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Hirschmann MARK 4E/2 Service Manual

Pat load moment indicator system
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LOAD MOMENT INDICATOR SYSTEM
MARK 4E/2
01
12.0ft
06
35.0ft
HIRSCHMANN
40000lb
6800lb
SERVICE MANUAL
P/N 031-300-190-075 REV D 12/19/2008

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Summary of Contents for Hirschmann MARK 4E/2

  • Page 1 HIRSCHMANN LOAD MOMENT INDICATOR SYSTEM MARK 4E/2 12.0ft 40000lb 35.0ft 6800lb SERVICE MANUAL P/N 031-300-190-075 REV D 12/19/2008...
  • Page 3 Mark 4E/2 NOTICE Hirschmann, Inc. makes no warranty of any kind with regard to this material, including, but not limited to, the implied warranties of merchantability and/or its fitness for a particular purpose. Hirschmann, Inc. will not be liable for errors contained in this manual or for incidental or consequential damages in connection with the furnishing, performance, or use of this manual.
  • Page 5 ERROR CODES ......................28 OPERATOR ERROR CODE TABLE..................28 SYSTEM ERROR CODE TABLE ................... 30 TROUBLESHOOTING MOISTURE................. 32 ........................32 ATER NGRESS ........................33 ONDENSATION 10 LMI SYSTEM TEST PROCEDURE .................34 11 APPENDIX........................35 ©Hirschmann Rev. D 12/19/08 WG/SC 190075_D...

  • Page 7: Mechanical Description Of The Components

    The console has pushbuttons to switch the operating modes (for selection of crane configurations and reeving of the block). It also has a warning light for overload, anti-two-block conditions and an override push-button for anti-two-block condition. ©Hirschmann Rev. D 12/19/08 WG/SC 190075_D...
  • Page 8 Description of the Housing: The MARK 4E/2 central unit has a water proof aluminum housing. It is mounted on the left side of the turntable weldment or on the counterweight. The cables are led into the central unit via strain reliefs and connected with fast-ons.

  • Page 9: Basic Adjustment Of The Hardware

    The output voltage of the pressure transducers should be 4.00ma. Check the function of the hoist limit switch (anti-two-block) Check function of lever lockout. Measure and record the power supply voltages. ©Hirschmann Rev. D 12/19/08 WG/SC 190075_D...

  • Page 10: Definitions

    ANALOGUE Electrical signals that vary in proportion to the quantities they represent. (Boom length, angle, and pressure transducer) DIGITAL Electrical signals of an on-and-off-state (two different voltage levels) to represent some quantity of operation. (A2B, area definition switch) ©Hirschmann Rev. D 12/19/08 WG/SC 190075_D...

  • Page 11: Drawings

    Drawings 5 DRAWINGS WIRING DIAGRAM - CENTRAL UNIT SHUT OFF WARNING: The connection to the ground must be as short as possible! ©Hirschmann Rev. D 12/19/08 WG/SC 190075_D...
  • Page 12 Service Manual MARK4E/2 CENTRAL PROCESSOR 12/24 VDC 1-0116440.00 Spare Parts List ITEM DESCRIPTION PART NUMBER Housing 1-0103719.00 P.C. Board (Central Processor) 1-0116073.00 Module (DC/DC Converter) 1-0028174.00 Key Switch 1-0103247.00 ©Hirschmann Rev. D 12/19/08 WG/SC 190075_D...

  • Page 13: Central Unit /Console

    Drawings ELECTRICAL DIAGRAM – CENTRAL UNIT/CONSOLE ©Hirschmann Rev. D 12/19/08 WG/SC 190075_D...

  • Page 14: List

    A2B Signal- (BRN) 2 closed = +12V 6 Pin Plug - Extension A2B Switch 031-002-060-014 Dummy Plug for 6 Pin Receptacal Main Boom only Boom Tip Cable Reel Core 068-308-060-001 Shield A2B Switch 031-002-060-011 ©Hirschmann Rev. D 12/19/08 WG/SC 190075_D...

  • Page 15: Part List

    Drawings CABLE REEL PARTS LIST ©Hirschmann Rev. D 12/19/08 WG/SC 190075_D...
  • Page 16 CABLE, LENGTH SINGLE CORE 002-148-131-013 STRAIN RELIEF, PG13.5 RED/WHT 031-300-100-206 CHEMICAL, CORROSION INHIBITOR 068-000-100-064 SLIP RING ASSEMBLY 2 POLE ANTI-TWO BLOCK SWITCH (PAT) 031-002-060-011 - main boom (with 12’ cable) 031-002-060-014 - jib (with 32’ cable) ©Hirschmann Rev. D 12/19/08 WG/SC 190075_D...

  • Page 17: S Witch (Kueger)

    Blind Plug 1-0010038.00 Shackle with Cotter Pin 1-0009999.00 Required for Mounting - Order Separately DESCRIPTION PART NUMBER Weld Plate 1-0010046.00 Hex Head Cap screw - M8 x 50 1-0010083.00 Lock Washer - M8 1-0010097.00 ©Hirschmann Rev. D 12/19/08 WG/SC 190075_D...

  • Page 18: Ransducer (250 Bar): 1-0108060.00

    Connector Cable - Straight x 7M. 1-0114293.00 Connector Cable - Straight x 10M. 1-0114294.00 Connector Cable - 90 Connector 1-0101758.00 5.11 PRESSURE TRANSDUCER (DAVS300 / 3401) Part Number 031-300-060-453 (4.20mA, 300 bar, M12, 9/16-18) ©Hirschmann Rev. D 12/19/08 WG/SC 190075_D...

  • Page 19: Pressure Trans ), 031-300-060-693

    Transdu cer 300bar Transdu cer 300bar 031-300-060-452 031-300-060-452 C rane V oltage -refer to C rane D W G .- 3 S S C able assem bly 031-300-060-693 3 S S C able assem bly 031-300-060-693 ©Hirschmann Rev. D 12/19/08 WG/SC 190075_D...

  • Page 20: E Xtension , 031-010-100-144

    Service Manual MARK4E/2 5.13 JUMPER CABLE ASSEMBLY FOR EXTENSION, 031-010-100-144 5.14 ROLLER SWITCH WIRING, 031-006-100-043 Central Unit 1-0116440.00 ©Hirschmann Rev. D 12/19/08 WG/SC 190075_D...

  • Page 21: Length And Angle Sensor Adjustment

    Procedures 6 LENGTH AND ANGLE SENSOR ADJUSTMENT ©Hirschmann Rev. D 12/19/08 WG/SC 190075_D...

  • Page 22: Central Unit

    3. Replace I.C. with notch down and flat side to the top as shown in diagram. WARNING: If I. C. is placed in wrong, the I.C. will be destroyed and a new I.C. will have to be ordered. ©Hirschmann Rev. D 12/19/08 WG/SC 190075_D...

  • Page 23: Adjust Pressure Rod

    21. Push down button until EXIT menu title is blinking then push P button. 22. Push down button to EXIT then P button until you get to the Program menu and enter the working display. ©Hirschmann Rev. D 12/19/08 WG/SC 190075_D...

  • Page 24: R Eplacement

    9. Re string cable through the roller guides and reconnect at the boom tip. 10. After cable replacement refer to length adjustment procedure to reset length. 11. Put cover on reel. Crane is ready to put back into service. ©Hirschmann Rev. D 12/19/08 WG/SC 190075_D...

  • Page 25: Troubleshooting Flow Charts

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

  • Page 26: Lever Lockout Activated

    Fault in Anti-Two Check lever lockout system in displays fault is located in LMI, Block system. crane. cables, wiring, fuses, or console. Refer to Section Read error code displayed on console display. Refer to Section ©Hirschmann Rev. D 12/19/08 WG/SC 190075_D...

  • Page 27: Blank Display

    X1.11-X1.20 when the short is found trace out short using wiring NEXT diagrams Refer to wiring diagram in PAGE Section 5. After short has been removed replace fuse with 2 amp fuse only. ©Hirschmann Rev. D 12/19/08 WG/SC 190075_D...
  • Page 28 If system returns to normal operation the voltmeter put positive lead at terminal X1.33 and crane is ready to be put back in service. ground at terminal X1.2. Voltage? Replace console. Replace or repair Electronic box CPU. ©Hirschmann Rev. D 12/19/08 WG/SC 190075_D...

  • Page 29: Anti-Two-Block Problem

    Remove cover from cable reel. Check with ohmmeter between terminals 2 and 3 on the slip ring disc Correct? with Two-Block switch down = 0 ohm. Replace Anti-Two-Block switch NEXT PAGE ©Hirschmann Rev. D 12/19/08 WG/SC 190075_D...
  • Page 30 = 0 ohm. Replace cable from plug at boom pivot Correct? point to electronic box. Use a voltmeter with ground lead on X1.41-50 and positive lead on X1.72 check for 12 vdc. NEXT PAGE ©Hirschmann Rev. D 12/19/08 WG/SC 190075_D...
  • Page 31 With 12vdc on terminal X1.72 and all checks have been completed you should have 12 vdc on terminal X1.71. If you have the correct voltages the Electronic Box P.C. Board is defective. Send to PAT America, Inc. for repair or replacement. ©Hirschmann Rev. D 12/19/08 WG/SC 190075_D...

  • Page 32: Length Reading Problem

    (1m) add or remove 1 rap from cable reel. be a defective length potentiometer. If this does not repair problem refer to Refer to Section? Length Adjustment Procedure section? ©Hirschmann Rev. D 12/19/08 WG/SC 190075_D...

  • Page 33: Angle Reading Problem

    If indication is correct at 0 degrees and If indication is off check the mechanical has bad indication the problem my be adjustment of the angle bracket. defective length potentiometer. Refer to Section 7. Refer to Section 7. ©Hirschmann Rev. D 12/19/08 WG/SC 190075_D...

  • Page 34: Error Codes

    Load Chart for configuration that has been the load chart. Check radius the configuration selected. indication to actual radius. selected. ©Hirschmann Rev. D 12/19/08 WG/SC 190075_D...
  • Page 35 Replace defective area unacceptable to May have defective roller roller switch. Replace wire the Load Chart for the switch or open wire to the from electronic box to roller configuration selected. roller switch. switch. ©Hirschmann Rev. D 12/19/08 WG/SC 190075_D...

  • Page 36: System Error Code Table

    Errors occur from improper If problem reoccurs contact programming of data PAT America, Inc. C.’s. E: 10C0 – 10CE Data Programming Programming errors in If problem recurs contact Errors EPROM 1. EPROM 1. PAT America, Inc. ©Hirschmann Rev. D 12/19/08 WG/SC 190075_D...
  • Page 37 E: F002 ADC timeout. Malfunction of A/D Replace electronic box P.C. converter. board. E: F040 – FE43 Hardware Error. The system has a hardware Contact PAT America, Inc. failure. or replace electronic box P.C. board. ©Hirschmann Rev. D 12/19/08 WG/SC 190075_D...

  • Page 38: Troubleshooting Moisture

    If the lid is bent or damaged, it needs to be replaced. Try to determine what has caused the lid to be bent and eliminate the reason for that. Order a new lid through your Hirschmann representative. ©Hirschmann Rev. D 12/19/08 WG/SC...
  • Page 39 If the internal wires turn with the outer cable, the strain relief is loose. Get a new grommet (insert) through your Hirschmann representative and replace the existing one with the new one. Tighten the strain relief correctly. Note: Whenever a strain relief is opened, i.e.

  • Page 40: Lmi System Test Procedure

    Note: This is a general standard and variations may exist, if in doubt contact the crane manufacturer. CALIBRATION TEST CRANE S/N:_____________ Parts of Main / B Main / B Jib / Ext Actual Indicated Actual Indicated Cutoff Mode Line Length Angle Length Offset Load Load Radius Radius ©Hirschmann Rev. D 12/19/08 WG/SC 190075_D...

  • Page 41: Appendix

    A-2-B BYPASS Console Shutoff Console RS422 RXD+ Not used Not used Console RS422 RXD- By-pass + Console RS422 TXD+ By-pass + Console RS422 TXD- By-pass out Console Heating GND By-pass out Console Heating 24/12V ©Hirschmann Rev. D 12/19/08 WG/SC 190075_D...
  • Page 42 Service Manual MARK4E/2 ©Hirschmann Rev. D 12/19/08 WG/SC 190075_D...
  • Page 43 ©Hirschmann Rev. D 12/19/08 WG/SC 190075_D...
  • Page 44 Service Manual MARK4E/2 ©Hirschmann Rev. D 12/19/08 WG/SC 190075_D...

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