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HIRSCHMANN LOAD MOMENT INDICATOR

1. TEST DER DIGITAL EIN UND AUSGAENGE Baugr Port Modus IN Wert IN Wert OUT Wert OUT Wert Status Taste Hex Bin Hex Bin NoLoad Basis 0 1 NORMAL 00 00000000 00000101 Basis 1 2 NORMAL 00 000000 000010 Basis 2 3 NORMAL 98 10011000 Erw 0 4 NORMAL 00 00000000 00000000 Erw 1 5 NORMAL 00000000 00000000 Erw 2 6 NORMAL 00000000 00000000 Baugruppencodierung Basis 00001111 Baugruppencodierung Erweit rung FF 11111111 Hubendschalter UNTB OFFEN OK KURZ 0000 DI 1 X Exit Blank Redraw S Slow F Fast DI 8 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 C U 70 pass connector pins X2 Resistor bank to measure digital input DI state Note must measure on bottom leg of the resistor Central Unit with cover removec 0 pass Connector Ref 14 5 IFLEX5 BCS ANALOG INPUTS AND PWM OUTPUTS Another useful tool to monitor analog inputs and PWM outputs is utilizing the i
2. table 2 Digital C U X2 Terminal Output Description 1 PWM 1 CM Proportional Solenoid 2 2 UB CAN bus 3 3 PWM 2 IM Proportional Solenoid 4 4 UB to Slew Potentiometer Electronics 5 5 PWM 3 Luffing Extension Proportional Solenoid 6 6 CM Extend Relay K1 Coil in Junction Box 7 7 PWM 4 Luffing Extension Proportional Solenoid 8 8 IM Extend Relay K2 Coil in Junction Box 9 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 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 DO 7 A Hirschmann Rev H 11 6 08 190154 H 28 Service Manual PAT iFLEX5 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
3. 36 15 3 1 Central Unit to Crane and Console Wiring Diagram 36 15 3 2 Cable Reel length angle sensor Wiring Diagram eere 37 15 3 3 Boom Extension Anti two Block Wiring Diagram 38 15 4 MAIN CENTRAL UNIT CONNECTOR cerne ne nene n ann ha hne uasa a Deae rra auae anna 38 15 5 ELECTRICAL SYSTEM DIAGRAM BOOM CONTROL 39 15 5 1 Central Unit to Crane Interface Wiring Diagram 39 15 5 2 Console and Sensor Wiring Diagram cease nnns 40 15 5 3 Cable Reel LWG520 0002 Wiring Diagram eene 42 15 5 4 Luffer Extension Wiring 1 43 16 Spare Part Lisilngs niunt eec aedi dis netus 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 22 2 22 46 16 4 CABLE REEL LWG508 PART NO 068 508 060 001 2 2 47 16 5 CABLE REEL LWG521 P
4. 5 15 5 8 Cable Reel LWG520 0002 Wiring Diagram TO PRESSURE TRANSDUCER BLOCK REFER TO CONSOLE AND SENSOR WIRING DIAGRAM a a 5 amp 6 amp x a 5 E vd B LE 2 28 J 4 D SE e Si D d PENNE Lu vy Voy v d e of af e o Egi e qe amp 54 a 8 s4 1 4d lt z BLK LS E E o we gt Za BLU a o aul esi Ek EE m p a a d si a i 29 aq a a S ag PNK lil 222 gi B amp amp 1 nt 16 17 18 BE 2 ic 7956 d et if lt 8 RA NIS L 9 WHT 1 202 e GEN d Sut n p NT WI E 15 z S P H GMK ABE SWITCH eo D x S g E M l 4 zy 5 GMK DUMMY PLUG 4 al oi E al i be 2 gt LG152 0056 REFER TO CABLE REEL LG
5. Luffing Extension Raise Output Note DO 1 1 DO 3 PWM 2 DO 5 PWM DO 7 PWM 4 Hirschmann Rev H 11 6 08 190154 H iFLEX5 Boom Control System BCS 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 Boom Status IM Tele Output Luffer Status 0 255 CM Tele Output Luffing Ext Raise 0 255 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 Hirschmann Rev H 11 6 08 31 190154 H 32 Service Manual PAT iFLEX5 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 3 596 out of sequence Refer to sequence charts in the manufacturers load capacity charts Another indication for out of seque
6. Hirschmann Rev H 11 6 08 190154 H Spare Part Listings 47 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 Hirschmann Rev H 11 6 08 190154 H 48 Service Manual PAT 5 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 Hirschmann Rev H 11 6 08 190154 H Spare Part Listings 49 16 5 CABLE REEL LWG521 PART NO 068 521 060 002 NO PART QTY DESCRIPTION 1 2 3 4 5 6 7 8 10 11 12 13 14 031 300 060 440 000 673 080 025 068 000 300 102 068 000 300 063 067 000 300 013 064 143 060 009 068 000 060 072 006 800 0
7. SE E EE EE E E 26 14 3 IFLEX5 BCS DIGITAL INPUTS RR CER EEN ENKEN 26 14 4 RT9000E RT800E IFLEX5 BCS DIGITAL 6 aa a aar aa aa 27 Hirschmann Rev H 11 6 08 190154 H Service Manual PAT iFLEX5 14 5 IFLEX5 BCS ANALOG INPUTS AND PWM OUTPUTS arta 29 14 6 IFEEX5 BCS TEST DISPLAY cran a Y ERR ru E Ne Du 31 14 7 BOOM OUT 32 14 8 TEEE ROD DRAIN ER geet elei Neu c ERU ro Od Ran eg EE ege ECH 32 14 9 TELE TWO STAGE RELIEF VALVE 32 14 10 HYDRAULIC LUFFING BOOM EXTENSION 33 15 DtawingS E 34 15 1 COMPONENTS OF THE LMI SYSTEM PAT 5 nnn nnne en arta 34 15 2 BLOCK DIAGRAM rana cun nir Fn an aua ca na Fe EE a RR a Dn oa un RR ER Ca a nuu a FRE a cu ER RE RR 35 15 3 ELECTRICAL SYSTEM DIAGRAM STANDARD SYSTEM
8. FLOW CHART Slew Sensing Error First verify the slew angle displayed through the console bv using the sensor output screen Press the info button twice Slew potentiometer is functioning NO 1 Does the displayed value differ from the actual value k Ensure that the slew pot unit is supplied with crane voltage The slew unit output can be found on pins 8 and 9 In order to Pin 7 must carry crane measrure current however you must disconnect a pin and voltage and Pin 2 is GND measure in line between the cable from the slew unit and the central unit The two outputs will vary as shown in chart below 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 Open the slip ring unit and determine if the slew potentiometer is set Hirschmann Rev H 11 6 08 190154 H No console display 15 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 No console display Ensure that no lights warning lights or backlighting is visible Check wiring harness and central unit NO Check if power is be
9. 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 When the operator is finished pressing the EXC or INFO key returns the console display to normal Hirschmann Rev H 11 6 08 190154_H 56 Service Manual PAT iFLEX5 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 O 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
10. 6 POL COMPUTER BRD X10 TO CONN BRD X23 050 150 300 072 1 5 LED BOARD LMI A2B ALARM LITE 050 150 300 073 1 8LED BOARD LED S BY SELECTION BUTTONS Hirschmann reserves proprietary rights to this drawing and to the data shown there The drawing and data are confidential and are not to be used or reproduced without the written consent of Hirschmann This drawing is subject to technical modification without prior notice Hirschmann Rev H 11 6 08 190154 H 46 Service Manual PAT 5 16 3 GRAPHIC CONSOLE ASSY PART 050 350 061 376 ITEM PART NO QTY DESCRIPTION 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 HIRSCHMANN 060000 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
11. ERROR CODES The following Error Code Table gives a brief description of Error Codes elimination Refer to the noted sections for detailed Troubleshooting information ErrorCode Error Causes Elimination Fallen below radius range or angle range exceeded Radius range exceeded or fallen below angle range e 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 e 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 e Luff down the boom to a radius or angle specified in the load chart e Luff up the boom to a radius or angle specified in the load chart Non permitted e The slewing zone with e Slew to permitted area slewing zone no load is not permitted load area Operating mode not e A non existing operating acknowledged or non permitted slewing zone Prohibited length range Hirschmann Rev H 11 6 08 mode has been selected e The boom is in a non permitted slewing zone e Boom has been extended either too far or not far enough e g if itis 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 e Length sensor adjustment has changed e g the cable slid off the length sensor reel e Clutch between length sensor pot and dr
12. 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 Connector M12 5 contacts Pin Layout CiA DR 303 1 7 2 Pin1 Shield 2 U Pin 3 Ground Pin 4 CAN High Pin5 CAN Low Hirschmann Rev H 11 6 08 190154 H 18 Service Manual PAT iFLEX5 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 Connect the two cables on the Transducer block together Replace Transducer Block Disconnect cables and connect cable from c u to transducer block Connect the cable reel can bus cable to Ohm cable from c u to the the transducer block Re
13. In order to voltage and Pin 2 is GND 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 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 Modular Slew Pot Output Currents mA 2 m mA 3 24 20 When the crane is over front you should 16 see about 4mA in one channel wire 2 and 12mA in the other channel wire 3 0 90 180 270 360 Degrees Hirschmann Rev H 11 6 08 190154 H 8 RE 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 e 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
14. Procedure eese 58 17 5 ANGLE SENSOR CALIBRATION emen anna nnn nume sana 59 17 6 ZERO SETTING THE SLEW POTENTIOMETER 61 18 Error Codes ain scu neta i eod eq rcd ep pue 62 19 Troubleshooting Moisture iare rtr gu Y cada Ra tcu Ex Deeg 72 19 1 WATER NORE SO 72 19 2 CONDENSATION 2 aranea ioa 73 Hirschmann Rev H 11 6 08 190154 H 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
15. 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 E A n Angle sensor 5 159514 117 3 4500mV at 0 2500 at 45 500 at 90 Recalibrate angle sensor Reference Angle sensor calibration procedure YES 1st _ Continue with angle sensing flow chart next page Open the cable reel and locate the angle sensor right and CAN Bus converter YES board left 2ND Does the displayed value differ from the actual value Angle sensor is NO functioning Unplug angle sensor and measure again Is the voltage between the range of 4 75 to 5 25V Verify that the sensor is 1ST NO being supplied with 5V by measuring between pin 5 GND and Pin 1 of terminal X21 4 C MEASURE AGAIN Replace converter S Is the voltage between the range of 4 75 to 5 25V 2ND YES 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 Hirschmann Rev H 11 6 08 190154 H Angle Sensing 7 Angle Sensor signal varies Ensure the angle sensor returns a voltage between 1 875V at 90 and 3 125V at 0 Angle Sensor Signal On Pin 3 Verify the voltage by Angle Voltage me
16. 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 Hirschmann Rev H 11 6 08 190154 H 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
17. 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 X1 CAN X14 A2B X20 length X21 angle LED AN 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 Terminal X20 1 4 8V 3 Signal 5 0 2V Hirschmann Rev H 11 6 08 190154 H Length Sensing 9 6 1 LENGTH SENSING ERROR FLOW CHART Length Sensing Error First verify the length displayed through the console is off by using the sensor output screen Press the info gt PISTON sum 46 button twice sm 11 ANGLE X1 LENGTHT 5 Di SLANG 2595 117 3 SL ANG nam ANGLE em 50 0 LENGTH om 8 0 Length sensor is Ensureihe functioning correctly cable reel has 5 8 turns of Does the displayed preloading on value differ from the the reel actual value Measure voltage between Pin 5 and Pin 3 signal Open the cable reel Fully retract the boom and turn the of terminal X20 and compare and locate the len
18. angle and one of the wipers of the slewing Replace slewing angle potentiometer is out of the sensor tolerance Error boom control The boom control task is Restart the system task not running Load the boom control task Error in the radius The computed radius is Check the programming determination too small negative in the crane data file deflection Operating mode The operating mode on Select operating mode switchover with the console has been without load on the boom load switched over with the boom loaded Wrong rigging The selected rigging Select another rigging condition condition is not contained condition in the crane data file Check the programming in the crane data file Hirschmann Rev H 11 6 08 190154 H Error Codes 69 Error Code Eror Cause Elimination No data trans e 24 V supply of the e Check 24 V at terminal X1 mission form the console is interrupted of the console electronics console to the central unit e Interruption or accidental e Check the connection ground in the line console electronics between console central unit In case of an electronics and central accidental ground the unit transmitter module of the console electronics might be damaged Therefore replaces the console electronics e Transmitter receiver e Exchange console module is defective electronics or LMI main board resp Error in the data e Loose connection in the e Check the connection transmission from lin
19. 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 Length Sensor Signal on Pin 3 Turns Voltage X20 5 to Voltage GND to X20 3 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 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 Hirschmann Rev H 11 6 08 190154 H Pressure Sensing 11 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 Pressure CAN Bus Measuring Converter Cells The signal runs from the pressure transducer as digital information on the CAN Bus to the central d unit 7 1 PRESSU
20. the sensor unit defective or not connected e Can bus port in the central unit defective Short circuit in a CAN Bus e Replace Can Bus cable cable e Replace the central unit Error in the can bus data transfer of the pressure transducer sensor unit Error in the can bus pressure transducer sensor unit Error in the can bus data transfer of the length angle sensor unit Error in the can bus length angle sensor unit Error in the can bus data transfer of the 2 length angle sensor unit Error in the can bus of the 2 length angle sensor unit Error in the can bus data transfer of the force sensor unit Check the cable to the sensor unit e Cable between the e central unit and the sensor unit defective e Can bus port in the central unit defective e Can bus port in the sensor unit is defective e Sensor unit is defective e Replace the sensor unit The analog values of the Replace the sensor unit sensor unit are invalid See E62 See E62 See E63 E63 See E62 inn EN E62 e See E63 e See E63 See E62 See E62 e Replace the central unit e Replace the sensor unit Error in the can bus See E63 See E63 force sensor unit Hirschmann Rev H 11 6 08 190154 H 68 Service Manual PAT iFLEX5 Error Code Eror Cause X Error in the slewing The difference between Check the slewing angle measurement the average of the potentiometer adjustment slewing
21. 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
22. 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 anti two 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
23. 05 002 092 000 060 387 068 000 100 196 002 090 100 031 068 000 110 031 068 000 110 038 NOT SHOWN ELI 3 Lad 3 gt 3 gt gt 9 Hirschmann Rev H 11 6 08 1 76 1 1 1 1 1 1 1 1 1 1 10 1 CABLE REEL ACCY LWG521 DRUM BODY W LENGTH CABLE LENGTH SENSOR CABLE 11 CORE BOARD 2 LENGTH AND ANGLE OUTPUT BOARD FILTER LENGTH POTENTIOMETER LWG ANGLE SENSOR WG143 09 SLIP RING ASSEMBLY 11 CONDUCTOR 24T GEAR WHEEL CONNECTOR 5 POLE W WIRES LID BLACK CABLE REEL ACCY GASKET FOR COVER CABLE REEL ACCY SCREW CAPTIVE GEAR WHEEL KT200 190154 H 50 Service Manual PPAT iFLEX5 16 6 CABLE REEL LWG152 PART NO 067 152 060 056 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 amp WASHER 4 FOR KT152 COVER 13 031 010 100 556 1 CABLE ASSEMBLY 2 5m NOT SHOWN Hirschmann Rev H 11 6 08 190154 H Spare Par
24. 152 0056 WIRING DIAGRAM SWITCH Hirschmann Rev H 11 6 08 190154 H Drawings 15 5 4 Luffer Extension Wiring Diagram e n oo ot ees L SE e o o e e o BOOM TIP CONNECTION TO LWG520 0002 REFER TO CABLE REEL LWG520 0002 WIRING DIAGRAM Hirschmann Rev H 11 6 08 DH e e e 9 6 6 e e e 43 190154 H 44 Service Manual PAT 5 16 SPARE PART LISTINGS 16 1 CENTRAL UNIT IFLEX5 PART NO 021 020 060 003 NO PART NO 1 024 000 100 041 2 022 022 300 031 3 024 350 100 661 4 031 300 110 151 5 024 350 100 135 6 031 300 101 131 7 024 350 110 066 ITEM NOT SHOWN Hirschmann Rev H 11 6 08 QTY 1 lA c 42 DESCRIPTION CENTRAL UNIT ACCY GROUNDING KIT BATTERY LITHIUM 3V KEY SWITCH CENTRAL UNIT COVER iFLEX SCREW SET SPARE KEY GASKET Spare Part Listings 45 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 2 050 150 100 065 1 KEYSWITCH WITH CABLE 3 031 300 110 149 1 FRONTFACE WITH DISPLAY COMPUTER BOARDS AND LED BOARDS 050 150 300 068 1 CONNECTION BOARD WITH BUZZER 031 300 050 223 1 FUSE 2AMP AUTO 050 150 290 061 1 CABLE 4 POL COMPUTER BRD X1 TO CONN BRD X6 X11 050 150 290 063 1 CABLE 10 POL COMPUTER BRD X2 TO CONN BRD X7 050 150 290 064 1 CABLE
25. 154 H 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 821 raise DI 9 1 lower The proportional solenoid on the luffing cylinder is energized by DO 5 amp 7 PWM 3 amp 4 if DI 821 The proporti
26. 1A measuring channel slewing angle 1 has been exceeded Upper limit value in refer to E1A refer to E1A measuring channel slewing angle 2 has been exceeded EE Upper limit value in e Angle potentiometer e Replace angle sensor measuring channel defective jib angle has been exceeded Electronic component in Replace sensor unit the measuring channel defective Hirschmann Rev H 11 6 08 190154 H 66 Service Manual PAT iFLEX5 Error Code Eror Gauss Elimination Error in the system program Error in the logical program flow System program and crane data file do not match System program and load chart file do not match Error in the write read memory Error in the monitored write read memory verification of the monitored write read memory provides an incoherent result Error in the crane data file Hirschmann Rev H 11 6 08 The system program file is defective e Upload valid system software Flash EPROM defective System program file is defective Replace central unit Upload valid system software Flash EPROM defective The system program in the LMI does not match to the programming in the crane data file The system program in the LMI and the programming in the load load chart file chart file do not match Write read memory e Replace central unit RAM or central unit defective The CRC sign of the e Restart the LMI monitored write re
27. ART 068 521 060 002 22 2 2 49 16 6 CABLE REEL LWG152 PART NO 067 152 060 056 17 nnn nnn 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 2 2 22 51 16 9 WIRING HARNESS sTANDARD PART NO 031 010 100 549 51 16 10 WIRING HARNESS BOOM CONTROL PART 031 010 100 554 52 16 11 CABLE ASSEMBLY 14M PART NO 031 010 100 555 22 2222 52 16 12 TRS05 REPEATER RADIO WINDSPEED KIT 031 300 104 087 53 17 Service Screen For Sensor Calibration 1c 54 17 1 ACTIVATING THE SERVICE SCREEN FOR SENSOR 54 17 2 ZERO SETTING THE TRANSDUCER INPUTS eene enne nnne nennen nhan nume enean ia nana ne an area run 55 17 3 ZERO SETTING THE SLEWING INPUTS 0 4 55 17 4 LENGTH SENSOR CALIBRATION PROCEDURE 56 17 4 1 Cable Reel LWG508 Adjustment Procedure eese 56 17 4 2 Length Sensor Adjustment 57 17 4 3 Cable Reel Length Cable Replacement
28. ENEN ENEE 4 4 7 KAVE AN cU o Rer RENE NS EEN 4 4 8 I HAVE A CAN BUS 4 4 9 NEED 5 5 4 4 10 HAVE NOTICED WATER IN SOME PART OF THE 4 5 Angle Sensing iioii eic teet diss fan eq tet ad neces 5 5 1 ANGLE SENSING ERROR FLOW nnne RR RR RR KEE RR SS ARR RR RD A RR RR RIA NR Narr a Ne 6 6 Length Sensing E 8 6 1 LENGTH SENSING ERROR FLOW CHART scsssscesccssseueecsnseueecnsseueucusueseucneneuenenuseseoeoaseeeannseessnnasses 9 7 Pressure SENSING ich siete artus uenti aes ULM 11 7 1 PRESSURE SENSING ERROR FLOW RR Rara dd 11 8 Slewindq SENSING aiu este NA 12 8 1 SLEW SENSING ERROR FLOW CHART 13 9 iii
29. HIRSCHMANN www hirschmann com PAT LOAD MOMENT INDICATOR IFLEX5 0335 456 90 05 269 lt _ lt v Ao o at 79 4 Leg ge 2273 505 SERVICE MANUAL P N 031 300 190 154 REV H 11 6 2008 Service Manual PAT iFLEX5 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 REV DATE NAME DESCRIPTION 04 10 02 ECN 02 122 06 03 02 MO ECN 02 122 06 15 02 MO ECN 02 122 06 2402 MO ECN 02 122 07 01 02 MO EC
30. 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 Hirschmann Rev H 11 6 08 190154 H 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 thr
31. N 02 122 12 04 02 CSH ECN 02 179 07 29 03 Cen ECN 03 088 06 05 06 SB 05 110 11 6 08 ECN 08 173 I mmoocG o 2006 Hirschmann Chambersburg PA 17201 USA Hirschmann Rev H 11 6 08 190154 H Service Manual PAT iFLEX5 TABLE OF CONTENTS 1 General Information KR KEREN KEEN KKK KR KEREN KREE KRK nnmnnn 1 2 LVI le SE 1 3 De scriptlon Of The System eo op ie te Ed eerie 2 3 1 DESCRIPTION OF SYSTEM FUNCTION cione nennen nana nana na aaa RR RR 2 3 2 DESCRIPTION OF A CAN BUS SYSTEM 5 riti ci caa coe sio EXE 2 3 3 DESCRIPTION OF THE SYSTEM na a A 3 4 What s KE 4 4 1 HAVE AN ERROR CODE INDICATED ON THE ranas aan 4 4 2 THE DISPLAYED ANGLE DOES NOT MATCH THE ACTUAL BOOM ANGLE enne 4 4 3 THE DISPLAYED LENGTH DOES NOT MATCH THE ACTUAL BOOM LENGTH nnn 4 4 4 THE DISPLAYED SLEWING DOES NOT MATCH THE ACTUAL SLEWING 4 4 5 THE DISPLAYED LOAD DOES NOT MATCH THE ACTUAL 4 4 6 THE CONSOLE DISPLAY IS BLANK 2 XY ERR RR SE
32. NTER YOUR SERVICE CODE 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 Hirschmann Rev H 11 6 08 190154 H Service Screen For Sensor Calibration 17 2 ZERO SETTING THE TRANSDUCER INPUTS 55 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 The display shows which transducer piston side 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
33. RE SENSING ERROR FLOW CHART First verify the pressure displayed through the console by using the sensor output screen Pressure transducers are functioning correctly 24 7 Press the info PISTON 581 D button twice MIBLET LENGTHT SL ANG SL ANG ANGLE LENGTH ow 0 8 Does the displayed value differ from the actual YES Ensure that the pressure lines are drained and disconnected The readout should Replace pressure transducers read 500mV 25mV and 0 PSI If the reading is slightly off small variations can be adjusted see section Service Screen For Sensor Calibration Note After exchanging the pressure transducer block BOTH transducer channels need to be zeroed see procedure Zero Setting The Transducer Inputs Hirschmann Rev H 11 6 08 190154 H 12 Service Manual PAT iFLEX5 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 Slew Potentiomet Current er with 2 Converter iFLEX5 CU Slip Ring Assembly outputs r E 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
34. TOOL5 or iFLASH terminal function At the flashing command prompt press and hold Ctrl and A to 29 enter the RTOS an asterisk will display Type adctest and press Enter The result should be the screen shown below Hirschmann Rev H 11 6 08 190154 H 30 Service Manual PAT iFLEX5 adctest EST DER ANALOGEINGAENGE Ch MUX Error Kanalt Value Value UADC Special Valid Hex Dec mV 0 ok 0008 0310 784 784 I Kanal 1 4 356 mA 1 ok 0009 0816 2070 2070 I Kanal 2 11 500 mA 2 ok 000A 0000 0 0 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 Lk 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 1 52 152 I PWM 1 D 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 Fast P PWM Settings T Test mode O Operating mode C ADC Clock set E Extension module T ES DER ANALOGEINGAENGE 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 A
35. 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 e Inner mid pilot operated 4 way directional control valve with extend and retract proportional solenoids located on the superstructure e Center mid pilot operated 4 way directional control valve with extend and retract proportional solenoids located on the superstructure e Tele two stage relief valve located on the superstructure 14 1 3 Manual Auto Mode There are two modes of opera
36. ad memory is wrong Replace central unit e Upload valid system program file or the valid crane data file e Upload valid system program file or the valid The buffer battery is decharged lt 2V at 1kOhm e Replace buffer battery on the central unit e Replace central unit Central unit defective No valid data in the crane data file e Upload valid crane data file Flash EPROM defective e Replace central unit e Upload valid load chart file No valid data in the load chart file Flash EPROM defective e Replace central unit e Restore or upload valid crane data file No valid data in the crane data file during calibration e Replace central unit Flash EPROM defective Calibration data file does not contain valid data e Upload calibration data file Flash EPROM defective e Replace central unit 190154_H Error Codes 67 Error Code Error 1 Cause Elimination The number of the selected File base and the programmed value are not identical e No valid data in the load chart file e Upload valid load chart file e Base number not programmed e Program the correct base number 1 for base 1 2 for base 2 e Check base programming in the load chart file e Load chart file wrongly programmed Error in the CAN bus data transfer for all CAN units Check the connection between the central unit and the sensor units e CAN Bus cable between e the central unit and
37. alue in measuring channel luffing jib angle Hirschmann Rev H 11 6 08 Front outrigger overloaded Cable between the central unit and the slewing angle sensor defective or loose Water inside the plug of the angle sensor Slewing angle potentiometer is defective Electronic component in the measuring channel defective refer to E1A Angle potentiometer defective Electronic component in the measuring channel defective Check cable as well as plugs replace if need be Replace slewing angle sensor Replace sensor unit refer to E1A Replace angle sensor Replace sensor unit 190154 H Error Codes 65 Eton cadenas ES Upper limit value in refer to E11 Elimination to E11 measuring channel main boom length has been exceeded Upper limit value in refer to E12 refer to E12 measuring channel pressure piston side has been exceeded Upper limit value in refer to E12 refer to E12 measuring channel pressure rod side has been exceeded Upper limit value in refer to E14 refer to E14 measuring channel force has been exceeded Upper limit value in refer to E15 refer to E15 measuring channel main boom angle has been exceeded Upper limit value in refer to E16 refer to E16 measuring channel angle 2 has been exceeded Upper limit value in refer to E17 refer to E17 measuring channel length telescope 11 has been exceeded Upper limit value in refer to E1A refer to E
38. asurement 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
39. asuring Between Pin 5 GND and Pin3 0 3 125 Note Actual voltages will vary slightly Does the indicated angle vary by more than 0 25 from the actual angle If this angle varies significantly from your actual angle YES replace the angle sensor Replace converter Ensure correct software has been board installed and crane operator is not in 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 Hirschmann Rev H 11 6 08 190154 H 8 Service Manual PAT 5 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 Length CAN Bus Sensor Converter Pressure Transducer 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 Cable Reel 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
40. console has a warning light for anti two block conditions and an override switch for overload or anti block condition Refer to Operator s Hanabook 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 Hirschmann Rev H 11 6 08 190154 H AOS vice Manual PAT FLEX 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 22 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 secti
41. 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 Hirschmann Rev H 11 6 08 190154 H 2 Service Manual PAT iFLEX5 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 me
42. e between console between console console to central electronics and central electronics and central unit unit unit e Transmitter receiver e Exchange console module is defective electronics or LMI main board resp Error in the data e refer to E92 e refer to E92 transmission from the central unit to the console No data trans e Interruption or accidental e Check line to the console mission from the ground in the line central in case of accidental central unit to the unit console ground replace console console electronics too e 5 V supply of the Check connection to the computer in the central power unit unit is missing LL us board e Transmitter receiver e Replace console module is defective electronics or LMI main board defective e Electro magnetic e Eliminate the source of interferences e g when interferences by inverse switching contactors or diodes or varistors valves Hirschmann Rev H 11 6 08 190154 H 70 Service Manual PAT iFLEX5 Error Code Error Error in the console The console File is Elimination the console File File defective Error in the internal e The CPU of the console Replace the CPU of the RAM of the console is defective console e The console main board e Replace the console main is defective board Error in the external The external RAM of the Replace the external RAM of the console console is defective RAM o
43. em 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 Hirschmann Rev H 11 6 08 190154 H 24 Service Manual PAT iFLEX5 14 IFLEX5 BOOM CONTROL SYSTEM BCS 14 4 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
44. ength cable using the following procedure Refer to system electrical wiring diagram and cable reel parts list g e O N 10 11 12 13 14 15 16 Cut old cable at cable drum Disconnect damaged length cable from junction box at the boom nose Open cable reel cover and disconnect bus connector Remove cable reel from mounting brackets Remove damaged length cable which is mounted to the slip rings in the cable reel from slip ring terminal 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 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 Reconnect the length cable to the slip ring Remount cable reel to the boom Turn reeling drum clockwise to spool the new cable neatly onto the drum Set pre load on cable reel by turning the drum counter clockwise 5 to 8 turns 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 Connect the length cable into the boom tip junction box Reset length potentiometer in length angle transducer screw is located in center of white gear with boom fully retracted turn potentiometer carefully counter clockwise unt
45. entral unit Hirschmann Rev H 11 6 08 190154 H cann bus communication 17 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 CU CAN Bus Converter Cable Reel Pressure Transducer 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
46. error code displayed To access the sensor output Screen press the INFO button twice 10 10 to review software version information press the INFO button once 2 To EXIT the sensor output screen press the INFO button once from the software version Screen to return to the operating screen 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 Press INFO To review software version information The values shown in the screen here are just examples of actual values Refer to the table listed below for actual value ranges Hirschmann Rev H 11 6 08 190154 H 22 Service Manual PAT iFLEX5 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 500mV 0 PSI 4500mV maximum PSI e Length sensor 500mV retracted boom length voltage ex
47. f 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 X1 CAN 8 e X14 A2B i X20 length DEI X21 angle LED Hirschmann Rev H 11 6 08 190154 H 20 Service Manual PAT iFLEX5 12 4 4 E64 Flow Chart EI Connect the two cables on the Transducer block together Ohm cable from the transducer 22 transducer block to cable reel OC Cable checks good Replace ves cable Check connector at cable reel Connector checks good Replace connector Replace can bus board in cable reel 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 Hirschmann Rev H 11 6 08 190154 H Troubleshooting a sensor problem using the display 21 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
48. f the console e Theconsole main board e Replace the console main is defective board LMI watchdog e LMI processing time limit e Reset system activated exceeded e Connect PC terminal and watch error messages Short circuit the Short circuit the A2B e Replace A2B switch A2B switch circuit switch e Short circuit inthe cable e Replace cable to the A2B to the A2B switch switch A2B switch circuit Disconnected cable in the Connect or replace cable disconnected A2B switch in the A2B switch e Disconnected cable to the e Connect or replace cable A2B switch to the A2B switch switch Prohibited area e Boom is about to collide Move boom to permitted with the engine hood area switch off e Check values in the data prom DGA 11 5 Approaching e Boom is about to collide Move boom to permitted prohibited area with the engine hood area prewarning e Check values in the data prom DGA 11 5 Angle range of Luffing jib is raised too far e Luff down the jib to a luffing jib exceeded angle specified in the load chart No valid A2B switch e Sensor wrong function e Replace A2B switch status e CAN bus delay e Replace cable to the A2B Hirschmann Rev H 11 6 08 190154 H Error Codes 71 Error Code Error Cause Elimination 0 Datalogger write Datalogger not connected e Check CAN bus error e No power supply connection e Wrong Dos drive status e Check power supply e Connect PC termina
49. gth screw of the length potentiometer sensor right and with a small screwdriver counter CAN Bus converter clockwise to a soft stop bringing the board left sensor voltage to OV 0 1 Volt pis 509 e Press the info Return to the indication screen and again Kan mnm ni button twice compare the indicated and actual length LENGTH SL ANG 1595 117 3 Replace length sensor YES _ NRW ANGLE em 98 0 LENGTH om 9 8 Does the indicated length vary significantly from the actual length more than 0 3 feet Proceed to next length sensing flow chart 4 NO Hirschmann Rev H 11 6 08 190154 H 10 Service Manual PAT iFLEX5 Length Sensor varies See length sensor signal chart below Ensure the length sensor is being supplied with 4 7V by measuring between Pin 5 and Pin 1 of the X20 terminal YES Is the voltage between the range of 4 7V to 5 0V Is the voltage between the range of 4 7V to 5 0V NO Replace converter Unplug the length board sensor and measure again If unplugging the length sensor made the voltage return to the acceptable range replace the length sensor Follow procedure for length sensor 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
50. hout the written consent of Hirschmann This drawing is subject to technical modification without prior notice 37 Hirschmann Rev H 11 6 08 190154 H 38 Service Manual PAT iFLEX5 15 3 3 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 PEE A Hirschmann Rev H 11 6 08 190154 H Drawings 39 15 5 ELECTRICAL SYSTEM DIAGRAM BOOM CONTROL SYSTEM 15 5 1 Central Unit to Crane Interface Wiring Diagram 74 I I 1 e o 9 N Ten Voy ovv Y Y Y Y Y 9 9 9 0 9 9 0 9 9 9 e e e oe oe 9 9 9 9 A e 4 e oe LI D La oe ege ooo ooo o e ee ees e AR m m A RRR RRR R RRR RRR RR RRR see ee e e e oo oo see 9 4 e 2 2 a deat Hirschmann Rev H 11 6 08 190154 H 40 Service Manual PAT iFLEX5 15 5 2 Console and Senso
51. il it stops Recheck length and angle display Refer to section Cable Reel LWG508 Adjustment Procedure Connect bus connector Follow Length Sensor Adjustment Procedure Hirschmann Rev H 11 6 08 190154 H Service Screen For Sensor Calibration 59 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 Select the angle calibration by pressing OK at the calibrate angle screen gt ADJUSTMENT SCREWS ADJUST TOP OF ANGLE SENSOR PARALLEL WITH BOOM Hirschmann Rev H 11 6 08 190154 H 60 Service Manual PAT iFLEX5 m A Boom up to the next correction angle 45 degrees range is 40 50 When the boom angle is within the 7727 calibration range the screen will add the CHANGE SET and OK text as shown on the left Boon 1045 H CHANGE Measure the boom angle with the inclinometer and P when the boom is positioned in the calibration range x 4 compare the measured angle to the displayed angle Boc C ESC m und EG 47 1 If the indicated angle is within 0 1 degrees of the A measured angle confirm with OK Otherwise select SET to adjust the angle E Once you push SET the screen is going to change to the angle ad
52. indicated length is within 0 1 of actual retracted boom length If itis 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 14 Cable Reel LWG508 Adjustment Procedure Lei Now perform Length Sensor Adjustment Procedure as detailed in section Length Sensor Adjustment Procedure Hirschmann Rev H 11 6 08 190154 H Service Screen For Sensor Calibration 57 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 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 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 Hirschmann Rev H 11 6 08 190154 H 58 Service Manual PAT iFLEX5 17 4 8 Cable Reel Length Cable Replacement Procedure Replace l
53. ing supplied by the Is power central unit Measure on the green being connector Pin 1 is Ub 12V and Pin 2 is supplied Check fuses in console one F6 is located on YES 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 Is power being supplied If no power was Are fuses lied on the run YES Check for power on connector SURP ine X6 of the connection board Pin 2 1 1 is Ub 12V and Pin 2 is GND Ween NO external connector the connection board must 4 be replaced Replace fuse Follow power from this connector to the console computer board connector X1 Pin 1 is Ub 12V and Pin 2 is Connecting Is power cable 5 NO being YES Check fuse F1 again Make sure all connectors supplied are correctly in place Conn Board Computer Board Pins X6 X1 4 X10 X22 6 Ensure TxD LED is on located in center of X7 10 the computer board and is normally X10 X22 could be plugged into X17 by mistake blinking when the console is defective Software is If voltage is present on all pins and connector are in place but you still do not get any console lighting Console electronics OR need replaced 190154 H Hirschmann Rev H 11 6 08 16 Service Manual PAT iFLEX5 11 A2B PROBLEM A2B problem Are the control
54. inputs ANGLE SL ANG 1 SL ANG 2 The table to the right show measured millivolt reading for deg mv mv the slew potentiotmeter 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 Modular Slew Pot Voltage on Service Screen 4000 3500 3000 2500 2000 1500 1000 e Potentiometer 1 Potentiometer 2 MLLIVOLTS 500 0 45 90 135 180 225 270 315 360 45 90 135 180 135 90 45 0 SLEW ANGLE Display screen for sensor inputs Hirschmann Rev H 11 6 08 190154 H Slewing Sensing 13 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 12 pin crane interface connector 81 SLEW SENSING ERROR FLOW CHART Slew Sensing Error First verify the slew angle displayed through the console by using the sensor output screen Slew potentiometer is functioning correctly Press the info button twice Does the displayed value differ from the actual value S i Ensure that the slew pot unit is supplied with crane voltage Pin 7 must carry crane The slew unit output can be found on pins 8 and 9
55. is drawing is subject to technical modification without prior notice Hirschmann Rev H 11 6 08 190154 H 36 Service Manual PAT iFLEX5 15 3 ELECTRICAL SYSTEM DIAGRAM STANDARD SYSTEM 15 3 1 Central Unit to Crane and Console Wiring Diagram D lt lt e e lt lt e e lt lt e e lt lt e e lt lt e lt lt e e lt lt e 5 lt lt e e lt lt e e D D e e e e D e e lt lt e lt lt e e e e e e e e e gt gt e e e e e gt gt e e gt e e e e e e e lt lt e e e e 1 e e gt gt e gt gt e e e e e e e e eg ki e gt gt e e e gt gt e Hirschmann Electronics Inc reserves proprietary rights to this drawing and to the data shown there on The drawing and data are confidential and are not to be used or reproduced without the written consent of Hirschmann This drawing is subject to technical modification without prior notice Hirschmann Rev H 11 6 08 190154 H Drawings 15 3 2 Cable Reel length angle sensor Wiring Diagram e e e e e D e e e e e e e e e e e e e e e e 4 e e gt gt 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 wit
56. ive is defective e Setthe correct operating mode for the operating state in question e Slew the boom to a permitted area e Extend retract boom to the correct length e 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 e Replace the complete clutch including drive wheel and adjust length sensor pot as described above 190154 H Error Codes 63 Error Code Error Cause sd Elimination 0 Radius range exceeded or fallen below angle range with luffing jib operation Overload relays check Fallen below lower limit value for measuring channel length main boom Fallen below the lower limit value in the measuring channel pressure piston side Fallen below lower limit value in the measuring channel pressure rod side Maximum radius as specified in the load chart exceeded or fallen below minimum angle due to luffing down the luffing jib too far 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 Length potentiometer is defective Electronic component in the measuring channel is defective Pressure transducer is defective Electronic component in the measuring channel is defective refer to E12 e Luff the jib to a radius or a
57. justment 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 Hirschmann Rev H 11 6 08 190154 H 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 Hirschmann Rev H 11 6 08 190154 H 62 Service Manual PAT iFLEX5 18
58. l and Refer to Dos drive status list e Temporary Press horn quit button to work without datalogger Datalogger setup Setup of the datalogger is transfer data and setup error cleared ser crane data datalogger again file or battery buffered e temporary Press horn RAM quit button to work without datalogger Datalogger e datalogger processing Reset system watchdog activated time limit exceeded e Connect PC terminal and watch error messages Battery empty e Battery check detecteda e change battery after this Ss low voltage of the battery setup of RTC e Temporary Press horn quit button to work without datalogger because other task saves few seconds data at the same time more data i o seconds LEN Watchdog e afunction needs more Message disappears after a PROM write Note If an error message is displayed which is not contained in above list please contact the competent PAT service department Hirschmann Rev H 11 6 08 190154 H 72 Service Manual PAT iFLEX5 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
59. levers locked out and is the crane in an anti two block condition Is the anti two block warning light on Lower the hook block and or headache ball to correct the Ensure the two block problem If two Turn power off remove bypass plug and bypass hoists are in use both measure the resistance at the boom nose box plug is hooks must be lowered between terminals 1 and 3 with an ohmmeter installed Switch closed 0 ohms weight installed Switch open 1 Megaohm weight removed Ensure bypass plug is plugged into the NO 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 gt 1 Meaaohm Are the ohmmeter readings correct Plug the bypass plug into the boom nose box and refer to system wiring to check wire connections in boom nose box Are the ohmmeter readings correct Check for damaged length cable and wiring If broken length cable refer to system wiring Remove wires and measure the A2B signal in the cable reel between terminal 7 and 8 with an ohmmeter Switch closed 4700 500 Ohms If wiring is Switch open gt 1 Megaohm correct replace A2B Are the ohmmeter readings correct Replace the slip ring A problem lies with either the wiring YES gt harness cable reel length angle boards and or the c
60. ls 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 DO 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 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 DOG are activated based on the current b
61. move can bus transducer block If cable checks connector at cable reel good replace c u Replace can bus cable between Cable reel and transducer block Ohm out connector in cable reel If connector Checks good replace can bus converter board Hirschmann Rev H 11 6 08 190154 H cann bus communication 19 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 I
62. nce are the flashing section percentages located at the bottom of the console display 456ft op Dr 2 Lbs boom section 82 73 500 percentage ACT Lbs display 34 9 oc 100 100 1007 1 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 Tele Rod Drain Solenoid IM retract sw OM retract sw Retract pressure sw DO13 DI 7 DI 6 DI 18 0 1 1 0 1 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 Tele Two Stage Relief Retract pressure Extend pressure OM Fly IM rertract CM retract Solenoid DO15 sw DI 18 sw DI 19 Percentage sw 017 sw DI 6 1 1 1 1 2496 0 1 1 Hirschmann Rev H 11 6 08 190
63. ngle specified in the load chart check cable to overload relays and CU input 20 check relays check CU input 20 reset system reset system Replace length potentiometer Replace sensor unit Replace pressure transducer Replace sensor unit refer to E12 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 Fallen below lower limit value in measuring channel angle main boom Hirschmann Rev H 11 6 08 Angle potentiometer defective Electronic component in the measuring channel defective Replace angle sensor Replace sensor unit 190154_H 64 Service Manual PAT iFLEX5 Error Code Eror Cause Elimination Fallen below lower limit value in measuring channel angle 2 Fallen below lower limit value length telescope 11 e Angle potentiometer defective Electronic component in the measuring channel defective Length potentiometer defective e Replace angle sensor Replace sensor unit Replace length sensor Electronic component in the measuring channel defective Replace sensor unit Front outrigger overloaded E17 E18 Fallen below lower limit value in measuring channel slewing angle 1 Fallen below lower limit value in measuring channel slewing angle 2 Fallen below lower limit v
64. on 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 HAVE A2B PROBLEM Please go to sectionA2B PROBLEM 48 A CAN BUS PROBLEM Please go to section CAN Bus Communication 49 INEED 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 Hirschmann Rev H 11 6 08 190154 H Angle Sensing 5 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 Angle CAN Bus Sensor Conve
65. onal 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 amp 11 respectively If DI 10 1 then DO 5 7 amp 9 1 If DI 1121 then DO 11 1 The proportional valve on the luffing cylinder is not be energized for luffer lower Hydraulically the proportional valve is bypassed for luffer lower See sketch below Hirschmann Rev H 11 6 08 190154 H 34 Service Manual PAT iFLEX5 15 DRAWINGS 15 1 COMPONENTS OF THE LMI SYSTEM PAT IFLEX5 PAT 5 m i LOCKOUT 2 OTHER 1 Central Micro Processor Unit 2 Operating Console 3 Pressure Transducers 4 Length Angle Sensor 5 Anti Two Block Switch es Hirschmann Rev 11 6 08 190154 H Drawings 35 15 2 BLOCK DIAGRAM 70 pin Connector RS 485 Serial Interface Crane Power Graphic Console Lockout CAN BUS i Current CAN connector 4 20mA CAN connector CAN connector p lege 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 Th
66. oom position figure 1 Refer to table 2 for digital output definitions Hirschmann Rev H 11 6 08 190154 H 26 14 2 TELE SEQUENCE RT9000E Mode A not available Service Manual PAT iFLEX5 RT800E Mode A Mode B table1 Mode B Extend Sequence in Percentage Tele 1 IM Tele 2 CM Tele 3 OM Fly 0 0 0 75 0 0 75 75 0 100 75 0 100 100 0 100 100 100 Jib Mode not selectable realized by operating mode selection table 2 Jib Mode Extend Sequence in Percentage Tele 1 IM Tele 2 CM Tele 3 OM Fly 100 0 0 100 100 0 100 100 100 Note Retract sequence is opposite of extend sequence 14 3 IFLEX5 BCS DIGITAL INPUTS table 1 Digital Description C U X2 MP Input Terminal 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 Hirschmann Rev H 11 6 08 190154 H iFLEX5 Boom Control System BCS 14 4 RT9000E RT800E IFLEX5 BCS DIGITAL OUTPUTS 27
67. ough 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 Hirschmann Rev H 11 6 08 190154 H
68. r Wiring Diagram LJ LJ D e TO LWG520 0002 REFER TO CABLE REEL LWG520 0002 WIRING DIAGRAM 4 X X X x e D D D e e e L e e LJ BOOM BASE CONNECTION S 9 e geht a eee e a e TO LG152 0056 E 2 j a REFER TO CABLE REEL Toa tal aah och Tl el al ch LG152 0056 WIRING DIAGRAM e e D e Hirschmann Electronics Inc reserves proprietary rights to this drawing to the data shown there on The drawing and data are confidential and are not to be used or reproduced without the written consent of Hirschmann This drawing is subject to technical modification without prior notice Hirschmann Rev 11 6 08 190154 H Drawings Cable Reel LG152 0056 Wiring Diagram TO LWG520 0002 TO BOOM BASE CONNECTOR REFER TO CABLE REEL LWG520 0002 REFER TO CONSOLE AND SENSOR WIRING DIAGRAM WIRING DIAGRAM DN 9 9 9 9 9 9 9 4 4 4 5 4 5 45 444 41 Hirschmann Electronics Inc reserves proprietary rights to this drawing and to the data shown there on The drawing and data are confidential and are not to be used or reproduced without the written consent of Hirschmann This drawing is subject to technical modification without prior notice Hirschmann Rev H 11 6 08 190154 H 42 Service Manual PAT
69. rter Pressure Transducer Cable Reel oed emus en E a per emn mq s E e ine e it eh en d m 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 X1 CAN e d r cera X14 A2B vs d X20 length miii 5 2 X21 angle LED 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 Terminal X21 1 45V 3 Signal 5 GND Hirschmann Rev H 11 6 08 190154 H 6 Service Manual PAT iFLEX5 5 1 ANGLE
70. s tti ordi as 14 9 1 LOAD SENSING ERROR FLOW CHART enean aa Rasa ARR RR DARAN RR DARAN RR DARAN RR ON KREE EEN 14 10 fas 15 11 Problem 16 12 EE 17 12 1 61 EENEG ERR EES EES ESA EELER Ee de Ree E 17 1211 E61 Flow e In EEN 18 LEE ee ee 19 12 3 63 2 19 M2 M lp ENEE 19 12 4 1 64 20 12 5 EEN 20 13 Troubleshooting a sensor problem using the display cernere 21 14 IFLEX5 Boom Control System 5 FO E vao EA PERRA o 24 14 1 RT9000E RTS00E BASICS 22 20 xa ENEE EES E 24 T3 KT lte e VE 24 dE RER uisi d Eu 24 14 1 3 Manual Auto 24 14 2 SEQUENCE
71. t 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 e 16 9 WIRING HARNESS STANDARD PART NO 031 010 100 549 Hirschmann Rev H 11 6 08 190154 H 52 Service Manual PAT 5 16 10 WIRING HARNESS BOOM CONTROL PART NO 031 010 100 554 6 Cables for 1 Console Crane interface 7 conductors Crane interface 24 conductors LG152 cable reel CAN bus cable Optional radio wind speed receiver oo mom 16 11 CABLE ASSEMBLY 14M PART NO 031 010 100 555 Hirschmann Rev H 11 6 08 190154 H Spare Part Listings 53 16 12 TRSO5 REPEATER RADIO WINDSPEED KIT 031 300 104 087 031 300 060 596 TRS 05 REPEATER 031 300 060 601 CABLE ASSY 15 2 COND SS 031 300 050 688 ANTENNA 918 MHz RCL 90 20AWG W 12 SKT DEUTSCH Hirschmann Rev H 11 6 08 190154 H 54 Service Manual iFLEX5 17 SERVICE SCREEN FOR SENSOR CALIBRATION 17 1 ACTIVATING THE SERVICE SCREEN FOR SENSOR CALIBRATION 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 At this point a five digit Authorization Number must be entered Only authorized personnel may adjust the zero point settings Use the gt key to switch between digits use the and keys to increase and decrease each digit Use the enter key to confirm entry E
72. tended depends on the various boom lengths e Angle sensor 4500mV at 0 2500mV at 45 500mV at 90 Please refer to table below for more values Voltage Values Value displayed Value displayed mV 10mV 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 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 Hirschmann Rev H 11 6 08 190154 H Troubleshooting a sensor problem using the display 23 SLEW POT SIGNALS Sig 1 mA Gg 2 mA Reference Angle 0 08mA 0 083mA 0 4 00 12 00 45 8 00 16 00 90 12 00 20 00 135 16 00 16 00 180 20 00 12 00 135 16 00 8 00 90 12 00 4 00 45 8 00 8 00 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 syst
73. tion manual or automatic mode This is selectable by a switch in the right hand arm rest the cab and is seen by the BCS as digital input 17 1720 is manual mode And DI 17 1 is auto mode 1 Refer to table 1 for digital input definitions Hirschmann Rev H 11 6 08 190154 H iFLEX5 Boom Control System BCS 25 14 1 3 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 signa

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