Hirschmann PAT IFLEX5 Service Manual

www.hirschmann.com

HIRSCHMANN

P/N 031-300-190-154 REV I 05/22/2017

LOAD MOMENT INDICATOR

iFLEX5

SERVICE MANUAL

Service Manual iFLEX5

REV

DATE

NAME

DESCRIPTION

-

04/10/02

CSH

ECN 02-122

A

06/03/02

MO

ECN 02-122

B

06/15/02

MO

ECN 02-122

C

06/24/02

MO

ECN 02-122

D

07/01/02

MO

ECN 02-122

E

12/04/02

CSH

ECN 02-179

F

07/29/03

CSH

ECN 03-088

G

06/05/06

SB

ECN 05-110

H

11/6/08

WG

ECN 08-173

I

05/22/17

AC

ECN 17-078

NOTICE

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.

MANUAL REVISIONS

Service Manual iFLEX5

TABLE OF CONTENTS

1 General Information ................................................................................................................. 1

2 Warnings ................................................................................................................................... 1

3 Description Of The System ...................................................................................................... 2

3.1 DESCRIPTION OF SYSTEM FUNCTION ........................................................................................... 2

3.2 DESCRIPTION OF A CAN BUS SYSTEM ......................................................................................... 2

3.3 DESCRIPTION OF THE SYSTEM COMPONENTS ............................................................................... 3

4 What’s Wrong? ......................................................................................................................... 4

4.1 I HAVE AN ERROR CODE INDICATED ON THE CONSOLE ................................................................... 4

4.2 THE DISPLAYED ANGLE DOES NOT MATCH THE ACTUAL BOOM ANGLE ............................................ 4

4.3 THE DISPLAYED LENGTH DOES NOT MATCH THE ACTUAL BOOM LENGTH ......................................... 4

4.4 THE DISPLAYED SLEWING DOES NOT MATCH THE ACTUAL SLEWING ANGLE .................................... 4

4.5 THE DISPLAYED LOAD DOES NOT MATCH THE ACTUAL LOAD .......................................................... 4

4.6 THE CONSOLE DISPLAY IS BLANK ................................................................................................. 4

4.7 I HAVE AN A2B PROBLEM ............................................................................................................ 4

4.8 I HAVE A CAN-BUS PROBLEM .................................................................................................... 4

4.9 I NEED TO IDENTIFY A SPARE PART ............................................................................................... 4

4.10 I HAVE NOTICED WATER IN SOME PART OF THE SYSTEM ................................................................. 4

5 Angle Sensing .......................................................................................................................... 5

5.1 ANGLE SENSING ERROR - FLOW CHART ........................................................................................ 6

6 Length Sensing ........................................................................................................................ 8

6.1 LENGTH SENSING ERROR - FLOW CHART..................................................................................... 9

7 Pressure Sensing ................................................................................................................... 11

7.1 PRESSURE SENSING ERROR - FLOW CHART ................................................................................ 11

8 Slewing Sensing ..................................................................................................................... 12

8.1 SLEW SENSING ERROR - FLOW CHART ........................................................................................ 13

9 Load sensing .......................................................................................................................... 14

9.1 LOAD SENSING ERROR - FLOW CHART ........................................................................................ 14

10 No console display ................................................................................................................. 15

11 A2B Problem ........................................................................................................................... 16

12 cann-bus communication ...................................................................................................... 17

12.1 E61 ......................................................................................................................................... 17

12.1.1 E61 - Flow Chart ............................................................................................................. 18

12.2 E62 ......................................................................................................................................... 19

12.3 E63 ......................................................................................................................................... 19

12.4 E64 ......................................................................................................................................... 19

12.4.1 E64 - Flow Chart ............................................................................................................. 20

12.5 E65 ......................................................................................................................................... 20

13 Troubleshooting a sensor problem using the display ......................................................... 21

14 iFLEX5 Boom Control System (BCS) .................................................................................... 24

14.1 RT9000E / RT800E BASICS ..................................................................................................... 24

14.1.1 Terminology: ................................................................................................................... 24

14.1.2 Components:................................................................................................................... 24

14.1.3 Manual / Auto Mode: ....................................................................................................... 24

14.2 TELE SEQUENCE: ..................................................................................................................... 26

Service Manual iFLEX5

14.3 IFLEX5 BCS DIGITAL INPUTS: .................................................................................................. 26

14.4 RT9000E / RT800E IFLEX5 BCS DIGITAL OUTPUTS: ............................................................... 27

14.5 IFLEX5 BCS ANALOG INPUTS AND PWM OUTPUTS: ................................................................. 29

14.6 IFLEX5 BCS TEST DISPLAY: .................................................................................................... 31

14.7 BOOM OUT OF SEQUENCE: ....................................................................................................... 32

14.8 TELE ROD DRAIN VALVE: .......................................................................................................... 32

14.9 TELE TWO STAGE RELIEF VALVE: ............................................................................................. 32

14.10 HYDRAULIC LUFFING BOOM EXTENSION: ............................................................................. 33

15 Drawings ................................................................................................................................. 34

15.1 COMPONENTS OF THE LMI SYSTEM PAT IFLEX5 ....................................................................... 34

15.2 BLOCK DIAGRAM ...................................................................................................................... 35

15.3 ELECTRICAL SYSTEM DIAGRAM STANDARD SYSTEM .................................................................. 36

15.3.1 Central Unit to Crane and Console Wiring Diagram .................................................... 36

15.3.2 Cable Reel (length/angle sensor) Wiring Diagram ....................................................... 37

15.3.3 Boom Extension Anti-two Block Wiring Diagram ........................................................ 38

15.4 MAIN CENTRAL UNIT CONNECTOR ............................................................................................. 38

15.5 ELECTRICAL SYSTEM DIAGRAM BOOM CONTROL SYSTEM .......................................................... 39

15.5.1 Central Unit to Crane Interface Wiring Diagram ........................................................... 39

15.5.2 Console and Sensor Wiring Diagram ............................................................................ 40

15.5.3 Cable Reel (LWG520/0002) Wiring Diagram .................................................................. 42

15.5.4 Luffer Extension Wiring Diagram .................................................................................. 43

16 Spare Part Listings................................................................................................................. 44

16.1 CENTRAL UNIT, IFLEX5 PART NO. 021-020-060-003 .......................................................... 44

16.2 GRAPHIC CONSOLE ASSY, VERTICAL PART NO. 050-350-061-356 ................................. 45

16.3 GRAPHIC CONSOLE ASSY, PART NO. 050-350-061-376 ................................................... 46

16.4 CABLE REEL, LWG508 PART NO. 068-508-060-001 ................................ ........................... 47

16.5 CABLE REEL, LWG521 PART NO. 068-521-060-002 ................................ ........................... 49

16.6 CABLE REEL, LWG152 PART NO. 067-152-060-056 ................................ ........................... 50

16.7 PRESSURE TRANSDUCER BLOCK, DAV314/0014 PART NO. 044-314-060-014 ........................ 51

16.8 CABLE ASSEMBLY 11M, PART NO. 031-010-101-007 ......................................................... 51

16.9 WIRING HARNESS STANDARD, PART NO. 031-010-100-549 ............................................. 51

16.10 WIRING HARNESS BOOM CONTROL, PART NO. 031-010-100-554 .............................. 52

16.11 CABLE ASSEMBLY, 14M PART NO. 031-010-100-555 ................................................... 52

16.12 TRS05 REPEATER, RADIO WINDSPEED KIT 031-300-104-087 ..................................... 53

17 Service Screen For Sensor Calibration ................................................................................ 54

17.1 ACTIVATING THE SERVICE SCREEN FOR SENSOR CALIBRATION .................................................. 54

17.2 ZERO-SETTING THE TRANSDUCER INPUTS ................................................................................. 55

17.3 ZERO-SETTING THE SLEWING INPUTS .............................................................................. 55

17.4 LENGTH SENSOR CALIBRATION PROCEDURE ............................................................................. 56

17.4.1 Cable Reel LWG508 Adjustment Procedure ................................................................. 56

17.4.2 Length Sensor Adjustment Procedure .......................................................................... 57

17.4.3 Cable Reel Length Cable Replacement Procedure ...................................................... 58

17.5 ANGLE SENSOR CALIBRATION PROCEDURE ............................................................................... 59

17.6 ZERO-SETTING THE SLEW POTENTIOMETER .............................................................................. 61

18 Error Codes ............................................................................................................................ 62

19 Troubleshooting Moisture ................................ ..................................................................... 72

19.1 WATER INGRESS ...................................................................................................................... 72

19.2 CONDENSATION ........................................................................................................................ 73

General Information

1

1 GENERAL INFORMATION

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 Verification of 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.

Service Manual iFLEX5

2

3 DESCRIPTION OF THE SYSTEM

3.1 DESCRIPTION OF SYSTEM FUNCTION

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.

Description Of The System

3

3.3 DESCRIPTION OF THE SYSTEM COMPONENTS

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.

Service Manual iFLEX5

4

4 WHAT’S WRONG?

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

Please go to section Troubleshooting Moisture!

Angle Sensing

5

Terminal X21

1

+ 5V

3

Signal

5

GND

Pressure Transducer

iFLEX5

CU

Angle

Sensor

CAN-Bus

Converter

Cable Reel

LED

X21 (angle)

X20 (length)

X14 (A2B)

X1 (CAN)

5 ANGLE SENSING

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:

6

5.1 ANGLE SENSING ERROR - FLOW CHART

Angle Sensing Error

First, verify the angle displayed through the console by using the sensor output screen.

Press the info button twice

Angle sensor is functioning

correctly.

Angle sensor range values:

4500mV at 0° 2500mV at 45° 500mV at 90°

Does the displayed

value differ from the

actual value?

Open the cable reel and locate the angle sensor (right) and CAN-Bus converter board (left).

Verify that the sensor is

being supplied with 5V

by measuring between

pin 5 (GND) and Pin 1

(+) of terminal X21.

Is the voltage

between the

range of 4.75

to 5.25V ?

Replace converter

board

If unplugging the angle sensor made the voltage return to

the acceptable range, replace the angle sensor. Follow

procedure for angle sensor installation and calibration.

compare

YES

NO

Is the voltage

between the

range of 4.75

to 5.25V ?

1ST

2ND

MEASURE AGAIN

Continue with angle sensing

flow chart (next page)

Unplug angle sensor

and measure again.

NO

2ND

Recalibrate angle

sensor. (Reference Angle sensor calibration

procedure).

Service Manual iFLEX5

Angle Sensing

7

Angle Sensor signal varies

Ensure the angle sensor returns a voltage

between 1.875V at 90° and 3.125V at 0°

Does the indicated angle vary by more than +/- 0.25° from

the actual angle?

Replace converter

board.

If this angle varies significantly

from your actual angle, replace

the angle sensor.

YES

Ensure correct software has been installed

and crane operator is not in error.

NO

Verify the voltage by measuring

Between Pin 5 (GND) and Pin3

(signal) of terminal X21.

Angle Sensor Signal On Pin 3:

Angle Voltage

90 1.875 75 2.083 60 2.292 45 2.500 30 2.708 15 2.917 0 3.125

Note: Actual voltages will vary slightly.

Note: If you need to determine the angle for voltages other than

shown above, do so by using the following formula:

Angle (degrees) = 90 degrees – ((Voltage-1.875) * 72)

Service Manual iFLEX5

8

Terminal X20

1

+ (~ 4.8V)

3

Signal

5

- (~ 0.2V)

Pressure Transducer

iFLEX5

CU

Cable Reel

Length

Sensor

CAN-Bus Converter

LED

X21 (angle)

X20 (length)

X14 (A2B)

X1 (CAN)

6 LENGTH SENSING

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:

Length Sensing

9

Length Sensing Error

First, verify the length displayed through the

console is off by using the sensor output screen.

Press the info button twice

Length sensor is

functioning correctly.

Does the displayed

value differ from the

actual value?

Open the cable reel

and locate the length

sensor (right) and

CAN-Bus converter

board (left).

Does the indicated

length vary

significantly from the

actual length (more

than 0.3 feet)?

Replace length

sensor.

Proceed to next length sensing flow chart.

NO

YES

Ensure the

cable reel has

5-8 turns of

preloading on

the reel.

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.

YES

NO

Press the info button twice

6.1 LENGTH SENSING ERROR - FLOW CHART

Service Manual iFLEX5

10

Length Sensor Signal on Pin 3

Turns

Voltage X20-5 to X20-3

Voltage GND to X20-3 0

0.00

0.16

1

0.46

0.62

2

0.93

1.09

3

1.40

1.56

4

1.87

2.03

5

2.34

2.50

6

2.81

2.97

7

3.28

3.44

8

3.75

3.91

9

4.22

4.38

10

4.68

4.84

Length Sensor varies

Replace

converter

board.

If unplugging the length sensor

made the voltage return to the

acceptable range, replace the

length sensor. Follow procedure

for length sensor calibration.

YES

NO

1ST

2ND

Ensure the length

sensor is being

supplied with 4.7V by

measuring between

Pin 5 (-) and Pin 1 (+)

of the X20 terminal.

Is the voltage

between the

range of 4.7V

to 5.0V ?

See length sensor

signal chart below.

YES

NO

Unplug the length

sensor and

measure again.

Is the voltage

between the

range of 4.7V

to 5.0V ?

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.

Pressure Sensing

11

iFLEX5

CU

Pressure Transducer

(2)

Pressure-

Measuring

Cells

CAN-Bus

Converter

Pressure Sensing Error

First, verify the pressure displayed through the

console by using the sensor output screen.

Press the info button twice

Pressure transducers are

functioning correctly.

Does the

displayed value

differ from the

actual value?

The readout should

read 500mV (+/-

25mV) and 0 PSI.

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.

Service Manual iFLEX5

12

0

500

1000

1500

2000

2500

3000

3500

4000

0 45 90 135 180 225 270 315 360

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.

Slewing Sensing

13

Modular Slew Pot - Output Currents

0

4

8

12

16

20

24

0 90 180 270 360

Degrees

mA

mA 2 mA 3

Slew Sensing Error

First, verify the slew angle displayed through

the console by using the sensor output screen.

Press the info button twice

Slew potentiometer is

functioning correctly.

Does the

displayed value

differ from the

actual value?

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)).

Service Manual iFLEX5

14

Correct whichever

value differs

Load Sensing Error

Verify operator’s settings are correct

Verify angle, length, and pressure readings

Press the info button twice

Do the

displayed

values differ

NO

YES

Zero pressure transducers,

calibrate angle and length

If a problem still persists,

replace the pressure

transducer block.

9 LOAD SENSING

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.

9.1 LOAD SENSING ERROR - FLOW CHART

No console display

15

No console display

Ensure that no lights, warning

lights, or backlighting is visible.

Check wiring harness

and central unit.

NO

Open console.

Check if power is being supplied by the

central unit. Measure on the green connector

(Pin 1 is +Ub 12V and Pin 2 is GND).

Is power

being

supplied?

YES

Check fuses in console: one (F6) is located on

the connection board (mounted to the inside of

the housing) which protects the override key

switch function and the bar-gragh. The main fuse

(F1) is locate on the console processor board.

Are fuses

NO

Replace fuse.

YES

Check for power on connector

X6 of the connection board. (Pin 1 is +Ub 12V and Pin 2 is GND).

Is power

being

supplied?

NO

YES

Follow power from this connector to the console computer

board, connector X1. (Pin 1 is +Ub 12V and Pin 2 is GND).

Is power

being

supplied?

NO

Connecting

cable is

loose or

defective.

YES

If voltage is present on all

pins and connector are in

place, but you still do not get

any console lighting.

Ensure TxD LED is on (located in center of

the computer board and is normally blinking

when the console is communicating).

Check fuse F1 again. Make sure all connectors are correctly in place.

Conn. Board Computer Board Pins

X6 X1 4 X10 X22 6 X7 X2 10

* X10-X22 could be plugged into X17 by mistake

Software is

defective.

OR

Console electronics

need replaced.

If no power was

supplied on the

connection board but

was supplied on the external connector, the connection board must

be replaced.

10 NO CONSOLE DISPLAY

If the console is not showing any lights, such as warning lights, backlighting, etc. it is most likely missing power. Start with the following:

16

A2B problem

Ensure the

bypass

plug is

installed.

Turn power off, remove bypass plug, and

measure the resistance at the boom nose box

between terminals 1 and 3 with an ohmmeter.

Switch closed = 0 ohms (weight installed)

Switch open = 1 Megaohm (weight removed)

Are the control levers

locked out and is the

crane in an anti-two

block condition?

Lower the hook block and/or

headache ball to correct the

two-block problem. If two

hoists are in use, both hooks

must be lowered.

If wiring is

correct, replace

A2B switch.

NO

Is the anti-two

block warning

light on?

NO

YES

Remove wires and measure the A2B

signal in the cable reel between terminal

7 and 8 with an ohmmeter.

Switch closed = 4700 +/- 500 Ohms

Switch open = > 1 Megaohm.

YES

Are the ohmmeter

readings correct?

YES

Plug the bypass

plug into the

boom nose box

and refer to

system wiring to

check wire

connections in

boom nose box.

NO

Check for

damaged length

cable and wiring.

If broken length

cable, refer to

system wiring.

Are the

ohmmeter

readings correct?

Are the

ohmmeter

readings correct?

NO

Replace the

slip ring.

YES

A problem lies with either the wiring

harness, cable reel length/angle

boards, and/or the central unit.

Ensure bypass plug is plugged into the

boom nose box. Remove wires and

measure the A2B signal in the cable reel

between the X1: (brown) an X2 (red) wires

on the slip ring with an ohmmeter.

Switch closed = 4700 +/- 500 Ohms

Switch open = > 1 Megaohm.

11 A2B PROBLEM

Service Manual iFLEX5

cann-bus communication

17

Connector M12, 5 contacts

Pin Layout (CiA DR-303-1 7.2)

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:

Service Manual iFLEX5

18

E61

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

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.

12.1.1 E61 - Flow Chart

cann-bus communication

19

X1 Pin

CAN

1

CAN_SHLD

2

CAN +UB

3

CAN GND

4

CAN_H

5

CAN_L

LED

X21 (angle)

X20 (length)

X14 (A2B)

X1 (CAN)

12.2 E62

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.

CAN-Bus electronics in cable reel.

20

12.4.1 E64 - Flow Chart

E64

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,

A2B PROBLEM) to continue trouble shooting.

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

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.

Service Manual iFLEX5

22

Voltage Values displayed [mV] +/- 10mV

Value displayed

Value

Pressure Transducers 300 bar, type 314

PSI

Bar

500

0 0 1500

1088

75

2500

2176

150

3500

3263

225

4500

4351

300

Angle Sensor

degrees

500

90

boom vertical

1500

67.5

2500

45

3500

22.5

4500

0

boom horizontal

Length Sensor

feet

500

0

fully retracted

1500

2500

3500

4500

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

180°

20.00

12.00

-135°

16.00

8.00

-90°

12.00

4.00

-45°

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.

Service Manual iFLEX5

24

1

14 IFLEX5 BOOM CONTROL SYSTEM (BCS)

14.1 RT9000E / RT800E BASICS

14.1.1 Terminology:

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.

Refer to table 1 for digital input definitions

iFLEX5 Boom Control System (BCS)

25

2

14.1.3.A Manual Mode Operation:

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.

figure 1

Refer to table 2 for digital output definitions

26

14.2 TELE SEQUENCE:

Digital

Input

Description

*C.U. X2 Terminal

**MP

6

CM (Center-Mid) Retracted (boom proximity switch)

54

R89

7

IM (Inner-Mid) Retracted (boom proximity switch)

55

R90

8

Luffing Extension Raise (cab switch)

56

R91

9

Luffing Extension Lower (cab switch)

57

R92

10

Luffing Extension Raise (remote switch on ext.)

58

R93

11

Luffing Extension Lower (remote switch on ext.)

59

R94

16

“A” Mode (cab switch)

64

R100

17

Auto Mode (cab switch)

65

R101

18

Boom Retract (pressure switch)

66

R102

19

Boom Extend (pressure switch)

67

R103

Mode "B" Extend Sequence in Percentage

Tele 1 (IM)

Tele 2 (CM)

Tele 3 (OM/Fly)

0 0 0

75 0 0

75

0

100

75

0

100

0

100

Jib Mode Extend Sequence in Percentage

Tele 1 (IM)

Tele 2 (CM)

Tele 3 (OM/Fly)

100 0 0

100

0

100

RT9000E: Mode “A” - not available RT800E: Mode “A”

Mode “B”

table1

Jib Mode (not selectable, realized by operating mode selection)

table 2

Note: Retract sequence is opposite of extend sequence.

14.3 IFLEX5 BCS DIGITAL INPUTS:

table 1

Service Manual iFLEX5

iFLEX5 Boom Control System (BCS)

27

Digital

Output

Description

C.U. X2 Terminal

1

PWM 1 CM Proportional Solenoid

2

+UB CAN bus

3

PWM 2 IM Proportional Solenoid

4

+UB to Slew Potentiometer Electronics

5

PWM 3 Luffing Extension Proportional Solenoid

6

CM Extend Relay K1 Coil in Junction Box

7

PWM 4 Luffing Extension Proportional Solenoid

8

IM Extend Relay K2 Coil in Junction Box

9

Luffing Extension Raise Solenoid

14

10

External LMI Alarm, Option on Boom

15

11

Luffing Extension Lower Solenoid

16

12

Rear Axle Oscillate Signal

17

13

Tele Rod Drain Solenoid

18

14

Boom Out of Sequence Lamp

19

15

Tele Two Stage Relief Solenoid

20

14.4 RT9000E / RT800E IFLEX5 BCS DIGITAL OUTPUTS:

table 2

*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

Service Manual iFLEX5

28

DO 16

DI 9

DI 1

DI 8

DO 1

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)

-------|--------|--------|---------|----------|----------|----------|-------- Basis | 0 : 1 | NORMAL | 00 | 00000000 | 05 | 00000101 | 0000-1 Basis | 1 : 2 | NORMAL | 00 | 00000000 | 82 | 10000010 | 0011-0 Basis | 2 : 3 | NORMAL | 98 | 10011000 | 00 | | Erw. | 0 : 4 | NORMAL | 00 | 00000000 | 00 | 00000000 | 1111-1 Erw. | 1 : 5 | NORMAL | 00 | 00000000 | 00 | 00000000 | 1111-1 Erw. | 2 : 6 | NORMAL | 00 | 00000000 | 00 | 00000000 | 1111-1

-------|--------|--------|---------|----------|----------|----------|--------

Baugruppencodierung Basis : 0F = 00001111

Baugruppencodierung Erweiterung: FF = 11111111 Hubendschalter UNTB/OFFEN/OK/KURZ: 0000

X:Exit Blank:Redraw S:Slow F:Fast

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

iFLEX5 Boom Control System (BCS)

29

Resistor bank to measure digital input (DI) state. Note: must measure on bottom leg of the resistor.

C.U. 70-pass connector pins (X2)

14.5 IFLEX5 BCS ANALOG INPUTS AND PWM OUTPUTS:

Another useful tool to monitor analog inputs and PWM outputs 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 “adctest” and press “Enter”. The result should be the screen shown below.

Service Manual iFLEX5

30

Kanal

Description

1

Slew Angle 1

2

Slew Angle 2

3

Wind Speed

5

Luffing Extension Offset Angle

PWM

Description

1

Center-Mid Tele Output

2

Inner-Mid Tele Output

3

Luffing Extension Raise Output

4

Luffing Extension Raise Output

*adctest

---+-----+-------+--------+-------+-------+------+----------------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

Note: DO 1 = PWM 1

DO 3 = PWM 2 DO 5 = PWM 3

DO 7 = PWM 4

iFLEX5 Boom Control System (BCS)

31

Boom Status / Luffer Status

IM Tele Output (0-255)

CM Tele Output (0-255)

Luffing Ext Raise Output (0-255)

Luffing Offset Angle(degrees)

Length 2 (IM) (feet)

Status No.

Description

1 - 11

Mode B extend

29

Error Mode B extend

31 - 41

Mode B retract

59

Error Mode B retract

61 - 67

Mode A extend

79

Error Mode A extend

81 - 85

Mode A retract

99

Error Mode A retract

100

Manual Mode A neutral or extend

101

Manual Mode B neutral or extend

102 - 108

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”.

Service Manual iFLEX5

32

Tele Rod Drain Solenoid

IM retract sw.

CM retract sw.

Retract pressure sw.

(DO13)

(DI 7)

(DI 6)

(DI 18)

0 1 1 0

1

Tele Two Stage Relief Solenoid (DO15)

Retract pressure sw. (DI 18)

Extend pressure sw. (DI 19)

OM/Fly Percentage

IM rertract sw. (DI 7)

CM retract sw. (DI 6)

1 1

>4%

0 1

1

boom section percentage display

14.7 BOOM OUT OF SEQUENCE:

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.

iFLEX5 Boom Control System (BCS)

33

14.10 HYDRAULIC LUFFING BOOM EXTENSION:

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.

Service Manual iFLEX5

34

1 Central-Micro-Processor Unit 2 Operating Console 3 Pressure Transducers 4 Length/Angle Sensor 5 Anti Two-Block Switch(es)

POWER

LOCKOUT

OTHER

PAT

15 DRAWINGS

15.1 COMPONENTS OF THE LMI SYSTEM PAT IFLEX5

Drawings

35

CAN-BUS

RS 485

Serial

Interface

Current

4..20mA

CAN-connector

iflex5 Central Unit

Dual Pressure

Graphic

Console

Length/Angle Sensor

A2B

Slew Sensor

70 pin

Connector

Crane Power

CAN-connector

Lockout

15.2 BLOCK 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.

36

15.3 ELECTRICAL SYSTEM DIAGRAM STANDARD SYSTEM

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

Service Manual iFLEX5

Drawings

37

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.

15.3.2 Cable Reel (length/angle sensor) Wiring Diagram

38

15.3.3 Boom Extension Anti-two Block 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.

15.4 MAIN CENTRAL UNIT CONNECTOR

This is a 70 pass connector.

Service Manual iFLEX5

Drawings

39

15.5 ELECTRICAL SYSTEM DIAGRAM BOOM CONTROL SYSTEM

15.5.1 Central Unit to Crane Interface Wiring Diagram

40

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.

15.5.2 Console and Sensor Wiring Diagram

Service Manual iFLEX5

Drawings

41

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.

Cable Reel (LG152/0056) Wiring Diagram

42

15.5.3 Cable Reel (LWG520/0002) Wiring Diagram

LUFFING JIB CONNECTION

REFER TO LUFFING EXTENSION

WIRING DIAGRAM

TO LG152/0056 REFER TO CABLE REEL

(LG152/0056) WIRING DIAGRAM

TO PRESSURE TRANSDUCER BLOCK REFER TO CONSOLE AND SENSOR WIRING DIAGRAM

Service Manual iFLEX5

Drawings

43

BOOM TIP CONNECTION TO LWG520/0002 REFER TO CABLE REEL (LWG520/0002) WIRING DIAGRAM

15.5.4 Luffer Extension Wiring Diagram

Service Manual iFLEX5

44

1

2

3

7

16 SPARE PART LISTINGS

16.1 CENTRAL UNIT, IFLEX5 PART NO. 021-020-060-003

NO. PART NO. QTY DESCRIPTION

1 024-000-100-041 1 CENTRAL UNIT ACCY, GROUNDING KIT 2 022-022-300-031 1 BATTERY, LITHIUM 3V 3 024-350-100-661 1 KEY SWITCH 4* 031-300-110-151 1 CENTRAL UNIT COVER iFLEX

5* 024-350-100-135 1 SCREW SET 6* 031-300-101-131 1 SPARE KEY 7 024-350-110-066 42” GASKET

* ITEM NOT SHOWN

Spare Part Listings

45

1,2

3

5

4

2

3 6 7

8

9

10

16.2 GRAPHIC CONSOLE ASSY, VERTICAL PART NO. 050-350-061-356

NO. PART NO. QTY DESCRIPTION

1 050-350-100-001 1 SPARE KEY, GRAPHIC CONSOLE 2 050-350-110-306 1 KEYSWITCH, DS350/1356 3 031-300-110-149 1 FRONTFACE WITH DISPLAY, COMPUTER BOARDS, AND

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.

46

1

factory serviceable only

1

Front face, 1376

2

factory serviceable only

1

Board, console main

3

factory serviceable only

1

Display, LCD 320 x 240

4

050-150-300-086

1

Board, console connection with horn

5

050-150-300-073

1

Board, 6 x LED

6

050-150-300-092

1

Board, 5 x LED

7

092-000-060-391

1

Cable, M12 5p female x 5p JST female x 10cm

8

050-150-290-063

1

Cable, 10p

9

050-150-290-064

1

Cable, 6p

10

050-150-290-061

1

Cable, 4p

11

031-300-050-223

2

Fuse, 2A

11

6

10

11

1 2 3 47 9 8

5

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.

Spare Part Listings

47

4 7 3

2

5

8

6

1

9

16.4 CABLE REEL, LWG508 PART NO. 068-508-060-001

NO. PART NO. QTY DESCRIPTION

1 031-300-060-468 1 CABLE REEL ACCY, LWG508 DRUM BODY W/LENGTH

CABLE 2 000-673-020-002 139’ LENGTH SENSOR CABLE 3 068-000-300-103 1 BOARD, LENGTH AND ANGLE OUTPUT 4 067-000-300-012 1 LENGTH POTENTIOMETER LWG508 5 064-143-060-009 1 ANGLE SENSOR, WG143/09 6 068-000-110-107 1 SLIP RING ASSEMBLY 2 CONDUCTOR 7* 006-800-005-001 1 25T GEAR WHEEL 8 068-000-110-038 1 75T GEAR WHEEL 9* 092-000-060-387 1 CONNECTOR, 5 POLE W/WIRES 10* 068-000-100-196 1 LID, BLACK 11* 068-000-110-003 1 CABLE REEL ACCY, GASKET FOR COVER 12* 068-000-110-031 10 CABLE REEL ACCY, SCREW/CAPTIVE * ITEM NOT SHOWN

Also see detail on next page.

Service Manual iFLEX5

48

3 4 5

6

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.

Spare Part Listings

49

16.5 CABLE REEL, LWG521 PART NO. 068-521-060-002

NO. PART NO. QTY DESCRIPTION

1 031-300-060-440 1 CABLE REEL ACCY, LWG521 DRUM BODY W/LENGTH CABLE 2* 000-673-080-025 176’ LENGTH SENSOR CABLE 11 CORE 3* 068-000-300-102 1 BOARD, 2 LENGTH AND ANGLE OUTPUT 4 068-000-300-063 1 BOARD, FILTER 5 067-000-300-013 1 LENGTH POTENTIOMETER LWG 6 064-143-060-009 1 ANGLE SENSOR, WG143/09 7 068-000-060-072 1 SLIP RING ASSEMBLY 11 CONDUCTOR 8 006-800-005-002 1 24T GEAR WHEEL 10* 092-000-060-387 1 CONNECTOR, 5 POLE W/WIRES 11* 068-000-100-196 1 LID, BLACK 12* 002-090-100-031 1 CABLE REEL ACCY, GASKET FOR COVER 13* 068-000-110-031 10 CABLE REEL ACCY, SCREW/CAPTIVE 14 068-000-110-038 1 GEAR WHEEL, KT200 * ITEM NOT SHOWN

Service Manual iFLEX5

50

7

13

3

2

1

5 9 6

8

16.6 CABLE REEL, LWG152 PART NO. 067-152-060-056

NO. PART NO. QTY DESCRIPTION

1 031-300-060-441 1 CABLE REEL ACCY, LG152 DRUM BODY W/LENGTH CABLE 2* 000-673-030-022 87’ LENGTH SENSOR CABLE 3 CORE 3 068-000-110-029 1 TERMINAL STRIP 4* 068-000-300-063 1 BOARD, FILTER 5 067-000-300-012 1 LENGTH POTENTIOMETER LWG 6 068-000-100-066 1 SLIP RING ASSEMBLY 4 CONDUCTOR 7 067-000-050-075 1 55T GEAR WHEEL ON POTENTIOMETER 8 068-000-050-083 1 45T GEAR WHEEL ON CENTER SHAFT 9 000-268-030-003 4 HARDWARE, STANDOFF 6MM X 117MM MM 10* 067-000-110-020 1 HARDWARE, GASKET 11* 067-000-050-059 1 SENSOR ACCY, COVER KT152 12* 067-000-110-025 1 SENSOR ACCY, NUTS (4) & WASHER (4) FOR KT152 COVER 13 031-010-100-556 1 CABLE ASSEMBLY, 2.5m * ITEM NOT SHOWN

Spare Part Listings

51

16.7 PRESSURE TRANSDUCER BLOCK, DAV314/0014 PART NO. 044-314-060-014

16.8 CABLE ASSEMBLY 11M, PART NO. 031-010-101-007

16.9 WIRING HARNESS STANDARD, PART NO. 031-010-100-549

Service Manual iFLEX5

52

16.10 WIRING HARNESS BOOM CONTROL, PART NO. 031-010-100-554

6 Cables for:

1. Console

2. Crane interface 7 conductors

3. Crane interface 24 conductors

4. LG152 cable reel

5. CAN bus cable

6. Optional radio wind speed receiver

16.11 CABLE ASSEMBLY, 14M PART NO. 031-010-100-555

Spare Part Listings

53

031-300-060-596 TRS 05 REPEATER 031-300-050-688 ANTENNA, 918 MHz RCL 90°

031-300-060-601 CABLE ASSY, 15' 2 COND SS 20AWG W/12 SKT DEUTSCH

16.12 TRS05 REPEATER, RADIO WINDSPEED KIT 031-300-104-087

Service Manual iFLEX5

54

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

normal.

Service Screen For Sensor Calibration

55

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.

Service Manual iFLEX5

56

17.4 LENGTH SENSOR CALIBRATION PROCEDURE

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

Procedure.

Service Screen For Sensor Calibration

57

Select the length calibration by pressing “OK”

at the “Calibrate Length” screen.

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.

Service Manual iFLEX5

58

17.4.3 Cable Reel Length Cable Replacement Procedure

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.

15. Connect bus connector

16. Follow Length Sensor Adjustment Procedure.

Service Screen For Sensor Calibration

59

Select the angle calibration by pressing “OK”

at the calibrate angle screen.

17.5 ANGLE SENSOR CALIBRATION PROCEDURE

Material required – calibrated inclinometer. See section Activating the Service Screen for Sensor Calibration on how to access the angle sensor

calibration screen.

Service Manual iFLEX5

60

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.

Press ESC to leave service screen.

Service Screen For Sensor Calibration

61

17.6 ZERO-SETTING THE SLEW POTENTIOMETER

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.

Service Manual iFLEX5

62

Error Code

Error

Cause

Elimination

E01

Fallen below radius range or angle range exceeded

 Fallen below the

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.

Error Codes

63

Error Code

Error

Cause

Elimination

E06

Radius range exceeded or fallen below angle range with luffing jib operation

 Maximum radius as

specified in the load chart exceeded or fallen below minimum angle due to luffing down the luffing jib too far

 Luff the jib to a radius or

angle specified in the load chart.

E07

Overload relays check

 relays = overload active

and CU input 20 = on

 relays = no overload

and CU input 20 = off

 PDB variable invalid  emergency stop caused

by system software

 check cable to overload

relays and CU input 20

 check relays  check CU input 20  reset system  reset system

E11

Fallen below lower limit value for measuring channel "length main boom"

 Length potentiometer is

defective

 Replace length

potentiometer

 Electronic component in

the measuring channel is defective

 Replace sensor unit

E12

Fallen below the lower limit value in the measuring channel "pressure piston side"

 Pressure transducer is

defective.

 Replace pressure

transducer

 Electronic component in

the measuring channel is defective.

 Replace sensor unit

E13

Fallen below lower limit value in the measuring channel "pressure rod side"

 refer to E12

E14

Fallen below lower limit value in measuring channel "force"

 Force transducer

defective

 Electronic component in

the measuring channel is defective.

 Replace force transducer  Replace sensor unit

E15

Fallen below lower limit value in measuring channel "angle main boom"

 Angle potentiometer

defective

 Replace angle sensor  Electronic component in

the measuring channel defective.

 Replace sensor unit

Service Manual iFLEX5

64

Error Code

Error

Cause

Elimination

E16

Fallen below lower limit value in measuring channel "angle 2"

 Angle potentiometer

defective

 Replace angle sensor  Electronic component in

the measuring channel defective.

 Replace sensor unit

E17

Fallen below lower limit value "length telescope I (+II)"

 Length potentiometer

defective

 Replace length sensor.  Electronic component in

the measuring channel defective

 Replace sensor unit

E18

Front outrigger overloaded

 Front outrigger

overloaded



E1A

Fallen below lower limit value in measuring channel "slewing angle 1".

 Cable between the

central unit and the slewing angle sensor defective or loose. Water inside the plug of the angle sensor

 Check cable as well as

plugs, replace, if need be.

 Slewing angle

potentiometer is defective

 Replace slewing angle

sensor

 Electronic component in

the measuring channel defective

 Replace sensor unit

E1B

Fallen below lower limit value in measuring channel "slewing angle 2"

 refer to E1A

E1C

Fallen below lower limit value in measuring channel "luffing jib angle"

 Angle potentiometer

defective

 Replace angle sensor  Electronic component in

the measuring channel defective.

 Replace sensor unit

Error Codes

65

Error Code

Error

Cause

Elimination

E21

Upper limit value in measuring channel "main boom length" has been exceeded.

 refer to E11

E22

Upper limit value in measuring channel "pressure piston side" has been exceeded

 refer to E12

E23

Upper limit value in measuring channel "pressure rod side" has been exceeded.

 refer to E12

E24

Upper limit value in measuring channel "force" has been exceeded.

 refer to E14

E25

Upper limit value in measuring channel "main boom angle" has been exceeded.

 refer to E15

E26

Upper limit value in measuring channel "angle 2" has been exceeded.

 refer to E16

E27

Upper limit value in measuring channel "length telescope I (+II) has been exceeded.

 refer to E17

E2A

Upper limit value in measuring channel "slewing angle 1" has been exceeded

 refer to E1A

E2B

Upper limit value in measuring channel "slewing angle 2" has been exceeded

 refer to E1A

E2C

Upper limit value in measuring channel "luffing jib angle" has been exceeded

 Angle potentiometer

defective

 Replace angle sensor  Electronic component in

the measuring channel defective.

 Replace sensor unit

Service Manual iFLEX5

66

Error Code

Error

Cause

Elimination

E31

Error in the system program

 The system program file

is defective.

 Flash-EPROM defective

 Upload valid system

software

 Replace central unit

E37

Error in the logical program flow

 System program file is

defective

 Flash-EPROM defective

 Upload valid system

software

 Replace central unit

E38

System program and crane data file do not match.

 The system program in

the LMI does not match to the programming in the crane data file

 Upload valid system

program file or the valid crane data file

E39

System program and load chart file do not match

 The system program in

the LMI and the programming in the load chart file do not match.

 Upload valid system

program file or the valid load chart file

E43

Error in the write/read memory, (RAM)

 Write/read memory

(RAM) or central unit defective.

 Replace central unit

E47

Error in the monitored write/ read memory.

The CRC verification of the monitored write/read memory provides an incoherent result

 The CRC sign of the

monitored write/read memory is wrong

 The buffer battery is

decharged (< 2V at 1kOhm).

 Central unit defective.

 Restart the LMI

 Replace buffer battery on

the central unit.

 Replace central unit

E51

Error in the crane data file

 No valid data in the crane

data file.

 Flash-EPROM defective

 Upload valid crane data

file

 Replace central unit

E52

Error in load chart file.

 No valid data in the load

chart file

 Flash-EPROM defective

 Upload valid load chart

file

 Replace central unit

E56

Error in crane data file.

 No valid data in the crane

data file during calibration.

 Flash-EPROM defective

 Restore or upload valid

crane data file

 Replace central unit

E57

Error in serial crane data file.

 Calibration data file does

not contain valid data.

 Flash-EPROM defective

 Upload calibration data

file

 Replace central unit

Error Codes

67

Error Code

Error

Cause

Elimination

E60

The number of the selected File base and the programmed value are not identical

 No valid data in the load

chart file

 Upload valid load chart

file

 Base number not

programmed

 Program the correct base

number (1 for base 1, 2 for base 2)

 Load chart file wrongly

programmed

 Check base programming

in the load chart file.

E61

Error in the CAN bus data transfer for all CAN units

 CAN Bus cable between

the central unit and the sensor unit defective or not connected.

 Check the connection

between the central unit and the sensor units

 Can bus port in the

central unit defective

 Replace the central unit

 Short circuit in a CAN Bus

cable

 Replace Can Bus cable

E62

Error in the can bus data transfer of the pressure transducer sensor unit

 Cable between the

central unit and the sensor unit defective.

 Check the cable to the

sensor unit

 Can bus port in the

central unit defective

 Replace the central unit

 Can bus port in the

sensor unit is defective

 Replace the sensor unit  Sensor unit is defective

 Replace the sensor unit

E63

Error in the can bus pressure transducer sensor unit

 The analog values of the

sensor unit are invalid

 Replace the sensor unit

E64

Error in the can bus data transfer of the length/angle sensor unit

 See E62

E65

Error in the can bus length/angle sensor unit

 See E63

E66

Error in the can bus data transfer of the 2nd length/angle sensor unit

 See E62

E67

Error in the can bus of the 2nd length /angle sensor unit

 See E63

E68

Error in the can bus data transfer of the force sensor unit

 See E62

E69

Error in the can bus force sensor unit

 See E63

Service Manual iFLEX5

68

Error Code

Error

Cause

Elimination

E80

Error in the slewing angle measurement

 The difference between

the average of the slewing angle and one of the wipers of the slewing potentiometer is out of the tolerance

 Check the slewing

potentiometer adjustment

 Replace slewing angle

sensor

E82

Error boom control task

 The boom control task is

not running

 Restart the system  Load the boom control

task

E84

Wrong rigging condition.

 The selected rigging

condition is not contained in the crane data file.

 Select another rigging

condition

 Check the programming

in the crane data file.

E85

Error in the radius determination

 The computed radius is

too small (negative deflection)

 Check the programming

in the crane data file.

E89

Operating mode switchover with load.

 The operating mode on

the console has been switched over with the boom loaded.

 Select operating mode

without load on the boom

Error Codes

69

Error Code

Error

Cause

Elimination

E91

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

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)

 Eliminate the source of

interferences by inverse diodes or varistors.

Service Manual iFLEX5

70

Error Code

Error

Cause

Elimination

E95

Error in the console File

 The console File is

defective.

 Replace the console File

E96

Error in the internal RAM of the console.

 The CPU of the console

is defective.

 The console main board

is defective.

 Replace the CPU of the

console

 Replace the console main

board.

E97

Error in the external RAM of the console

 The external RAM of the

console is defective.

 The console main board

is defective.

 Replace the external

RAM of the console.

 Replace the console main

board.

E98

LMI watchdog activated

 LMI processing time limit

exceeded

 Reset system  Connect PC terminal and

watch error messages

EAB

Short circuit in the A2B switch circuit

 Short circuit in the A2B

switch

 Short circuit in the cable

to the A2B switch

 Replace A2B switch

 Replace cable to the A2B

switch

EAC

A2B switch circuit disconnected

 Disconnected cable in the

A2B switch

 Disconnected cable to the

A2B switch

 Connect or replace cable

in the A2B switch

 Connect or replace cable

to the A2B switch

EAD

No valid A2B switch status

 Sensor wrong function  CAN bus delay

 Replace A2B switch  Replace cable to the A2B

switch

EC0

Prohibited area

 Boom is about to collide

with the engine hood, switch off

 Move boom to permitted

area

 Check values in the data

prom DGA 11.5.

EC1

Approaching prohibited area

 Boom is about to collide

with the engine hood, prewarning

 Move boom to permitted

area

 Check values in the data

prom DGA 11.5.

EC2

Angle range of luffing jib exceeded

 Luffing jib is raised too far

 Luff down the jib to a

angle specified in the load chart.

Error Codes

71

Error Code

Error

Cause

Elimination

EDA

Datalogger write error

 Datalogger not connected  No power supply  Wrong Dos drive status

 Check CAN bus

connection

 Check power supply  Connect PC terminal and

Refer to Dos drive status list

 Temporary: Press horn

quit button to work without datalogger

EDB

Datalogger setup error

 Setup of the datalogger is

cleared (ser. crane data file or battery buffered RAM)

 transfer data and setup

datalogger again

 temporary: Press horn

quit button to work without datalogger

EDC

Datalogger watchdog activated

 datalogger processing

time limit exceeded

 Reset system  Connect PC terminal and

watch error messages

EDD

Battery empty

 Battery check detected a

low voltage of the battery

 change battery, after this

setup of RTC

 Temporary: Press horn

quit button to work without datalogger

EDE

Record lost

 Not possible to save data

because other task saves data at the same time

Message disappears after a

few seconds

EDF

Flash block full

 Not possible to save any

more data

Message disappears after a

few seconds

EFD

LMI Watchdog extra time

 a function needs more

than 0.5 sec, e.g. Flash PROM write

Message disappears after a

few seconds

Note:

If an error message is displayed which is not contained in above list, please contact the competent PAT service department.

Service Manual iFLEX5

72

19 TROUBLESHOOTING MOISTURE

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.

Troubleshooting Moisture

73

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 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.