of Hirschmann. This drawing is
subject to technical modification without prior notice.
16.3 GRAPHIC CONSOLE ASSY, PART NO. 050-350-061-376
ITEM PART NO. QTY DESCRIPTION
Service Manual iFLEX5
Hirschmann Electronics, Inc. reserves proprietary rights to this document and to the data shown there on. This
document and data are confidential and are not to be used or reproduced without the written consent of
Hirschmann Electronics, Inc. This document is subject to technical modification without prior notice.
Hirschmann reserves proprietary rights to this drawing and to the data shown there on. The drawing and data are
confidential and are not to be used or reproduced without the written consent of Hirschmann. This drawing is
subject to technical modification without prior notice.
To activate the service screen and sensor
calibration function, press the INFO key on
the console to activate the INFO Function.
Now press the CTRL key.
10
.
11
At this point, a five digit
Authorization Number must
be entered. Only authorized
personnel may adjust the
zero-point settings.
Use the “>” key to switch
between digits; use the “+”
and “-“ keys to increase and
decrease each digit. Use
the enter key to confirm
entry.
17 SERVICE SCREEN FOR SENSOR CALIBRATION
17.1 ACTIVATING THE SERVICE SCREEN FOR SENSOR CALIBRATION
Now, having successfully entered a valid password, the piston-side zero-point setting function is
activated.
The ESC key will allow you to leave the sensor calibration function.
The return key toggles between the piston-side, the rod-side zero setting, and length, and angle
calibration.
To adjust piston pressure now, see next section 6.2 of this manual.
The return key toggles between the piston-side, the rod-side zero setting, slew angle, length, and
boom angle calibration.
When the sensor calibration is finished, pressing the ESC or INFO key returns the console display to
The display shows which transducer (pistonside, rod-side or force) is being zeroed and a
horizontal dial marks the present pressure (or
force) difference in %. NOTE: there are 2
screens piston and rod transducers. By pressing
the + key, the input pressure (or force) is
adjusted upwards, and by pressing the minus (-)
key, the input value is adjusted downwards.
When the plus (+) and minus (-) keys are
pressed simultaneously, the zero setting occurs
automatically. Manual adjustments may be
preformed using + or -.
Now, having successfully entered a valid
password, the piston-side zero-point setting
function is activated. Press enter through the
piston and rod zero adjustment screens to the
slew zero-point adjustment function is activated.
An indicator line shows the current position of
the slew pot signal. Note: the indicator line must
be shown in the display scale from -10° to +10°
for this zeroing procedure.
By pressing the two center keys simultaneously,
the zero setting occurs automatically. Note: The
indicator line will move to zero on the bar graph.
17.2 ZERO-SETTING THE TRANSDUCER INPUTS
NOTE: The only thing adjustable for the pressure transducers is the zero point, which is the voltage
the transducer outputs when there is no (zero) pressure sensed.
CAUTION: Ensure there is no pressure in the hydraulic line when disconnecting the hoses from
pressure transducers.
17.3 ZERO-SETTING THE SLEWING INPUTS
When the operator is finished, pressing the EXC or INFO key returns the console display to normal.
NOTE: The length sensor can be calibrated for its zero point and its full range. This means, for the
correct voltage for retracted boom and for the extended boom. With retracted boom, the
potentiometer of the length sensor has to be at its 0 position, which is all the way counter-clockwise.
For extended boom, the adjustment is done by software as described in 6 section Length Sensor
Adjustment Procedure.
The length should be calibrated to be about 0.1 feet (or 0.05m for metric) accurate for retracted and
extended lengths. Perform the following steps:
Fully retract the main boom and check if indicated length is within 0.1’ of actual retracted boom length.
If it is not, adjust length potentiometer as described in 6.3.1. Afterwards always adjust retracted length
by software as described in section Length Sensor Adjustment Procedure.
17.4.1 Cable Reel LWG508 Adjustment Procedure
Now perform Length Sensor Adjustment Procedure as detailed in section Length Sensor Adjustment
The screen will change now and show the
picture to the right.
Fully retract the main boom and verify the
indicated boom length matches the retracted
boom length of your crane. If incorrect, make
sure you have adjusted the length pot in cable
reel (see section Cable Reel LWG508
Adjustment Procedure.)
Now, press the ‘OK’ button to calibrate
retracted length. The indication will change to
show your correct retracted boom length.
Now extend main boom all the way out. Make
sure you are within the allowed operating
range (especially maximum radius).
17.4.2 Length Sensor Adjustment Procedure
See section Activating the Service Screen for Sensor Calibration on how to access the length sensor
calibration screen.
Replace length cable using the following procedure:
Refer to system electrical wiring diagram and cable reel - parts list
1. Cut old cable at cable drum.
2. Disconnect damaged length cable from junction box at the boom nose.
3. Open cable reel cover and disconnect bus connector.
4. Remove cable reel from mounting brackets.
5. Remove damaged length cable, which is mounted to the slip rings in the cable reel, from slip ring
terminal.
6. On the backside of the cable reel, open the strain relief attached to the axle in the center of the
drum. Pull existing length cable out of the cable reel.
7. Pull new length cable through the hole, pipe and strain relief and push it through the axle of the
reeling drum. Tighten new strain relief to ensure sealing.
8. Reconnect the length cable to the slip ring.
9. Remount cable reel to the boom.
10. Turn reeling drum clockwise to spool the new cable neatly onto the drum.
11. Set pre-load on cable reel by turning the drum counter-clockwise 5 to 8 turns.
12. Run the new length cable through the cable guides and wrap the length cable around the boom
tip anchor pin (4 or 5 wraps) and secure with tie wraps. Leave enough length cable to connect
into the boom tip junction box.
13. Connect the length cable into the boom tip junction box.
14. Reset length potentiometer in length angle transducer (screw is located in center of white gear);
with boom fully retracted, turn potentiometer carefully counter-clockwise until it stops. Recheck
length and angle display. Refer to section Cable Reel LWG508 Adjustment Procedure.
Boom up to the next correction angle, 45 degrees
(range is 40°- 50°). When the boom angle is within
the calibration range, the screen will add the
‘CHANGE’,‘SET’ and
‘OK’ text as shown on the left.
Measure the boom angle with the inclinometer and
when the boom is positioned in the calibration range,
compare the measured angle to the displayed angle.
If the indicated angle is within +/- 0.1 degrees of the
measured angle, confirm with ‘OK’. Otherwise, select
‘SET’ to adjust the angle.
Once you push ‘SET’ , the screen is going to
change to the angle adjustment screen. Use
the ‘+’ and ‘-‘ buttons to adjust the indicated
angle to match the measured angle.
When the display shows the correct angle,
press ‘OK’.
Repeat the above procedure to verify/set the angle at 60 (range 55°- 65°) and 70 (range 65°- 75°).
boom angles.
NOTE: The only thing adjustable for the slew potentiometer is the zero point, which is complete when
the boom is at the 0 position over the front of the crane.
Defining the crane zero position:
The zero setting consists of defining zero-point offset. To define the zero-point or the slew
potentiometer the super structure must be positioned so the boom is in the zero degree position over
the front and the house lock pin engaged.
Using graphic console for zero-setting of slew pot potentiometer:
Press return until the slew adjustment screen is displayed.
The display shows a scale from –10 to +10 degree, a horizontal mark shows the current position of
the slew pot wiper.
By pressing the “+” and “-“ keys simultaneously, the zero setting occurs automatically. Note: The
indicator line will move to zero on the bar graph.
When the operator is finished, pressing the ESC key returns the console display to normal.
minimum radius or gone
past the maximum angle
specified in the respective
load chart due to luffing
up the boom too far
Luff down the boom to a
radius or angle specified
in the load chart.
E02
Radius range
exceeded or fallen
below angle range
Gone past the maximum
radius or fallen below the
minimum angle specified
in the respective load
chart due to luffing down
the boom too far
Luff up the boom to a
radius or angle specified
in the load chart.
E03
Non-permitted
slewing zone (no
load area)
The slewing zone with
load is not permitted
Slew to permitted area
E04
Operating mode not
acknowledged or
non permitted
slewing zone
A non existing operating
mode has been selected
Set the correct operating
mode for the operating
state in question
The boom is in a non-
permitted slewing zone
Slew the boom to a
permitted area.
E05
Prohibited length
range
Boom has been extended
either too far or not far
enough, e.g. if it is
prohibited to go beyond a
certain maximum boom
length or with load curves
for jibs where the main
boom has to be extended
to a certain length
Extend/retract boom to
the correct length
Length sensor adjustment
has changed, e.g. the
cable slid off the length
sensor reel.
Retract boom. Check the
prestress of the cable reel
(cable must be taut).
Open the length sensor
and carefully turn the
length sensor pot
counterclockwise until the
detent by means of a
screw driver
Clutch between length
sensor pot and drive is
defective
Replace the complete
clutch including drive
wheel and adjust length
sensor pot as described
above
18 ERROR CODES
The following Error Code Table gives a brief description of Error Codes elimination. Refer to the
noted sections for detailed Troubleshooting information.
No data transmission form the
console to the
central unit
24 V supply of the
console is interrupted
Check 24 V at terminal
X1 of the console
electronics
Interruption or accidental
ground in the line
between console
electronics and central
unit
Check the connection
console electronics central unit. In case of an
accidental ground, the
transmitter module of the
console electronics might
be damaged. Therefore,
replaces the console
electronics.
Transmitter/receiver
module is defective
Exchange console
electronics or LMI main
board resp.
E92
Error in the data
transmission from
console to central
unit
Loose connection in the
line between console
electronics and central
unit
Transmitter/receiver
module is defective
Check the connection
between console
electronics and central
unit
Exchange console
electronics or LMI main
board resp.
E93
Error in the data
transmission from
the central unit to
the console
refer to E92
refer to E92
E94
No data transmission from the
central unit to the
console
Interruption or accidental
ground in the line central
unit – console
Check line to the console
(in case of accidental
ground, replace console
electronics, too).
5 V supply of the
computer in the central
unit is missing
Check connection to the
power unit
5 V supply is too low
Exchange the LMI main
board
Transmitter/receiver
module is defective
Replace console
electronics or LMI main
board
Computer module is
defective
Replace processor board.
Electro-magnetic
interferences (e.g. when
switching contactors or
valves)
The PAT iFLEX5 LMI 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.
19.1 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 PAT LMI system 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 PAT representative.
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 PAT 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 PAT 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.
19.2 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 PAT representative for
breathing elements to than can be added to the box and will help to reduce the effects of
humid climates.