Hirschmann MARK 4E/2 Manuel utilisateur

HIRSCHMANN

LOAD MOMENT INDICATOR SYSTEM

MARK 4E/2

01 12.0ft 40000lb

06 35.0ft 6800lb

SERVICE MANUAL

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

Service Manual Mark 4E/2

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

NOTICE

Hirschmann, Inc. makes no warranty of any kind with regard to this material, including, but not limited

to, the implied warranties of merchantability and/or its fitness for a particular purpose.

Hirschmann, Inc. will not be liable for errors contained in this manual or for incidental or consequential

damages in connection with the furnishing, performance, or use of this manual. This document

contains proprietary information, which is protected by copyright, and all rights are reserved.

No part of this document may be photocopied, reproduced, or translated to another language without

the prior written consent of Hirschmann, Inc.

Hirschmann, Inc. reserves proprietary rights to all drawings, photos and the data contained therein.

The drawings, photos and data are confidential and cannot be used or reproduced without the written

consent of Hirschmann, Inc. The drawings and/or photos are subject to technical modification without

prior notice.

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

MANUAL REVISIONS

REV DATE NAME DESCRIPTION

- 7/25/2002 SB Created service manual, ECN 02-205

A 9/15/2003 SB Add Console/Central Unit Connections, ECN 03-115

B 4/29/2008 SC ECN 08-071 (include PAT sensors & revise wiring)

C 10/10/2008 WG ECN 08-149 (revise wiring)

D 12/19/2008 WG ECN 08-204 (Wiring diagrams added to end of manual)

Service Manual Mark 4E/2

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

TABLE OF CONTENTS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Mechanical Description Of The Components

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

1 MECHANICAL DESCRIPTION OF THE COMPONENTS

Pressure Transducer:

The pressure transducer transforms hydraulic pressure into an electric analogue voltage signal. Two

pressure transducers are connected, one to the rod side and one to the piston side of the lift cylinder.

The pressure transducer is connected to the central unit with a four conductor, double shielded cable.

The power supply voltage is +12V.

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

Cable Reel:

The cable reel houses the length-angle transducer, slip ring disc and slip ring pick up (to feed and

return A-2-B signal). The PE cable goes through the drum and out to the tip where it is wired to the

Anti-Two-Block switch. The reel is driven by a tensioned spring and should be handled with caution.

The Length-Angle Transducer:

The length-angle sensor (LWG) is a combination of two transducers in cable reel, fitted at the base

section of the boom. It measures the length and the angle of the boom. A reeling drum drives a

potentiometer, which is the length transducer. Part of the length transducer is the length cable on the

drum, which is a two-conductor cable (shield and core). It is connected to the anti-two-block switch at

the boom head and to a slip ring body in the LWG. The angle transducer is fitted in the cable reel. A

pendulum drives the axle of the angle potentiometer.

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

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

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

Anti-Two-Block Switch:

The anti-two-block switch monitors the load block and its relationship with the head of the boom. In

working condition, the switch is closed with a 4.7k ohm resistor in series. When the hook block strikes

the weight the circuit opens, disengaging a relay output to the lock out solenoid valves, where

applicable. The weight at the anti-two-block switch keeps the switch closed until the hook block

strikes it.

Console:

The console displays all geometrical information such as length and angle of main boom and working

radius. It also displays the actual load and the maximum load permitted by load chart. Furthermore, it

has an alarm horn and a warning light for overload, and a pre-warning light. The LED’s instrument

shows a percentage of the total permissible moment. The console has pushbuttons to switch the

operating modes (for selection of crane configurations and reeving of the block). It also has a warning

light for overload, anti-two-block conditions and an override push-button for anti-two-block condition.

Service Manual

MARK 4E/2

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

2 MECHANICAL AND ELECTRICAL DESCRIPTION OF THE CENTRAL

UNIT

All data of the crane are stored inside the central unit in EPROMs. The central unit gets all actual

information of the crane. This is computed against the reference data and the crane status

continually monitored.

Description of the Housing:

The MARK 4E/2 central unit has a water proof aluminum housing. It is mounted on the left side of the

turntable weldment or on the counterweight. The cables are led into the central unit via strain reliefs

and connected with fast-ons. An override switch is mounted on the housing to override the LMI

function. The system is protected by a 2-AMP fuse that is mounted on the lower right side.

Description of the Boards:

Inside the central unit there is one board. The main board that has terminal strips where power and

various components are connected with fast-ons to the terminal strip. The main board is the heart of

the system. It contains the main computer and the necessary electronics to receive, evaluate, process

and direct the continuous data. There are overload and anti-two-block relays, which control the Bosch

relay for lever lockout, also mounted on this board.

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

An analogue input part, which receives and prepares all the signals from the transducers for further

processing.

An analogue/digital converter part , which converts all the processed analogue signals into digital

ones.

A digital part , which contains the main computer and the ancillary electronics.

Incoming Signals:

The signals from the transducers are connected to the terminal board. The signals of the angle-length

transducer are connected to terminal #56 (angle) and terminal #53 (length).

The signal on terminal #56 (angle) is between approximately 20.00ma to 4.00ma.

The signal on terminal #53 (length) is between 4.00ma and 20.00ma.

The signals from the pressure transducers are connected to terminal #52 (rod side) and terminal #51

(piston side). The signals on terminals #51 and #52 range between 4.00ma and 20.00ma.

The signal from the force transducer is connected to the terminals #51 and #52 range between4.00ma

and 20.00ma. The supply voltage +12vdc for the anti-two-block switch is terminal #72 and return

signal on terminal #71.

Outgoing Signal:

The outgoing signal of the terminal board is the signal for lever lockout of terminal #87 on the Bosch

relay. In normal working conditions there are 12 or 24 volts at this terminal. When there is an

overload or anti-two-block condition the signal becomes 0 volts. Furthermore, all voltages for the

transducers and console are going out via the terminal strip.

Basic Adjustment of Hardware

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

3 BASIC ADJUSTMENT OF THE HARDWARE

Length:

Ensure that the length cable tension is correct with fully retracted boom by turning the cable reel 2 to

check that the reel fully retracts. Then remove cover from cable reel and adjust the potentiometer till

fully counter clockwise to the soft stop.

Angle:

Set the boom to 0 degrees and set a digital level on the boom. Adjust the angle sensor to the same

angle as the boom. Check the angle at 20 degrees, 45 degrees, 70 degrees. Angle display should be

less than r.2 degrees of the value of the inclinometer.

Pressure Channel:

Rest the boom and disconnect the pressure transducers. Measure the voltage of both pressure

transducers on the terminal board. The output voltage of the pressure transducers should be 4.00ma.

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

Check function of lever lockout.

Measure and record the power supply voltages.

Service Manual

PRS145

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

4 DEFINITIONS

BOOM LENGTH The straight line thru the centerline of boom pivot pin to the centerline of the boom

point load hoist sheave pin measured along the longitudinal axis of the boom. (Indicator r2%)

BOOM ANGLE The angle between the longitudinal centerline of the boom base section and the

horizontal plane. (Indicator 65° to 90° boom angle + 0°/2°; less than 65° boom angle + 0°/-3°)

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

the supporting surface, before loading, to the center of the vertical hoist line or tackle with rated load

applied. (Indicator 100% to 110%)

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

crane configuration, boom length, boom angle, or functions or these variables. For radii outside those

shown on the load ratings chart, the rated load is to be considered as zero.

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

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

CRANE CONFIGURATION The physical arrangement of the crane as prepared for a particular

operation in conformance with the manufacturer’s operating instructions and load rating chart.

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

boom point machinery.

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

angle, and pressure transducer)

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

quantity of operation. (A2B, area definition switch)

Table des matières

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