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iFLEX5

SERVICE MANUAL

SkyAzúl, Equipment Solutions
6126

www.skyazul.com

301-371-

NOTICE
SkyAzúl 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.
SkyAzúl 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 SkyAzúl.
SkyAzúl 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 SkyAzúl. The drawings and/or photos are subject to technical modification without prior
notice.
All information in this document is subject to change without notice.

SkyAzúl, Inc.
200 W. Main Street, Suite, 2A
Middletown, MD 21769
Fax 301-371-0029

info@skyazul.com

SkyAzúl, Equipment Solutions

www.skyazul.com

301-371-6126

SkyAzúl, Equipment Solutions

www.skyazul.com

301-371-6126

................................. 4 5 Angle Sensing .................................. 19 12.......................................com 301-371-6126 ........................................................... 2 3...1 RT9000E / RT800E BASICS....................................................................................................1 E61 ........ 4 4...................................2 Components: ...............3 E63 .............................1 ANGLE SENSING ERROR ...................................................................................5 5..............................................2 3............15 11 A2B Problem...................................Flow Chart ........................................ 24 14.......................1 DESCRIPTION OF SYSTEM FUNCTION..............................................1 LOAD SENSING ERROR .......................... 4 4.......................................................................................................................... 11 8 Slewing Sensing.................................................................................................. 6 6 Length Sensing ............................ 20 13 Troubleshooting a sensor problem using the display...........................................................................................................................................................................................................FLOW CHART .....................4.................................. 17 12.............................Service Manual iFLEX5 TABLE OF CONTENTS 1 General Information ......... 19 12.................................FLOW CHART ...................10 I HAVE NOTICED WATER IN SOME PART OF THE SYSTEM ....................................................8 6........ 27 SkyAzúl.......1 Terminology: .....................................................................................................................................FLOW CHART ...............skyazul.................................................................................2 DESCRIPTION OF A CAN BUS SYSTEM ......................................................................................................................2 E62 .................................................................. 14 10 No console display............................................................................ 20 12..............1 2 Warnings ........................... 24 14.........................................................................................................7 I HAVE AN A2B PROBLEM ......................................................................................................... 26 14...................................1................................................................................................FLOW CHART............ 26 14......17 12..................................................1 E64 ...................................................................................8 I HAVE A CAN-BUS PROBLEM ............................................................................. 4 4.......... 24 14................................................1............ 4 4.................................14 9....................................................................................... 4 4.................................................................... 19 12..........................................................3 THE DISPLAYED LENGTH DOES NOT MATCH THE ACTUAL BOOM LENGTH ............................................................................ 3 4 What’s Wrong? .................................................................................................................................. 4 4..........................................3 IFLEX5 BCS DIGITAL INPUTS: .................................................................................................................................................... 2 3.........................................................................................................FLOW CHART ..........24 14..... 24 14....3 DESCRIPTION OF THE SYSTEM COMPONENTS .....................................................1 PRESSURE SENSING ERROR ......................................2 TELE SEQUENCE: ..............................................................................................................................................1 I HAVE AN ERROR CODE INDICATED ON THE CONSOLE .................................................1 3 Description Of The System ................................................................................................21 14 iFLEX5 Boom Control System (BCS)..........................................5 THE DISPLAYED LOAD DOES NOT MATCH THE ACTUAL LOAD ................................................1..................................2 THE DISPLAYED ANGLE DOES NOT MATCH THE ACTUAL BOOM ANGLE ..............Flow Chart . 4 4...............3 Manual / Auto Mode:............. 4 4...4 THE DISPLAYED SLEWING DOES NOT MATCH THE ACTUAL SLEWING ANGLE ................ Equipment Solutions www.......16 12 cann-bus communication......................................................................................12 8........ 9 7 Pressure Sensing ...1 E61 .................................................................. 18 12...4 RT9000E / RT800E IFLEX5 BCS DIGITAL OUTPUTS: .......................................................1 LENGTH SENSING ERROR ............................................................................................................................................................................................................................................................. 13 9 Load sensing .............................................................................................................................................6 THE CONSOLE DISPLAY IS BLANK ............ 4 4...........4 4.................5 E65 ..................................4 E64 ...9 I NEED TO IDENTIFY A SPARE PART .11 7................................................................1..................1 SLEW SENSING ERROR ................................................................................

........3 Cable Reel Length Cable Replacement Procedure ........ 14M PART NO...2 GRAPHIC CONSOLE ASSY........................ 39 15......................5.....................................................3............................................. 32 14.. 36 15... 31 14..........................................................12 TRS05 REPEATER........................ Equipment Solutions www..1 ACTIVATING THE SERVICE SCREEN FOR SENSOR CALIBRATION ............. 51 16.................1 Central Unit to Crane Interface Wiring Diagram ..........................................5 ANGLE SENSOR CALIBRATION PROCEDURE ............... 32 14................10 WIRING HARNESS BOOM CONTROL........................................................................ 55 17. 50 16............................................... 57 17............................................ 46 16.............3 ZERO-SETTING THE SLEWING INPUTS ................................................................7 BOOM OUT OF SEQUENCE:...........................5............4........2 Length Sensor Adjustment Procedure....................1 Cable Reel LWG508 Adjustment Procedure ...... PART NO............................... 021-020-060-003...................4 CABLE REEL......................................................... 49 16..6 ZERO-SETTING THE SLEW POTENTIOMETER .......................................................................................................................................................................................3 ELECTRICAL SYSTEM DIAGRAM STANDARD SYSTEM .........................5 ELECTRICAL SYSTEM DIAGRAM BOOM CONTROL SYSTEM.......4.... VERTICAL PART NO............3 Boom Extension Anti-two Block Wiring Diagram ...................2 ZERO-SETTING THE TRANSDUCER INPUTS ....3....................................62 19 Troubleshooting Moisture... 56 17...............com 301-371-6126 .........44 16................... 044-314-060-014 ............................ 43 16 Spare Part Listings ...... 067-152-060-056......................8 TELE ROD DRAIN VALVE: ..........................................................34 15....................................... IFLEX5 PART NO........54 17..................................................2 Console and Sensor Wiring Diagram . 050-350-061-356 ...........6 IFLEX5 BCS TEST DISPLAY: .............................. 29 14...1 Central Unit to Crane and Console Wiring Diagram ........ LWG521 PART NO.. 51 16..............................................................................6 CABLE REEL....................................... 39 15................................. 031-010-100-555 ....11 CABLE ASSEMBLY............... 45 16................ 73 SkyAzúl............................. 42 15......................3.......8 CABLE ASSEMBLY 11M................................................................................................... 51 16..........3 GRAPHIC CONSOLE ASSY.........1 CENTRAL UNIT.......... PART NO.......................... 34 15................................4 Luffer Extension Wiring Diagram......5.......................... RADIO WINDSPEED KIT 031-300-104-087 .............. 40 15....... 32 14............... 031-010-100-554 ..........................................................................................3 Cable Reel (LWG520/0002) Wiring Diagram.......................................10 HYDRAULIC LUFFING BOOM EXTENSION: ............. PART NO......................................1 COMPONENTS OF THE LMI SYSTEM PAT IFLEX5.......... 55 17....1 WATER INGRESS ....... 33 15 Drawings ................................................................ 36 15...............................4 LENGTH SENSOR CALIBRATION PROCEDURE ................................. DAV314/0014 PART NO................. 52 16...................72 19............... 56 17.......................................................................5 CABLE REEL.....................................................7 PRESSURE TRANSDUCER BLOCK........................................................................ 59 17.............................................2 Cable Reel (length/angle sensor) Wiring Diagram .......2 BLOCK DIAGRAM.... LWG152 PART NO.................... 38 15............. 050-350-061-376 ..... 61 18 Error Codes ...... 72 19.........................4..................... 031-010-101-007.................................................5 IFLEX5 BCS ANALOG INPUTS AND PWM OUTPUTS: ........................... 37 15................................ 068-508-060-001................................................................................................................................................. 58 17................................................................................... PART NO........9 TELE TWO STAGE RELIEF VALVE: ...... 44 16....................9 WIRING HARNESS STANDARD.............................................. 38 15............................... 068-521-060-002..... 35 15....... 47 16............................................................................................................... 031-010-100-549 ..................2 CONDENSATION ................................................................ LWG508 PART NO.................. 53 17 Service Screen For Sensor Calibration.............. 54 17..................................................4 MAIN CENTRAL UNIT CONNECTOR ..........5.....Service Manual iFLEX5 14................................................... 52 16...................................................................................skyazul............................

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NOTE: Knowledge of how to use a voltmeter to measure both voltage and current is assumed. A digital voltmeter with the capability to measure current will be required. To prevent material damage and serious or even fatal accidents. and shall not be. Equipment Solutions www. along with standard maintenance and service tools. The responsibility for the safe crane operation shall remain with the crane operator who shall ensure that all warnings and instructions supplied are fully understood and observed. SkyAzúl. Refer to Section 6. 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. Pre-Operation Inspection and Calibration Verification of the operator’s manual.com 301-371-6126 . refer to the consoles operator’s manual 031-300-190-147. Prior to operating the crane. REFERENCE: For system operation. 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. The LMI can only work correctly.skyazul. a substitute for good operator judgment. 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. if all adjustments have been properly set. the correct adjustment of the LMI has to be ensured before starting the crane operation.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. For correct adjustment. experience and use of accepted safe crane operating procedures. Proper functioning depends upon proper daily inspection and observance of the operating instructions set forth in this manual.

Each controller connected through a CAN chip is called a "node" and is mostly used to acquire data from a sensor. The cable bus is a twisted pair of shielded wire. it will be processed. The interactive user guidance considerably simplifies the input of operating modes as well as the setting of geometry limit values. such as hoist up. Boom length and boom angle are registered by the length/angle sensor. Equipment Solutions www. boom weights. operating console. will be stopped. 3. The boom length is measured by the cable reel cable. The crane load is measured by pressure transducer block attached to the piston and rod side of the hoist cylinders. When limits are reached. For longer network distances the maximum transfer rate must be reduced to 50 Kbit/s for a 1 km network distance. Its intended use is as a serial bus system for a network of controllers. Also. mounted inside the cable reel. 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. centers of gravity and dimensions are stored in memory chips in the central processor unit. the higher the priority. If the message is relevant. all nodes are able to transmit data on that bus however only one node at a given time has write access to the bus.com 301-371-6126 . stored in the central processor memory and evaluated in the microprocessor. SkyAzúl. The lower the numerical value of the identifier. All components and sensors are equipped with CAN bus controllers. otherwise it is ignored. All nodes are connected to a common bus and all nodes are able to simultaneously read the data on that bus. length/angle sensor. pressure transducers. which is mounted on the boom. the aggravating crane movements. which also serves as an electrical conductor for the anti two-block switches. The fixed data regarding the crane. The real value.1 iFLEX5 DESCRIPTION OF THE SYSTEM DESCRIPTION OF SYSTEM FUNCTION The iFLEX5 system is a CAN bus system made up of a central microprocessor unit. an overload warning signal is generated at the operator’s console.skyazul. and anti-two block switches. The unique identifier also determines the priority of the message.Service Manual 2 3 3. At the same time.2 DESCRIPTION OF A CAN BUS SYSTEM CAN stands for “Controller Area Network”. The PAT Load Moment Indicator system operates on the principle of reference/real comparison. telescope out and boom down. CAN will operate in extremely harsh environments and the extensive error checking mechanisms ensure that any transmission errors are detected. such as capacity charts. resulting from the pressure measurement is compared with the reference data. This data is the reference information used to calculate the operating conditions.

CAN bus converter board. working radius and head height of the boom. Equipment Solutions www.20mA analog signals. and slew indication. and troubleshooting sensor output screen. The slew input to the central unit is not a CAN signal. A pressure transducer block houses two transducers. It is part of the electrical swivel (slip ring assembly). and green colors. The angle transducer is a potentiometer driven by a weighted pendulum that is oil damped. Console: The graphic console displays all geometrical information such as length and angle of main boom. In working condition the switch is closed. yellow.. The potentiometer has two wipers which are used to determine the slewing angle (rotational positioning) of the super structure in relation to the carrier.3 3 DESCRIPTION OF THE SYSTEM COMPONENTS Pressure Transducer: The pressure transducer converts hydraulic pressure into an electric signal. One pressure transducer is connected to the piston side of the lift cylinder and the other to the rod side. It measures the length and the angle of the boom. installed on the base section of the boom. it has an alarm horn. The board has a hard mounted connector for power. The graphic display allows for a simple interactive configuration setup. The Length-Angle Transducer: The length-angle sensor (LWG). (short circuit to ground) there is a 4. to give a signal back to the central unit. The console has a warning light for anti-two-block conditions and an override switch for overload or anti-block condition. Anti-Two-Block Switch: The anti-two-block switch monitors the load block and it’s relationship with the head of the boom. Refer to Operator’s Handbook for detailed operation of the console. Part of the length transducer circuit is the length cable on the drum. Central Unit: Inside the central unit there is a CPU and connection board. Furthermore.7k resistor between ground and the contact of the switch. Slew Potentiometer: This component is not supplied by PAT/Hirschmann.com 301-371-6126 . as well as sensor calibration (zero adjustment). indicating relay energized and a communication LED that flashes through red. The board has a green LED. is a combination of two transducers in one box. which is a multi-conductor cable. which is connected to the bus system. A reeling drum drives a potentiometer. To check the cable for damage. and a pre-warning light. where applicable. Both length and angle transducer are connected to a CAN bus controller board. The weight at the anti-two-block switch keeps the switch closed until the load block strikes it. a warning light for overload.Description Of The System 3. but rather two 4. and two bus connectors.skyazul. disengaging a relay output to the lock out solenoid valves. It also displays the actual load and the maximum load permitted by load chart. When the load block strikes the weight the circuit opens. which is the length transducer. often referred to as the “cable reel”. SkyAzúl. bus controller. It is connected to the antitwo-block switch at the boom head and to a slip ring body in the LWG. ground.

If the load display is off. let us try to guide you quickly to solving the problem. no buzzer.10 I HAVE NOTICED WATER IN SOME PART OF THE SYSTEM Please go to section Troubleshooting Moisture! SkyAzúl.9 I NEED TO IDENTIFY A SPARE PART Please go to the Spare Part Listings! 4. what’s wrong? Assuming you are reading these pages because of some kind of problem with the PAT system.Service Manual 4 4 iFLEX5 WHAT’S WRONG? So. 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.1 I HAVE AN ERROR CODE INDICATED ON THE CONSOLE Please go to section Error Codes! 4.7 I HAVE AN A2B PROBLEM Please go to sectionA2B PROBLEM 4. or the console itself. In most cases.6 THE CONSOLE DISPLAY IS BLANK If the console does not show any sign at all (no lights.skyazul. and all the sensor inputs.8 I HAVE A CAN-BUS PROBLEM Please go to section CAN-Bus Communication! 4.com 301-371-6126 . the problem is either in the wiring between console and central unit.4 THE DISPLAYED SLEWING DOES NOT MATCH THE ACTUAL SLEWING ANGLE Refer to section Slewing Sensing to check the slew sensor. Refer to section No console display for further troubleshooting.3 THE DISPLAYED LENGTH DOES NOT MATCH THE ACTUAL BOOM LENGTH Start in section Length Sensing to check the indicated length. 4. your problem will fall under the following categories: 4. 4. no display). the operator’s selections. 4. Equipment Solutions www. 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. 4.2 THE DISPLAYED ANGLE DOES NOT MATCH THE ACTUAL BOOM ANGLE Start in section Angle Sensing to check the indicated angle.

what do you do when you are having a problem with your angle read-out? Start by verifying the angle display. The angle sensor is contained within the cable reel.Angle Sensing 5 5 ANGLE SENSING The System measures the angle of the main boom of the machine with an angle sensor.com 301-371-6126 . The terminal used is X21. both located in the cable reel. Refer to the section “Troubleshooting A Sensor Problem Using The Display” to call up the sensor signal on your console display. The angle sensor is connected as follows: Terminal X21 1 + 5V 3 Signal 5 GND SkyAzúl. Block Diagram Angle Sensor CAN-Bus Converter Cable Reel iFLEX5 CU Pressure Transducer The signal runs from the angle sensor to the Can-Bus converter board. Equipment Solutions www. The angle sensor has a potentiometer built in that is driven by a pendulum. From there. The converter board supplies a constant voltage of 5V to the angle sensor and in return monitors the voltage of the potentiometer.skyazul. X1 (CAN) X14 (A2B) X20 (length) X21 (angle) LED CAN-Bus electronics in cable reel. So. The CAN-Bus is digital and as such will either transmit the signal correctly or not at all. If your readings are off. As the angle changes. which acts as a T-connector to the main CAN-Bus running to the central unit. you have to determine what is causing the problem (reference the following flow charts). so will the pendulum and with it the potentiometer’s axle. located on the left side of the main boom. it travels as digital information on the CAN-Bus to the pressure transducer.

75 to 5. Follow procedure for angle sensor installation and calibration.75 to 5. Does the displayed value differ from the actual value? YES. SkyAzúl. verify the angle displayed through the console by using the sensor output screen.1 iFLEX5 ANGLE SENSING ERROR .25V ? Unplug angle sensor and measure again.FLOW CHART Angle Sensing Error First. replace the angle sensor. 1st NO Continue with angle sensing flow chart (next page) Is the voltage between the range of 4. 1ST Angle sensor range values: 4500mV at 0° 2500mV at 45° 500mV at 90° Recalibrate angle sensor. Equipment Solutions www. YES 2ND Angle sensor is functioning correctl Verify that the sensor is being supplied with 5V by measuring between pin 5 (GND) and Pin 1 (+) of terminal X21. Press the info button twice compare Open the cable reel and locate the angle sensor (right) and CAN-Bus converter board (left). NO MEASURE AGAIN 2ND Is the voltage between the range of 4.com 301-371-6126 .Service Manual 6 5.skyazul. (Reference Angle sensor calibration procedure).25V ? NO Replace converter board YES If unplugging the angle sensor made the voltage return to the acceptable range.

25° from the actual angle? NO Replace converter board.875 75 2.skyazul.875V at 90° and 3.875) * 72) SkyAzúl. Angle Sensor Signal On Pin 3: Angle Voltage 90 1.292 45 2. Ensure correct software has been installed and crane operator is not in Note: If you need to determine the angle for voltages other than shown above. YES Does the indicated angle vary by more than +/.com 301-371-6126 . do so by using the following formula: Angle (degrees) = 90 degrees – ((Voltage-1. replace the angle sensor.708 15 2.500 30 2.Angle Sensing 7 Angle Sensor signal varies Ensure the angle sensor returns a voltage between 1.125V at 0° Verify the voltage by measuring Between Pin 5 (GND) and Pin3 (signal) of terminal X21.0.917 0 3. If this angle varies significantly from your actual angle.083 60 2. Equipment Solutions www.125 Note: Actual voltages will vary slightly.

both located in the cable reel. Block Diagram Length Sensor CAN-Bus Converter Cable Reel iFLEX5 CU Pressure Transducer The signal runs from the length sensor to the CAN-Bus converter board. it travels as digital information on the CAN-Bus to the pressure transducer. located on the left side of the main boom. The converter board supplies a voltage of about 4. Refer to the section “Troubleshooting A Sensor Problem Using The Display” to call up the sensor signal on your console display. The length sensor is contained within the cable reel. X1 (CAN) X14 (A2B) X20 (length) X21 (angle) LED CAN-Bus electronics in cable reel. The CAN-Bus is digital and as such will either transmit the signal correctly or not at all. Equipment Solutions www. The terminal used is X20. which acts as a T-connector to the main CAN-Bus running to the central unit. you have to determine what is causing the problem (reference the following flow charts).(~ 0. The length sensor is connected as follows: Terminal X20 1 + (~ 4. the cable drum will turn and with it the potentiometer’s axle.8V) 3 Signal 5 . So.skyazul. As the length changes. If your readings are off. The length sensor has a potentiometer built in that is driven by a gear drive from the cable drum.2V) SkyAzúl. From there.Service Manual 8 6 iFLEX5 LENGTH SENSING The system measures the length of the main boom of the machine with a length sensor. what do you do when you are having a problem with your length read-out? Start by verifying the length display.com 301-371-6126 .7V to the length potentiometer and in return monitors the output voltage of the potentiometer.

verify the length displayed through the console is off by using the sensor output screen.0. bringing the sensor voltage to 0V (+/. YES Open the cable reel and locate the length sensor (right) and CAN-Bus converter board (left).FLOW CHART Length Sensing Error First. Press the info button twice Measure voltage between Pin 5 (-) and Pin 3 (signal) of terminal X20 and compare. Return to the indication screen and again compare the indicated and actual length.1 9 LENGTH SENSING ERROR .com 301-371-6126 . Does the displayed value differ from the actual value? NO Fully retract the boom and turn the screw of the length potentiometer with a small screwdriver counterclockwise to a soft stop.1 Volt). Replace length sensor.3 feet)? Proceed to next length sensing flow chart.skyazul. Length sensor is functioning correctly. SkyAzúl.Length Sensing 6. Press the info button twice Ensure the cable reel has 5-8 turns of preloading on the reel. Equipment Solutions YES NO www. Does the indicated length vary significantly from the actual length (more than 0.

What we can give you for trouble-shooting.84 Note: Actual voltages will vary slightly.38 4. though: Length Sensor Signal on Pin 3 Turns Voltage X20-5 to X20-3 0 0. the length sensors are the same as described above with the exception of cable reel internals (location of hardware. replace the length sensor.7V to 5. wiring. YES Is the voltage between the range of 4.7V to 5. and gear wheels).0V ? NO NO YES Unplug the length sensor and measure again.87 5 2.00 1 0.75 9 4.40 4 1.44 3.0V ? 1ST Ensure the length sensor is being supplied with 4.16V at 0 turns of the length pot (= fully retracted) and 4.Service Manual 10 iFLEX5 Length Sensor varies See length sensor signal chart below. 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. Refer to the LWG520 and LG152 spare part list for these differences.56 2. For the boom control system.93 3 1. SkyAzúl. Equipment Solutions www.com 301-371-6126 .91 4. How many turns you get at full extension depends on the gear ratio. If unplugging the length sensor made the voltage return to the acceptable range.skyazul. the boom length. Replace converter board. Follow procedure for length sensor The length sensor returns a voltage between 0.28 8 3. so we cannot provide a standard table for it.97 3. Note that this does not sync to the number of turns of the cable reel.62 1.50 2. the length cable used and the spooling pattern.22 10 4.03 2.09 1.68 Voltage GND to X20-3 0.46 2 0.81 7 3.7V by measuring between Pin 5 (-) and Pin 1 (+) of the X20 terminal.34 6 2. 2ND Is the voltage between the range of 4.84V at 10 turns.16 0.

SkyAzúl. BOTH transducer channels need to be zeroed.Pressure Sensing 7 11 PRESSURE SENSING The System measures the pressure of the boom lift cylinder for both rod. see procedure Zero-Setting The Transducer Inputs. If the reading is slightly off. Note: After exchanging the pressure transducer block. Block Diagram: (2) PressureMeasuring Cells CAN-Bus Converter iFLEX5 CU The signal runs from the pressure transducer as digital information on the CAN-Bus to the central unit. Equipment Solutions www. small variations can be adjusted. Does the displayed value differ from the actual NO YES Ensure that the pressure lines are drained and disconnected.FLOW CHART Pressure Sensing Error First. see section Service Screen For Sensor Calibration. verify the pressure displayed through the console by using the sensor output screen.1 PRESSURE SENSING ERROR . Both sensors are contained within one box that also contains the electronics needed for amplification and creation of the CAN-Bus signal. Replace pressure transducers. Press the info button twice Pressure transducers are functioning correctly.com 301-371-6126 . Pressure Transducer 7.and piston-side. The readout should read 500mV (+/25mV) and 0 PSI.skyazul.

9 120. The table to the right show measured millivolt reading for the slew potentiotmeter. Block Diagram Slew Potentiomet er with (2) outputs Current Converter iFLEX5 CU Slip Ring Assembly The slew potentiometer has two potentiometers built in that are driven by the slip ring axle.1 180 -150.skyazul. Use the display screen by pressing ‘i’ (info) twice to show all sensor inputs. As the slewing angle changes. The slewing sensor is contained within the slip ring assembly.1 -90 -60. ANGLE (deg) 0 30.1 150.com 270 -90 315 -45 360 0 301-371-6126 . so will the axle and with it the potentiometer’s outputs.1 -30 0 SL ANG 1 (mv) 717 1174 1680 2158 2641 3144 3595 3144 2642 2160 1681 1172 718 SL ANG 2 (mv) 2161 2645 3150 3595 3141 2639 2161 1681 1180 718 1168 1680 2161 Modular Slew Pot . Equipment Solutions 90 90 135 135 180 225 180 -135 SLEW ANGLE www.3 60 89.Voltage on Service Screen 4000 MILLIVOLTS 3500 3000 2500 2000 1500 Potentiometer 1 1000 Potentiometer 2 500 0 0 0 45 45 Display screen for sensor inputs SkyAzúl.Service Manual 12 8 iFLEX5 SLEWING SENSING The system measures the slewing (rotational position) of the crane’s upper with a slewing sensor.1 -120.

FLOW CHART Slew Sensing Error First.skyazul. Equipment Solutions www. Pin 7 must carry crane voltage and Pin 2 is GND. 20 mA 16 12 8 4 0 0 90 180 270 360 De gr e e s SkyAzúl. Slew potentiometer is functioning correctly.1 to 5. The potentiometer and the board output two signals between 4 and 20mA that go to the central unit. You can measure them at the 12pin crane interface connector. verify the slew angle displayed through the console by using the sensor output screen. you should see about 4mA in one channel (wire #2) and 12mA in the other channel (wire #3)). You can also leave the wires connected as use your meter in Voltage-mode to measure the output signals.5 Volt range. however. NO YES The slew unit output can be found on pins 8 and 9. In order to measure current.Slewing Sensing 13 The converter board is supplied with 12V from the central unit.com 301-371-6126 .Output Curre nts mA 3 24 (When the crane is over front. In this case. the problem may be mechanical. If the voltage or currents do not fall in line with the charts and tables shown below. you will see the 4…20mA range as a 1.1 SLEW SENSING ERROR . *The two outputs will vary as shown in chart below. Open the slip ring unit and determine if the slew potentiometer is set mA 2 M odular Sle w Pot . you must disconnect a pin and measure in line (between the cable from the slew unit and the central unit). 8. and no system errors are present. Press the info button twice Does the displayed value differ from the actual value? Ensure that the slew pot unit is supplied with crane voltage.

skyazul. etc. you will see the 4…20mA range as a 1. Pin 7 must carry crane voltage and Pin 2 is GND. but a calculated value that is based on a lot of factors.FLOW CHART Slew Sensing Error First.5 Volt range.com 301-371-6126 . LOAD SENSING ERROR . those include: x x x x x x x x x 9. In order to measrure current. If the voltage or currents do not fall in line with the charts and tables shown below. Outside of the measured values (sensors). *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.1 to 5. Tip height (length of load line used) Boom weights Boom attachments such as Stowed jibs Auxiliary boom nose. NO YES The slew unit output can be found on pins 8 and 9. In this case.Service Manual 14 9 iFLEX5 LOAD SENSING Please note that the load displayed by the LMI is not a direct measurement. verify the slew angle displayed through the console by using the sensor output screen.1 Operator settings such as: o Operating mode/configuration o Parts of Line/Reeving Rigging parts such as: Hookblock weight Sling weights. the problem may be Open the slip ring unit and determine if the slew potentiometer is set SkyAzúl. you must disconnect a pin and measure in line (between the cable from the slew unit and the central unit). Equipment Solutions www. Slew potentiometer is functioning Press the info button twice Does the displayed value differ from the actual value? Ensure that the slew pot unit is supplied with crane voltage. however. and no system errors are present. etc.

Is power being supplied? Check for power on connector X6 of the connection board. Equipment Solutions OR www. SkyAzúl.skyazul. NO If no power was supplied on the connection board but was supplied on the external connector. it is most likely missing power. Make sure all connectors are correctly in place. Start with the following: No console display Ensure that no lights. or backlighting is visible. such as warning lights. (Pin 1 is +Ub 12V and Pin 2 is Is power being supplied? NO Ensure TxD LED is on (located in center of the computer board and is normally blinking when the console is YES Check fuse F1 again. Follow power from this connector to the console computer board. etc. Check wiring harness and central unit. Conn. but you still do not get any console lighting.No console display 15 10 NO CONSOLE DISPLAY If the console is not showing any lights. (Pin 1 is +Ub 12V and Pin 2 is GND). warning lights. YES NO Replace fuse. Measure on the green connector (Pin 1 is +Ub 12V and Pin 2 is Is power being supplied? Check fuses in console: one (F6) is located on the connection board (mounted to the inside of the housing) which protects the override key switch function and the bar-gragh. Board Computer Board Pins X6 X1 4 X10 X22 6 X7 X2 10 * X10-X22 could be plugged into X17 by mistake Software is If voltage is present on all pins and connector are in place. connector X1. Check if power is being supplied by the central unit. 301-371-6126 . the connection board must be replaced.com Console electronics need replaced. The main fuse (F1) is locate on the console processor YES Are fuses in line? YES NO Open console. backlighting. Connecting cable is loose or defective.

skyazul.com A problem lies with either the wiring harness.500 Ohms Switch open = > 1 Megaohm. Equipment Solutions Is the anti-two block warning light on? NO NO Ensure the bypass plug is installed. and measure the resistance at the boom nose box between terminals 1 and 3 with an ohmmeter. Switch closed = 0 ohms (weight installed) Switch open = 1 Megaohm (weight removed) Are the ohmmeter readings correct? YES NO Check for damaged length cable and wiring. 301-371-6126 . If two hoists are in use. If wiring is correct. SkyAzúl. remove bypass plug.Service Manual 16 iFLEX5 11 A2B PROBLEM A2B problem Are the control levers locked out and is the crane in an anti-two block condition? YES Lower the hook block and/or headache ball to correct the two-block problem. NO Replace the slip ring. YES Are the ohmmeter readings correct? YES www. Are the ohmmeter readings correct? Remove wires and measure the A2B signal in the cable reel between terminal 7 and 8 with an ohmmeter. 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. Plug the bypass plug into the boom nose box and refer to system wiring to check wire connections in boom nose box. Switch closed = 4700 +/. and/or the central unit. replace A2B Turn power off. both hooks must be lowered. If broken length cable.500 Ohms Switch open = > 1 Megaohm. Ensure bypass plug is plugged into the boom nose box. cable reel length/angle boards. refer to system wiring. Switch closed = 4700 +/.

the pressures of the lift cylinder. E63 means that the pressure transducer is available. and the A2B state of the machine via a CAN-Bus connection. Instead.1 E61 In case of an E61. If it sees only the pressure transducer. So. start by connecting the two cables on the transducer block together. Since this is a digital bus connection. if an E61 still appears check your cabling. but is reporting an internal error. the angle of the main boom. 5 contacts Pin Layout (CiA DR-303-1 7. it will report an E64 (cable reel missing). Equipment Solutions Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Shield + Ub Ground CAN High CAN Low www. the LMI provides you with error codes that give you an indication of the bus state. If it sees only the cable reel. reconnect the cable from the from the central unit to the transducer block.com 301-371-6126 . E65 means that the cable reel unit is available. At this point. it will report an E61. the transducer block must be replaced. If an E61 appears. it is not possible to measure the signals on the bus with a multimeter. but is reporting an internal error.cann-bus communication 17 12 CANN-BUS COMMUNICATION The System measures the length of the main boom. it will report an E62 (pressure transducer missing).skyazul. what do you do when you are having a problem with one of those codes? 12. You can verify that power is being supplied to the sensor by testing the CAN connectors per this layout: Connector M12. If an E62 appears. The error codes are one of the following: E61 E62 E63 E64 E65 Error in the CAN bus data transfer for all CAN units 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 Block Diagram E65 CAN-Bus Converter E61 E64 iFLEX5 CU E62 Pressure Transducer Cable Reel E63 The block diagram tries to clarify that: If the CU does not see any CAN-Bus component.2) SkyAzúl.

Remove can bus connector at cable reel Ohm cable from c/u to the transducer block. 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. If connector Checks good replace can bus converter board. If the E61 error code has become an E64. The central unit must be replaced if this cable is functioning correctly. the can bus cable between the cable reel and transducer block must be replaced. connect the cable reel can bus cable to the transducer block and remove the can bus connector at the cable reel. check all pins for continuity. SkyAzúl. Equipment Solutions www.1.skyazul.Service Manual 18 iFLEX5 Measure between pins 3 and 2 for crane voltage. If you see voltage.1 E61 E61 . If cable checks good replace c/u Yes E61 Yes Replace can bus cable between Cable reel and transducer block No E64 Ohm out connector in cable reel. If an E64 remains. 12. If this causes an E61 to appear.Flow Chart Connect the two cables on the Transducer block together E61 E62 Yes Replace Transducer Block Disconnect cables and connect cable from c/u to transducer block No E64 E61 Connect the cable reel can bus cable to the transducer block.com 301-371-6126 .

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). Check all pins of the CAN bus cable for continuity and cross-check for short circuits. the transducer block must be replaced. If the cable appears to be fine. Start by checking your cabling between CU and pressure transducer. but need to replace the pressure transducer. 12. the pressure transducer is reporting an internal problem.com 301-371-6126 . If the connector checks properly. If an E62 occurs. X1 Pin CAN 1 2 3 4 5 CAN_SHLD CAN +UB CAN GND CAN_H CAN_L SkyAzúl. Equipment Solutions www. Start by connecting the two cables on the transducer block together. 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.4 E64 In case of an E64.2 19 E62 In case of an E62 the CU is reporting no signal from the pressure transducer. You can verify that power is being supplied to the sensor by testing the CAN connectors per the above pin layout. Replace the connector if this check fails.3 E63 In case of an E63. X1 (CAN) X14 (A2B) X20 (length) X21 (angle) LED CAN-Bus electronics in cable reel. you have to replace the pressure transducer. 12. You cannot troubleshoot any further. the CU is reporting no signal from the cable reel unit. If the continuity check fails. If you are sure that the sensor is being supplied.skyazul. If an E61 occurs.cann-bus communication 12. the board in the cable reel might be defective. measure the cable from the transducer block to the cable reel with an Ohm-meter. the cable must be replaced.

Service Manual 20 12. SkyAzúl. Equipment Solutions www. A2B PROBLEM) to continue trouble shooting. Length Sensing. length potentiometer or A2B wiring.1 iFLEX5 E64 .com 301-371-6126 .skyazul. Cable checks good No Replace cable Yes Check connector at cable reel Connector checks good No Yes Replace connector Replace can bus board in cable reel 12.5 E65 In case of an E65. Go to those chapters (Angle Sensing. this will be an angle sensor. In most cases.4.Flow Chart Connect the two cables on the Transducer block together E64 E62 Replace transducer block E61 Yes Ohm cable from the transducer block to cable reel. the cable reel is reporting an internal problem.

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 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

10
.

To EXIT the sensor output screen, press the
“INFO” button once from the software version
screen to return to the operating screen

10
.

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

10

The values shown in the screen here are just examples of actual values. Refer to the table listed
below for actual value ranges.

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Service Manual

22

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:
x
x
x

Pressure transducers (piston and rod), 500mV @ 0 PSI; 4500mV @ maximum PSI
Length sensor, 500mV @ retracted boom length; voltage extended depends on the various
boom lengths.
Angle sensor, 4500mV at 0q; 2500mV at 45q; or 500mV at 90q

Please refer to table below for more values.
Voltage Values
Value displayed Value
displayed [mV] +/- 10mV

Pressure Transducers
300 bar, type 314
500
1500
2500
3500
4500
Angle Sensor
500
1500
2500
3500
4500
Length Sensor
500
1500
2500
3500
4500

PSI
0
1088
2176
3263
4351

Bar
0
75
150
225
300

degrees
90
67.5
45
22.5
0

boom horizontal

feet
0

fully retracted

boom vertical

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

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Troubleshooting a sensor problem using the display

SLEW POT SIGNALS:
Sig 1 (mA)
Reference Angle r0.03mA

4.00
45°
8.00
90°
12.00
135°
16.00
180°
20.00
-135°
16.00
-90°
12.00
-45°
8.00

23

Sig 2 (mA)
r0.03mA
12.00
16.00
20.00
16.00
12.00
8.00
4.00
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 system status. It
can be useful in the case that the iflex refuses terminal communication - otherwise the terminal is a
much more powerful diagnostic tool.
During initialization (after reset) the LED shows some of the initialization steps, so if the reset
procedure hangs, it is easier to find out where. The cycle is:
x RESET: red+small red (for approx 5 us)
x Wait for RAM: green (for approx 200 ms)
x Clear RAM: yellow
(for approx 1 s)
x CRC-Check System program: light yellow (2.5 s)
x Init RS232/RS485 : yellow (1 s)
x 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.

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Service Manual

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iFLEX5

14 IFLEX5 BOOM CONTROL SYSTEM (BCS)
14.1
14.1.1

RT9000E / RT800E BASICS
Terminology:

BCS
IM
CM
OM/Fly
DI
DO
PWM
0
1

= boom control system
= innermid boom section
= center-mid boom section
= outer-mid and fly boom section
= digital input, refer to table 3 for definitions
= digital output, refer to table 4 for definitions
= pulse width modulation
= off with regard to digital inputs and outputs
= on with regard to digital inputs and outputs

The BCS controls the boom telescoping sequence by controlling the current supplied to the
proportional solenoids on the 4-way directional control valves. These valves provide oil to the
telescoping cylinders. Here are the basic components, inputs, outputs, and logical functions to
make this happen.
14.1.2

x
x
x
x
x
x
x
x
x
x
x
x
x
x

Components:

iFLEX5 control system (central unit), located in the cab.
BCS relay junction box assy, located on rear exterior of cab.
Cable reel to measure overall length, located on boom base section.
Cable reel to measure inner-mid length, located on boom base section.
Proximity switch to sense inner-mid fully retracted, located on boom base section.
Proximity switch to sense center-mid fully retracted, located on boom inner-mid section.
Auto/Manual switch, located on the right hand arm rest in the cab.
Section selector switch, located on the right hand arm rest in the cab.
Boom out of sequence light, located on the front console in the cab.
Extend pressure switch, located on superstructure.
Retract pressure switch, located on superstructure.
Inner-mid pilot operated 4-way directional control valve with extend and retract
proportional solenoids, located on the superstructure.
Center-mid pilot operated 4-way directional control valve with extend and retract
proportional solenoids, located on the superstructure.
Tele two stage relief valve, located on the superstructure.

14.1.3

Manual / Auto Mode:

There are two modes of operation, manual or automatic mode. This is selectable by a switch
in the right hand arm rest in the cab, and is seen by the BCS as digital input 17. DI1 17=0 is
manual mode. And DI 17=1 is auto mode.
1

Refer to table 1 for digital input definitions

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Figure 1 illustrates how DO 3 is directed to the solenoid valve. the BCS turns off DO 9 (IM extend) and simultaneously turns on DO 6 (CM extend) and DO 1 (PWM 1. DO 1 is a PWM output and ramps the output according to variables in the data software. IM proportional solenoid). The pressure switch signals are seen as digital inputs to the BCS.skyazul. This means the telescoping action is controlled directly by moving the joystick or foot operated treadle valve. When IM selected. When the IM section approaches a change over point (change in sequence). 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. As an example of extend from fully retracted.iFLEX5 Boom Control System (BCS) 14. And so on. DO 1 or DO 3 are activated based on the current boom position. CM proportional solenoid). The BCS does not control movement. Note: In the event of an LMI error. crane electric provides full power to the extend and retract proportional solenoids on the CM pilot operated 4-way directional control valve. DO 3 is a PWM output and ramps the output according to variables in the data software. DO 3 is ramped down according to variables in the data software. Likewise when CM is selected. At the specified change over point.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.1. overload. either from the central unit or console. Ramp-up output is time based. When retracting.com 301-371-6126 . the BCS realizes DO 18=1 (retract pressure switch) and does not activate DO 6 or DO 9. Equipment Solutions www. In manual mode the boom is controlled by the section selector switch in the right hand arm rest in the cab. See table 1 and table 2 for sequencing information.1. crane electric provides full power to the extend and retract proportional solenoids on the IM pilot operated 4-way directional control valve. Ramp-down output is percentage based. figure 1 2 Refer to table 2 for digital output definitions SkyAzúl. the BCS realizes DI 19=1 (extend pressure switch on) and simultaneously activates DO2 9 (IM extend) and DO 3 (PWM 2.3. When the CM section approaches a change over point DO 1 ouput is ramped down according to variables in the data software.A 25 Manual Mode Operation: Primarily used for boom maintenance and function the boom in an unlikely event of a BCS failure. or A2B condition the proportional valves will be not be energized unless the LMI bypass is activated.3. 14. 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.

not available 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.3 IFLEX5 BCS DIGITAL INPUTS: table 1 Digital Input 6 7 8 9 10 11 16 17 18 19 Description CM (Center-Mid) Retracted (boom proximity switch) IM (Inner-Mid) Retracted (boom proximity switch) Luffing Extension Raise (cab switch) Luffing Extension Lower (cab switch) Luffing Extension Raise (remote switch on ext.U. 14.) “A” Mode (cab switch) Auto Mode (cab switch) Boom Retract (pressure switch) Boom Extend (pressure switch) SkyAzúl.skyazul. X2 Terminal 54 55 56 57 58 59 64 65 66 67 **MP R89 R90 R91 R92 R93 R94 R100 R101 R102 R103 301-371-6126 . 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. Equipment Solutions www.) Luffing Extension Lower (remote switch on ext.Service Manual 26 14.2 iFLEX5 TELE SEQUENCE: RT9000E: Mode “A” .com *C.

com 301-371-6126 .U. R89 designates resistor number. Equipment Solutions www. Notes: must measure on bottom leg of the resistor. = Central Unit **MP = Measuring Point.U.e.4 27 RT9000E / RT800E IFLEX5 BCS DIGITAL OUTPUTS: table 2 Digital Output 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 C. X2 Terminal Description PWM 1 CM Proportional Solenoid +UB CAN bus PWM 2 IM Proportional Solenoid +UB to Slew Potentiometer Electronics PWM 3 Luffing Extension Proportional Solenoid CM Extend Relay K1 Coil in Junction Box PWM 4 Luffing Extension Proportional Solenoid IM Extend Relay K2 Coil in Junction Box Luffing Extension Raise Solenoid External LMI Alarm. DO 1 = PWM 1 DO 3 = PWM 2 DO 5 = PWM 3 DO 7 = PWM 4 SkyAzúl.skyazul. Option on Boom Luffing Extension Lower Solenoid Rear Axle Oscillate Signal Tele Rod Drain Solenoid Boom Out of Sequence Lamp Tele Two Stage Relief Solenoid 2 3 4 5 6 7 8 9 14 15 16 17 18 19 20 *C.iFLEX5 Boom Control System (BCS) 14. i. see sketches below for specific location.

G 06/05/06 190154_G . | 1 : 5 | NORMAL | 00 | 00000000 | 00 | 00000000 | 1111-1 Erw.U. Junction Box Assy – located on rear exterior of cab © Hirschmann Rev. | Port | Modus | IN-Wert | IN-Wert | OUT-Wert | OUT-Wert | Status | :Taste | | (Hex) | (Bin) | (Hex) | (Bin) | =NoLoad -------|--------|--------|---------|----------|----------|----------|-------Basis | 0 : 1 | NORMAL | 00 | 00000000 | 05 | 00000101 | 0000-1 Basis | 1 : 2 | NORMAL | 00 | 00000000 | 82 | 10000010 | 0011-0 Basis | 2 : 3 | NORMAL | 98 | 10011000 | 00 | | Erw.E I N U N D A U S G A E N G E ======================================================================= Baugr. | 2 : 6 | NORMAL | 00 | 00000000 | 00 | 00000000 | 1111-1 -------|--------|--------|---------|----------|----------|----------|-------Baugruppencodierung Basis : 0F = 00001111 DO 1 Baugruppencodierung Erweiterung: FF = 11111111 Hubendschalter UNTB/OFFEN/OK/KURZ: 0000 DO 16 DI 9 X:Exit Blank:Redraw S:Slow F:Fast DI 1 DI 8 Other methods to determine digital input and output states is by probing the junction box mounted on the rear of the cab. or terminal strip in the.Service Manual 28 iFLEX5 A convenient method to monitor digital inputs (DI) and digital outputs (DO) is utilizing the iTOOL5 or iFLASH terminal function. See table above and sketches below. Be cautious not to short the probe across connector pins. | 0 : 4 | NORMAL | 00 | 00000000 | 00 | 00000000 | 1111-1 Erw. 70-pass connector pins (X2). or specific resistors on the main board. the C. At the flashing command prompt press and hold “Ctrl” and “A” to enter the RTOS (an asterisk will display). *digshow (RTOS command to display digital inputs and outputs) T E S T D E R D I G I T A L . The result should be the screen shown below. Type “digshow” and press “Enter”. The inputs and outputs are counted from right to left and top to bottom as illustrated below.

Type “adctest” and press “Enter”. The result should be the screen shown below.5 IFLEX5 BCS ANALOG INPUTS AND PWM OUTPUTS: Another useful tool to monitor analog inputs and PWM outputs is utilizing the iTOOL5 or iFLASH terminal function.U. SkyAzúl. 14.skyazul. Note: must measure on bottom leg of the resistor. Equipment Solutions www. At the flashing command prompt press and hold “Ctrl” and “A” to enter the RTOS (an asterisk will display).com 301-371-6126 .iFLEX5 Boom Control System (BCS) 29 C. 70-pass connector pins (X2) Resistor bank to measure digital input (DI) state.

Equipment Solutions www.444 mA 5 | 1 | ok | 000D | 0000 | 0 | 0 | I_Kanal 6 = 0.com 301-371-6126 .356 mA 1 | | ok | 0009 | 0816 | 2070 | 2070 | I_Kanal 2 = 11.000 mA 5 | 4 | ok | 000D | 0098 | 152 | 152 | I_PWM 1 = 0 mA 5 | 5 | ok | 000D | 0014 | 20 | 20 | I_PWM 2 = 10 mA 5 | 6 | ok | 000D | 0000 | 0 | 0 | I_PWM 3 = 0 mA 5 | 7 | ok | 000D | 0000 | 0 | 0 | I_PWM 4 = 0 mA OPERATINGMODE X: Exit Blank: Redraw S: Slow F: Fast P: PWM-Settings T: Test mode O: Operating mode C: ADC-Clock set E: Extension module E S T D E R A N A L O G E I N G A E N G E Kanal 1 2 3 5 Description Slew Angle 1 Slew Angle 2 Wind Speed Luffing Extension Offset Angle PWM 1 2 3 4 Description Center-Mid Tele Output Inner-Mid Tele Output Luffing Extension Raise Output Luffing Extension Raise Output T Note: DO 1 = PWM 1 DO 3 = PWM 2 DO 5 = PWM 3 DO 7 = PWM 4 SkyAzúl.500 mA 2 | | ok | 000A | 0000 | 0 | 0 | I_Kanal 3 = 0.Service Manual 30 iFLEX5 *adctest T E S T D E R A N A L O G E I N G A E N G E =============================================== Ch | MUX | Error | Kanal+ | Value | Value | UADC | Special | | | Valid | (Hex) | (Dec) | [mV] | ---+-----+-------+--------+-------+-------+------+----------------0 | | ok | 0008 | 0310 | 784 | 784 | I_Kanal 1 = 4.000 mA 5 | 3 | ok | 000D | 0000 | 0 | 0 | I_Kanal 8 = 0.000 mA 5 | 2 | ok | 000D | 0000 | 0 | 0 | I_Kanal 7 = 0.skyazul.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.

Out of Sequence Mode A or B.85 99 100 101 102 .iFLEX5 Boom Control System (BCS) 14.202 210 . Equipment Solutions www.6 31 IFLEX5 BCS TEST DISPLAY: To view additional information on the console display. error condition Mode A.11 29 31 .skyazul.67 79 81 . To return to the normal screen push button “F1” or “F4”. Out of Sequence Mode B. push buttons “F1” and “F4” simultaneously. A2B.108 110 112 127 200 .212 Description Mode B extend Error Mode B extend Mode B retract Error Mode B retract Mode A extend Error Mode A extend Mode A retract Error Mode A retract Manual Mode A neutral or extend Manual Mode B neutral or extend Manual Mode retract at overload. 1 .41 59 61 . neutral position Luffing jib raise Luffing jib lower SkyAzúl.com 301-371-6126 . Boom Status / Luffer Status IM Tele Output (0-255) CM Tele Output (0-255) Luffing Ext Raise Output (0-255) Luffing Offset Angle(degrees) Length 2 (IM) (feet) Status No.

located on the front crane console. (DI 19) OM/Fly Percentage 1 >4% 0 SkyAzúl. Refer to sequence charts in the manufacturers’ load capacity charts. See the logic chart below.com IM rertract sw. Another indication for out of sequence are the flashing section percentages located at the bottom of the console display. (DI 18) 1 1 1 Extend pressure sw. Digital Output 13 is on unless: Tele Rod Drain Solenoid (DO13) 0 0 14.7 iFLEX5 BOOM OUT OF SEQUENCE: Digital Output 14 boom out of sequence is lamp. The valve is de-energized to prevent flow to tank. boom section percentage display 14.9 IM retract sw. (DI 6) 1 Retract pressure sw. is activated when the sections become greater than 3. (DI 7) 1 CM retract sw. The Boom Control System energizes this valve at all times unless the boom is fully retracted. Equipment Solutions www.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. or the retract pressure switch is activated. (DI 6) 1 1 301-371-6126 .5% out of sequence. or when the OM/Fly section is greater than 4% while extending. (DI 18) 1 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. Tele Two Stage Relief Solenoid (DO15) Retract pressure sw.skyazul.Service Manual 32 14. (DI 7) CM retract sw. See the logic chart below. The Boom Control System energizes this valve when the retract pressure switch is activated.

The opposite end of a lever arm mounted on the potentiometer shaft rests on and follows the structure which offsets. It raises or lowers the extension by controlling the raise and lower solenoids on the four–way three position directional valve. a proportional control valve and a double acting cylinder. The other is a RAISE/LOWER switch. three position directional control valve. There are two solenoids for directing the flow for extension or retraction of the cylinder. DI 8=1 (raise) DI 9=1 (lower). The proportional valve on the luffing cylinder is not be energized for luffer lower. Remote raise is DI 10 and remote lower is DI 11. three position directional control valve is mounted on the turntable. This switch has momentary positions on either side.10 HYDRAULIC LUFFING BOOM EXTENSION: Hydraulic control of the extension consists of a four-way. This switch also sends an actuation signals to the LMI.skyazul. then DO 11=1. If DI 11=1. a hose reel. 7. and a return to center position. The first is two switches located in the left hand armrest.com 301-371-6126 . The proportional solenoid on the luffing cylinder is energized by DO 5 & 7 (PWM 3 & 4) if DI 8=1.iFLEX5 Boom Control System (BCS) 33 14. The raise and lower solenoids on the turntable are energized by DO 9 & 11 respectively. then DO 5. & 9=1. If DI 10=1. The four-way. The hose reel is mounted on the boom and conveys the hydraulic fluid to the cylinder on the boom extension. Hydraulically the proportional valve is bypassed for luffer lower. SkyAzúl. The proportional valve on the luffing cylinder is not be energized for luffer lower. PAT does not supply the potentiometer. The offset angle is measured directly by a potentiometer located on the base adapter. Equipment Solutions www. See sketch below. One switch is a luffing system ON/OFF switch. Raise and lower can also be activated form remote switches located on the extension. Hydraulically the proportional valve is bypassed for luffer lower. There are two ways to offset the luffing extension. The proportional control valve is mounted to the cylinder on the boom extension.

Service Manual 34 iFLEX5 15 DRAWINGS 15.skyazul.com 301-371-6126 . Equipment Solutions www.1 COMPONENTS OF THE LMI SYSTEM PAT IFLEX5 PAT POWER LOCKOUT OTHER 1 Central-Micro-Processor Unit 2 Operating Console 3 Pressure Transducers 4 Length/Angle Sensor 5 Anti Two-Block Switch(es) SkyAzúl.

Drawings 15.2 35 BLOCK DIAGRAM 70 pin Connector RS 485 Serial Interface Crane Power Graphic Console iflex5 Central Unit Lockout CANBUS Current 4. Inc.. SkyAzúl. Equipment Solutions www.20mA CAN-connector CAN-connector Slew Sensor CAN-connector Dual Pressure Length/Angle Sensor A2B Switch Hirschmann Electronics. The drawing and data are confidential and are not to be used or reproduced without the written consent of Hirschmann. reserves proprietary rights to this drawing and to the data shown there on.com 301-371-6126 . This drawing is subject to technical modification without prior notice.skyazul.

reserves proprietary rights to this drawing and to the data shown there on.1 iFLEX5 ELECTRICAL SYSTEM DIAGRAM STANDARD SYSTEM Central Unit to Crane and Console Wiring Diagram Hirschmann Electronics. This drawing is subject to technical modification without prior notice. Equipment Solutions www. Inc.com 301-371-6126 .Service Manual 36 15.3.skyazul. The drawing and data are confidential and are not to be used or reproduced without the written consent of Hirschmann.3 15. SkyAzúl.

Inc. This drawing is subject to technical modification without prior notice.3.com 301-371-6126 . SkyAzúl. reserves proprietary rights to this drawing and to the data shown there on. Equipment Solutions www.Drawings 15.skyazul.2 37 Cable Reel (length/angle sensor) Wiring Diagram Hirschmann Electronics. The drawing and data are confidential and are not to be used or reproduced without the written consent of Hirschmann.

skyazul. Equipment Solutions www.com 301-371-6126 .Service Manual 38 15.4 MAIN CENTRAL UNIT CONNECTOR This is a 70 pass connector.3 iFLEX5 Boom Extension Anti-two Block Wiring Diagram Hirschmann Electronics. The drawing and data are confidential and are not to be used or reproduced without the written consent of Hirschmann. Inc.3. 15. reserves proprietary rights to this drawing and to the data shown there on. SkyAzúl. This drawing is subject to technical modification without prior notice.

skyazul.5.5 15.Drawings 15.1 39 ELECTRICAL SYSTEM DIAGRAM BOOM CONTROL SYSTEM Central Unit to Crane Interface Wiring Diagram SkyAzúl. Equipment Solutions www.com 301-371-6126 .

SkyAzúl. Equipment Solutions www.Service Manual 40 15. This drawing is subject to technical modification without prior notice.com 301-371-6126 .5. Inc. The drawing and data are confidential and are not to be used or reproduced without the written consent of Hirschmann. reserves proprietary rights to this drawing and to the data shown there on.skyazul.2 iFLEX5 Console and Sensor Wiring Diagram TO LWG520/0002 REFER TO CABLE REEL (LWG520/0002) WIRING DIAGRAM BOOM BASE CONNECTION TO LG152/0056 REFER TO CABLE REEL (LG152/0056) WIRING DIAGRAM Hirschmann Electronics.

com 301-371-6126 . The drawing and data are confidential and are not to be used or reproduced without the written consent of Hirschmann. reserves proprietary rights to this drawing and to the data shown there on. SkyAzúl.Drawings 41 Cable Reel (LG152/0056) Wiring Diagram TO LWG520/0002 REFER TO CABLE REEL LWG520/0002 WIRING DIAGRAM TO BOOM BASE CONNECTOR REFER TO CONSOLE AND SENSOR WIRING DIAGRAM Hirschmann Electronics. Equipment Solutions www.skyazul. Inc. This drawing is subject to technical modification without prior notice.

skyazul.5.Service Manual 42 15.3 iFLEX5 Cable Reel (LWG520/0002) Wiring Diagram LUFFING JIB CONNECTION REFER TO LUFFING EXTENSION WIRING DIAGRAM TO PRESSURE TRANSDUCER BLOCK REFER TO CONSOLE AND SENSOR WIRING DIAGRAM TO LG152/0056 REFER TO CABLE REEL (LG152/0056) WIRING DIAGRAM SkyAzúl. Equipment Solutions www.com 301-371-6126 .

4 43 Luffer Extension Wiring Diagram BOOM TIP CONNECTION TO LWG520/0002 REFER TO CABLE REEL (LWG520/0002) WIRING DIAGRAM SkyAzúl.5.com 301-371-6126 .skyazul. Equipment Solutions www.Drawings 15.

skyazul. Equipment Solutions www. 021-020-060-003 NO. IFLEX5 PART NO.com 301-371-6126 . GROUNDING KIT BATTERY.Service Manual 44 iFLEX5 16 SPARE PART LISTINGS 16.1 CENTRAL UNIT. LITHIUM 3V KEY SWITCH CENTRAL UNIT COVER iFLEX SCREW SET SPARE KEY GASKET * ITEM NOT SHOWN 7 2 1 3 SkyAzúl. 1 2 3 4* 5* 6* 7 QTY DESCRIPTION 024-000-100-041 022-022-300-031 024-350-100-661 031-300-110-151 024-350-100-135 031-300-101-131 024-350-110-066 1 1 1 1 1 1 42” CENTRAL UNIT ACCY. PART NO.

10 POL COMPUTER BRD X2 TO CONN BRD X7 050-150-290-064 1 CABLE. 4 POL COMPUTER BRD X1 TO CONN BRD X6. LED’S BY SELECTION BUTTONS 4 9 3 3 5 6 7 1.2 NO. Equipment Solutions www.com 301-371-6126 . AND LED BOARDS 050-150-300-068 1 CONNECTION BOARD WITH BUZZER 031-300-050-223 1 FUSE. 050-350-061-356 PART NO. 2 AMP AUTO 050-150-290-061 1 CABLE. This drawing is subject to technical modification without prior notice.2 8 10 2 Hirschmann reserves proprietary rights to this drawing and to the data shown there on. QTY DESCRIPTION 050-350-100-001 1 SPARE KEY. 6 POL COMPUTER BRD X10 TO CONN BRD X23 050-150-300-072 1 5 LED BOARD. WITH CABLE 031-300-110-149 1 FRONTFACE WITH DISPLAY. The drawing and data are confidential and are not to be used or reproduced without the written consent of Hirschmann. SkyAzúl. LMI/A2B ALARM LITE 050-150-300-073 1 8 LED BOARD. 1 2 3 4 5 6 7 8 9 10 45 GRAPHIC CONSOLE ASSY. COMPUTER BOARDS.skyazul.Spare Part Listings 16. VERTICAL PART NO.X11 050-150-290-063 1 CABLE. GRAPHIC CONSOLE 050-150-100-065 1 KEYSWITCH.

factory serviceable only factory serviceable only factory serviceable only 050-150-300-086 050-150-300-073 050-150-300-092 092-000-060-391 050-150-290-063 050-150-290-064 050-150-290-061 031-300-050-223 QTY 1 1 1 1 1 1 1 1 1 1 2 DESCRIPTION Front face. This document is subject to technical modification without prior notice. console connection with horn Board.3 ITEM 1 2 3 4 5 6 7 8 9 10 11 iFLEX5 GRAPHIC CONSOLE ASSY. 050-350-061-376 PART NO. 4p Fuse. 2A 11 1 4 7 10 8 9 6 3 2 11 5 Hirschmann Electronics. LCD 320 x 240 Board.skyazul.Service Manual 46 16. M12 5p female x 5p JST female x 10cm Cable. PART NO. SkyAzúl. reserves proprietary rights to this document and to the data shown there on. Equipment Solutions www. Inc. This document and data are confidential and are not to be used or reproduced without the written consent of Hirschmann Electronics. 10p Cable. 5 x LED Cable. 6 x LED Board. 1376 Board.com 301-371-6126 . 6p Cable. Inc. console main Display.

Spare Part Listings 47 16. LWG508 PART NO. SkyAzúl.skyazul. Equipment Solutions www. GASKET FOR COVER CABLE REEL ACCY. 068-508-060-001 NO. BLACK CABLE REEL ACCY. 5 POLE W/WIRES LID.com 301-371-6126 . 031-300-060-468 QTY 1 2 000-673-020-002 3 068-000-300-103 4 067-000-300-012 5 064-143-060-009 6 068-000-110-107 7* 006-800-005-001 8 068-000-110-038 9* 092-000-060-387 10* 068-000-100-196 11* 068-000-110-003 12* 068-000-110-031 * ITEM NOT SHOWN 139’ 1 1 1 1 1 1 1 1 1 10 DESCRIPTION CABLE REEL ACCY. 1 PART NO. LENGTH AND ANGLE OUTPUT LENGTH POTENTIOMETER LWG508 ANGLE SENSOR.4 CABLE REEL. LWG508 DRUM BODY W/LENGTH CABLE LENGTH SENSOR CABLE BOARD. SCREW/CAPTIVE 3 2 4 5 8 1 7 9 6 Also see detail on next page. WG143/09 SLIP RING ASSEMBLY 2 CONDUCTOR 25T GEAR WHEEL 75T GEAR WHEEL CONNECTOR.

Equipment Solutions www.com 301-371-6126 . SkyAzúl. The drawing and data are confidential and are not to be used or reproduced without the written consent of Hirschmann.Service Manual 48 iFLEX5 8 4 3 5 6 Hirschmann reserves proprietary rights to this drawing and to the data shown there on.skyazul. This drawing is subject to technical modification without prior notice.

LWG521 PART NO.com 301-371-6126 . Equipment Solutions www. 5 POLE W/WIRES 1 LID. QTY 031-300-060-440 2* 000-673-080-025 3* 068-000-300-102 4 068-000-300-063 5 067-000-300-012 6 064-143-060-009 7 068-000-060-072 8* 006-800-005-001 9 068-000-110-025 10* 092-000-060-387 11* 068-000-100-196 12* 068-000-110-003 13* 068-000-110-031 * ITEM NOT SHOWN DESCRIPTION 1 CABLE REEL ACCY. LWG521 DRUM BODY W/LENGTH CABLE 176’ LENGTH SENSOR CABLE 11 CORE 1 BOARD. BLACK 1 CABLE REEL ACCY. WG143/09 1 SLIP RING ASSEMBLY 11 CONDUCTOR 1 25T GEAR WHEEL 1 90T GEAR WHEEL 1 CONNECTOR. FILTER 1 LENGTH POTENTIOMETER LWG 1 ANGLE SENSOR. SCREW/CAPTIVE 2 4 6 3 9 7 5 10 1 SkyAzúl.Spare Part Listings 49 16. GASKET FOR COVER 10 CABLE REEL ACCY. 1 PART NO. 068-521-060-002 NO.skyazul.5 CABLE REEL. 2 LENGTH AND ANGLE OUTPUT 1 BOARD.

Equipment Solutions www. NUTS (4) & WASHER (4) FOR KT152 COVER 1 CABLE ASSEMBLY. PART NO. LG152 DRUM BODY W/LENGTH CABLE 87’ LENGTH SENSOR CABLE 3 CORE 1 TERMINAL STRIP 1 BOARD. 2. FILTER 1 LENGTH POTENTIOMETER LWG 1 SLIP RING ASSEMBLY 4 CONDUCTOR 1 55T GEAR WHEEL ON POTENTIOMETER 1 45T GEAR WHEEL ON CENTER SHAFT 4 HARDWARE.5m 1 9 6 8 13 7 5 3 2 SkyAzúl.skyazul.com 301-371-6126 . COVER KT152 1 SENSOR ACCY.6 iFLEX5 CABLE REEL. 067-152-060-056 NO. STANDOFF 6MM X 117MM MM 1 HARDWARE. QTY 1 031-300-060-441 2* 000-673-030-022 3 068-000-110-029 4* 068-000-300-063 5 067-000-300-012 6 068-000-100-066 7 067-000-050-075 8 068-000-050-083 9 000-268-030-003 10* 067-000-110-020 11* 067-000-050-059 12* 067-000-110-025 13 031-010-100-556 * ITEM NOT SHOWN DESCRIPTION 1 CABLE REEL ACCY. LWG152 PART NO.Service Manual 50 16. GASKET 1 SENSOR ACCY.

skyazul. PART NO.7 PRESSURE TRANSDUCER BLOCK. DAV314/0014 PART NO.9 WIRING HARNESS STANDARD. Equipment Solutions www. 044-314-060-014 16. PART NO.Spare Part Listings 51 16.com 301-371-6126 . 031-010-100-549 SkyAzúl. 031-010-101-007 16.8 CABLE ASSEMBLY 11M.

LG152 cable reel 5. PART NO.10 WIRING HARNESS BOOM CONTROL. 031-010-100-555 SkyAzúl.com 301-371-6126 . Crane interface 7 conductors 3. Console 2. CAN bus cable 6.11 CABLE ASSEMBLY. 031-010-100-554 6 Cables for: 1. Equipment Solutions www.skyazul. Optional radio wind speed receiver 16. Crane interface 24 conductors 4. 14M PART NO.Service Manual 52 iFLEX5 16.

15' 2 COND SS 20AWG W/12 SKT DEUTSCH www.com 301-371-6126 . RADIO WINDSPEED KIT 031-300-104-087 031-300-060-596 TRS 05 REPEATER 031-300-050-688 ANTENNA. 918 MHz RCL 90° SkyAzúl. Equipment Solutions 031-300-060-601 CABLE ASSY.Spare Part Listings 53 16.skyazul.12 TRS05 REPEATER.

Now. Use the “>” key to switch between digits. and angle calibration.2 of this manual. length.com 301-371-6126 . a five digit Authorization Number must be entered. The return key toggles between the piston-side.Service Manual 54 iFLEX5 17 SERVICE SCREEN FOR SENSOR CALIBRATION 17. slew angle. pressing the ESC or INFO key returns the console display to normal. Use the enter key to confirm entry. the rod-side zero setting. Equipment Solutions www. and length. To adjust piston pressure now. Only authorized personnel may adjust the zero-point settings. the piston-side zero-point setting function is activated. use the “+” and “-“ keys to increase and decrease each digit. press the INFO key on the console to activate the INFO Function. and boom angle calibration. 10 11 Now press the CTRL key. At this point. the rod-side zero setting. . see next section 6. SkyAzúl. The ESC key will allow you to leave the sensor calibration function. having successfully entered a valid password. When the sensor calibration is finished. The return key toggles between the piston-side.1 ACTIVATING THE SERVICE SCREEN FOR SENSOR CALIBRATION To activate the service screen and sensor calibration function.skyazul.

When the operator is finished. CAUTION: Ensure there is no pressure in the hydraulic line when disconnecting the hoses from pressure transducers. By pressing the two center keys simultaneously. the input pressure (or force) is adjusted upwards. Manual adjustments may be preformed using + or -.Service Screen For Sensor Calibration 17. and by pressing the minus (-) key. having successfully entered a valid password. When the plus (+) and minus (-) keys are pressed simultaneously. 17. Equipment Solutions www.skyazul. Press enter through the piston and rod zero adjustment screens to the slew zero-point adjustment function is activated. the input value is adjusted downwards. Note: the indicator line must be shown in the display scale from -10° to +10° for this zeroing procedure.3 ZERO-SETTING THE SLEWING INPUTS Now.2 55 ZERO-SETTING THE TRANSDUCER INPUTS NOTE: The only thing adjustable for the pressure transducers is the zero point. An indicator line shows the current position of the slew pot signal. Note: The indicator line will move to zero on the bar graph. the zero setting occurs automatically. SkyAzúl. NOTE: there are 2 screens piston and rod transducers.com 301-371-6126 . which is the voltage the transducer outputs when there is no (zero) pressure sensed. the zero setting occurs automatically. By pressing the + key. pressing the EXC or INFO key returns the console display to normal. The display shows which transducer (pistonside. rod-side or force) is being zeroed and a horizontal dial marks the present pressure (or force) difference in %. the piston-side zero-point setting function is activated.

which is all the way counter-clockwise.4 iFLEX5 LENGTH SENSOR CALIBRATION PROCEDURE NOTE: The length sensor can be calibrated for its zero point and its full range.3.Service Manual 56 17. Equipment Solutions www. 17. SkyAzúl. adjust length potentiometer as described in 6. This means. the adjustment is done by software as described in 6 section Length Sensor Adjustment Procedure. the potentiometer of the length sensor has to be at its 0 position. Afterwards always adjust retracted length by software as described in section Length Sensor Adjustment Procedure. With retracted boom.1’ of actual retracted boom length. Perform the following steps: Fully retract the main boom and check if indicated length is within 0.05m for metric) accurate for retracted and extended lengths.4. For extended boom.1 feet (or 0. If it is not.1 Cable Reel LWG508 Adjustment Procedure Now perform Length Sensor Adjustment Procedure as detailed in section Length Sensor Adjustment Procedure.skyazul.1. The length should be calibrated to be about 0.com 301-371-6126 . for the correct voltage for retracted boom and for the extended boom.

) Now.2 57 Length Sensor Adjustment Procedure See section Activating the Service Screen for Sensor Calibration on how to access the length sensor calibration screen. Now extend main boom all the way out. SkyAzúl. The screen will change now and show the picture to the right. Select the length calibration by pressing “OK” at the “Calibrate Length” screen.4.com 301-371-6126 . If incorrect. Equipment Solutions www. Make sure you are within the allowed operating range (especially maximum radius).Service Screen For Sensor Calibration 17.skyazul. The indication will change to show your correct retracted boom length. Fully retract the main boom and verify the indicated boom length matches the retracted boom length of your crane. make sure you have adjusted the length pot in cable reel (see section Cable Reel LWG508 Adjustment Procedure. press the ‘OK’ button to calibrate retracted length.

Remount cable reel to the boom.4. Set pre-load on cable reel by turning the drum counter-clockwise 5 to 8 turns. Remove damaged length cable. 9. Turn reeling drum clockwise to spool the new cable neatly onto the drum. 11.Service Manual 58 17.skyazul. 10. 2. 8. Reconnect the length cable to the slip ring. 4. Remove cable reel from mounting brackets.parts list 1. 5. Refer to section Cable Reel LWG508 Adjustment Procedure. 16.3 iFLEX5 Cable Reel Length Cable Replacement Procedure Replace length cable using the following procedure: Refer to system electrical wiring diagram and cable reel . Cut old cable at cable drum. Equipment Solutions www. 14. 15. Leave enough length cable to connect into the boom tip junction box. 3. from slip ring terminal. 12. Pull existing length cable out of the cable reel. 6. Connect bus connector Follow Length Sensor Adjustment Procedure. Open cable reel cover and disconnect bus connector. turn potentiometer carefully counter-clockwise until it stops. On the backside of the cable reel. Reset length potentiometer in length angle transducer (screw is located in center of white gear).com 301-371-6126 . Disconnect damaged length cable from junction box at the boom nose. SyAzúl. open the strain relief attached to the axle in the center of the drum. 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. 7. with boom fully retracted. pipe and strain relief and push it through the axle of the reeling drum. Connect the length cable into the boom tip junction box. which is mounted to the slip rings in the cable reel. Pull new length cable through the hole. Tighten new strain relief to ensure sealing. Recheck length and angle display. 13.

com 301-371-6126 . 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.5 59 ANGLE SENSOR CALIBRATION PROCEDURE Material required – calibrated inclinometer.Service Screen For Sensor Calibration 17.skyazul. SkyAzúl. Equipment Solutions www.

Once you push ‘SET’ . Repeat the above procedure to verify/set the angle at 60q (range 55°. the screen is going to change to the angle adjustment screen. press ‘OK’.Service Manual 60 iFLEX5 Boom up to the next correction angle. select ‘SET’ to adjust the angle.65°) and 70q (range 65°. ‘SET’ and ‘OK’ text as shown on the left. When the boom angle is within the calibration range. confirm with ‘OK’. If the indicated angle is within +/.1 degrees of the measured angle. SkyAzúl. Measure the boom angle with the inclinometer and when the boom is positioned in the calibration range. Equipment Solutions www. Press ESC to leave service screen.0. Use the ‘+’ and ‘-‘ buttons to adjust the indicated angle to match the measured angle. the screen will add the ‘CHANGE’. boom angles.50°). Otherwise.75°).com 301-371-6126 .skyazul. When the display shows the correct angle. 45 degrees (range is 40°. compare the measured angle to the displayed angle.

The display shows a scale from –10 to +10 degree.Service Screen For Sensor Calibration 17. the zero setting occurs automatically. pressing the ESC key returns the console display to normal. When the operator is finished. SkyAzúl. Defining the crane zero position: The zero setting consists of defining zero-point offset.skyazul. By pressing the “+” and “-“ keys simultaneously. Equipment Solutions www. Using graphic console for zero-setting of slew pot potentiometer: Press return until the slew adjustment screen is displayed.6 61 ZERO-SETTING THE SLEW POTENTIOMETER NOTE: The only thing adjustable for the slew potentiometer is the zero point.com 301-371-6126 . a horizontal mark shows the current position of the slew pot wiper. which is complete when the boom is at the 0q position over the front of the crane. 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. Note: The indicator line will move to zero on the bar graph.

g. if it is prohibited to go beyond a certain maximum boom length or with load curves for jibs where the main boom has to be extended to a certain length x Length sensor adjustment has changed. Equipment Solutions www. e.skyazul. in the respective load chart due to luffing down the boom too far x The slewing zone with x Slew to permitted area load is not permitted Non-permitted slewing zone (no load area) Operating mode not x A non existing operating acknowledged or mode has been selected non permitted slewing zone x The boom is in a nonpermitted slewing zone Prohibited length x Boom has been extended range either too far or not far enough.com Elimination x Set the correct operating mode for the operating state in question x Slew the boom to a permitted area.Service Manual 62 iFLEX5 18 ERROR CODES The following Error Code Table gives a brief description of Error Codes elimination. Open the length sensor and carefully turn the length sensor pot counterclockwise until the detent by means of a screw driver x Replace the complete clutch including drive wheel and adjust length sensor pot as described above x 301-371-6126 . Error Code E01 Error Cause Fallen below radius range or angle range exceeded E02 Radius range exceeded or fallen below angle range E03 x Fallen below the x Luff down the boom to a minimum radius or gone radius or angle specified past the maximum angle in the load chart. Refer to the noted sections for detailed Troubleshooting information. specified in the respective load chart due to luffing up the boom too far x Gone past the maximum x Luff up the boom to a radius or fallen below the radius or angle specified minimum angle specified in the load chart. the cable slid off the length sensor reel. x Extend/retract boom to the correct length x Retract boom. Check the prestress of the cable reel (cable must be taut). e. E04 E05 x Clutch between length sensor pot and drive is defective SkyAzúl.g.

com x check cable to overload relays and CU input 20 x check relays x check CU input 20 x reset system x reset system x Replace length potentiometer x Replace pressure transducer x refer to E12 x Replace angle sensor 301-371-6126 .Error Codes 63 Error Code E06 Error Cause Elimination Radius range exceeded or fallen below angle range with luffing jib operation x Luff the jib to a radius or angle specified in the load chart. x Angle potentiometer defective x Replace force transducer x Replace sensor unit x Electronic component in the measuring channel defective. E07 Overload relays check E11 Fallen below lower limit value for measuring channel "length main boom" x Maximum radius as specified in the load chart exceeded or fallen below minimum angle due to luffing down the luffing jib too far x relays = overload active and CU input 20 = on x relays = no overload and CU input 20 = off x PDB variable invalid x emergency stop caused by system software x Length potentiometer is defective x Electronic component in the measuring channel is defective x Pressure transducer is defective.skyazul. x refer to E12 x Replace sensor unit x Force transducer defective x Electronic component in the measuring channel is defective. x Replace sensor unit E12 E13 E14 E15 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" Fallen below lower limit value in measuring channel "force" Fallen below lower limit value in measuring channel "angle main boom" SkyAzúl. x Replace sensor unit x Electronic component in the measuring channel is defective. Equipment Solutions www.

E1B E1C iFLEX5 Fallen below lower limit value in measuring channel "slewing angle 2" Fallen below lower limit value in measuring channel "luffing jib angle" SkyAzúl. replace.com x Replace length sensor. x Replace sensor unit Fallen below lower limit value "length telescope I (+II)" E18 Front outrigger overloaded E1A Fallen below lower limit value in measuring channel "slewing angle 1". x Angle potentiometer defective x Replace angle sensor x Electronic component in the measuring channel defective. x x Replace slewing angle sensor x Replace sensor unit x refer to E1A 301-371-6126 . x Length potentiometer defective x Replace sensor unit x Electronic component in the measuring channel defective x Front outrigger overloaded x Replace sensor unit x Cable between the central unit and the slewing angle sensor defective or loose. Equipment Solutions www.Service Manual 64 Error Code E16 E17 Error Cause Elimination Fallen below lower limit value in measuring channel "angle 2" x Angle potentiometer defective x Replace angle sensor x Electronic component in the measuring channel defective. if need be. Water inside the plug of the angle sensor x Slewing angle potentiometer is defective x Electronic component in the measuring channel defective x refer to E1A x Check cable as well as plugs.skyazul.

Upper limit value in measuring channel "slewing angle 1" has been exceeded Upper limit value in measuring channel "slewing angle 2" has been exceeded Upper limit value in measuring channel "luffing jib angle" has been exceeded x refer to E11 x refer to E11 x refer to E12 x refer to E12 x refer to E12 x refer to E12 x refer to E14 x refer to E14 x refer to E15 x refer to E15 x refer to E16 x refer to E16 x refer to E17 x refer to E17 x refer to E1A x refer to E1A x refer to E1A x refer to E1A x Angle potentiometer defective x Replace angle sensor x Electronic component in the measuring channel defective. Upper limit value in measuring channel "length telescope I (+II) has been exceeded. Upper limit value in measuring channel "pressure piston side" has been exceeded Upper limit value in measuring channel "pressure rod side" has been exceeded. Upper limit value in measuring channel "main boom angle" has been exceeded.Error Codes Error Code E21 E22 E23 E24 E25 E26 E27 E2A E2B E2C 65 Error Cause Elimination Upper limit value in measuring channel "main boom length" has been exceeded.com 301-371-6126 . Upper limit value in measuring channel "force" has been exceeded.skyazul. Equipment Solutions www. Upper limit value in measuring channel "angle 2" has been exceeded. x Replace sensor unit SkyAzúl.

not contain valid data. x No valid data in the crane x Upload valid crane data data file. x Write/read memory (RAM) or central unit defective. x Upload valid system software E37 Error in the logical program flow x Flash-EPROM defective x System program file is defective x x E38 System program and crane data file do not match. x Flash-EPROM defective x The system program in the LMI does not match to the programming in the crane data file x The system program in the LMI and the programming in the load chart file do not match. file Error in crane data file.skyazul. E47 E51 The CRC verification of the monitored write/read memory provides an incoherent result Error in the crane data file Error in load chart file.Service Manual 66 Error Code E31 iFLEX5 Error Cause Elimination Error in the system program x The system program file is defective.com x Replace central unit 301-371-6126 . x Replace buffer battery on the central unit. (RAM) Error in the monitored write/ read memory. Equipment Solutions www. x Upload valid system program file or the valid load chart file x Replace central unit x Restart the LMI x Replace central unit x Central unit defective. x Flash-EPROM defective SkyAzúl. x Replace central unit x Upload valid system program file or the valid crane data file E39 System program and load chart file do not match E43 Error in the write/read memory. file x Flash-EPROM defective E52 Replace central unit Upload valid system software x No valid data in the load chart file x Replace central unit x Upload valid load chart file x Flash-EPROM defective E56 E57 x Replace central unit x No valid data in the crane x Restore or upload valid data file during crane data file calibration. x Replace central unit x Flash-EPROM defective Error in serial crane x Calibration data file does x Upload calibration data data file. x The CRC sign of the monitored write/read memory is wrong x The buffer battery is decharged (< 2V at 1kOhm).

skyazul. x Check the connection between the central unit and the sensor units x Load chart file wrongly programmed Error in the CAN x CAN Bus cable between bus data transfer for the central unit and the all CAN units sensor unit defective or not connected.com 301-371-6126 . sensor unit x Can bus port in the x Replace the central unit central unit defective x Can bus port in the x Replace the sensor unit sensor unit is defective x Sensor unit is defective x Replace the sensor unit Error in the can bus x The analog values of the x Replace the sensor unit pressure transducer sensor unit are invalid sensor unit Error in the can bus x See E62 x See E62 data transfer of the length/angle sensor unit Error in the can bus x See E63 x See E63 length/angle sensor unit Error in the can bus x See E62 x See E62 data transfer of the 2nd length/angle sensor unit Error in the can bus x See E63 x See E63 of the 2nd length /angle sensor unit Error in the can bus x See E62 x See E62 data transfer of the force sensor unit Error in the can bus x See E63 x See E63 force sensor unit SkyAzúl.Error Codes Error Code E60 E61 E62 E63 E64 E65 E66 E67 E68 E69 67 Error Cause Elimination The number of the selected File base and the programmed value are not identical x No valid data in the load chart file x Upload valid load chart file x Base number not programmed x Program the correct base number (1 for base 1. x Can bus port in the x Replace the central unit central unit defective x Short circuit in a CAN Bus x Replace Can Bus cable cable Error in the can bus x Cable between the x Check the cable to the data transfer of the central unit and the sensor unit pressure transducer sensor unit defective. 2 for base 2) x Check base programming in the load chart file. Equipment Solutions www.

x The computed radius is x Check the programming too small (negative in the crane data file. Equipment Solutions iFLEX5 Elimination x Check the slewing potentiometer adjustment x Replace slewing angle sensor x Restart the system x Load the boom control task x The selected rigging x Select another rigging condition is not contained condition in the crane data file. www. SkyAzúl.skyazul.com x Select operating mode without load on the boom 301-371-6126 . x Check the programming in the crane data file. E85 Error in the radius determination E89 Operating mode switchover with load.Service Manual 68 Error Code E80 E82 Error Cause Error in the slewing x The difference between angle measurement the average of the slewing angle and one of the wipers of the slewing potentiometer is out of the tolerance Error boom control x The boom control task is task not running E84 Wrong rigging condition. deflection) x The operating mode on the console has been switched over with the boom loaded.

x Eliminate the source of interferences by inverse diodes or varistors. the transmitter module of the console electronics might be damaged. x Check the connection between console electronics and central unit x Exchange console electronics or LMI main board resp. replaces the console electronics. Therefore. 301-371-6126 . x Check connection to the power unit x Exchange the LMI main board x Replace console electronics or LMI main board x Replace processor board. replace console electronics.Error Codes Error Code E91 69 Error Cause Elimination No data transmission form the console to the central unit x 24 V supply of the console is interrupted x Check 24 V at terminal X1 of the console electronics x Interruption or accidental ground in the line between console electronics and central unit x Check the connection console electronics central unit.com x Check line to the console (in case of accidental ground. x Exchange console electronics or LMI main board resp.skyazul. x refer to E92 x Transmitter/receiver module is defective E92 Error in the data transmission from console to central unit x Loose connection in the line between console electronics and central unit x Transmitter/receiver module is defective E93 Error in the data transmission from the central unit to the console No data transmission from the central unit to the console x refer to E92 E94 x Interruption or accidental ground in the line central unit – console x 5 V supply of the computer in the central unit is missing x 5 V supply is too low x Transmitter/receiver module is defective x Computer module is defective x Electro-magnetic interferences (e. when switching contactors or valves) SkyAzúl. too).g. Equipment Solutions www. In case of an accidental ground.

5. Angle range of x Luffing jib is raised too far x Luff down the jib to a luffing jib exceeded angle specified in the load chart. SkyAzúl. x Replace the console main board. x Reset system x Connect PC terminal and watch error messages x Replace A2B switch x Replace the CPU of the console E98 LMI watchdog activated x The console main board is defective.5. area prewarning x Check values in the data prom DGA 11. Error in the internal x The CPU of the console RAM of the console. x Replace the external RAM of the console. area switch off x Check values in the data prom DGA 11.com 301-371-6126 . x Replace the console main board. is defective.skyazul. Error in the external x The external RAM of the RAM of the console console is defective. x Replace the console File x The console main board is defective. Approaching x Boom is about to collide x Move boom to permitted prohibited area with the engine hood.Service Manual 70 Error Code E95 E96 E97 Error Cause iFLEX5 Elimination Error in the console x The console File is File defective. x LMI processing time limit exceeded EAB Short circuit in the A2B switch circuit x Short circuit in the A2B switch A2B switch circuit disconnected x Short circuit in the cable x Replace cable to the A2B to the A2B switch switch x Disconnected cable in the x Connect or replace cable A2B switch in the A2B switch EAC EAD EC0 EC1 EC2 x Disconnected cable to the x Connect or replace cable A2B switch to the A2B switch No valid A2B switch x Sensor wrong function x Replace A2B switch status x CAN bus delay x Replace cable to the A2B switch Prohibited area x Boom is about to collide x Move boom to permitted with the engine hood. Equipment Solutions www.

e.5 sec.Error Codes 71 Error Code EDA Error Cause Datalogger write error Elimination EDB Datalogger setup error EDC Datalogger watchdog activated EDD Battery empty EDE Record lost EDF Flash block full EFD LMI Watchdog extra time x Datalogger not connected x Check CAN bus connection x No power supply x Check power supply x Wrong Dos drive status x Connect PC terminal and Refer to Dos drive status list x Temporary: Press horn quit button to work without datalogger x Setup of the datalogger is x transfer data and setup cleared (ser. please contact the competent PAT service department.g. after this low voltage of the battery setup of RTC x Temporary: Press horn quit button to work without datalogger x Not possible to save data Message disappears after a few seconds because other task saves data at the same time x Not possible to save any Message disappears after a few seconds more data Message disappears after a x a function needs more few seconds than 0. Equipment Solutions www. crane data datalogger again file or battery buffered x temporary: Press horn RAM) quit button to work without datalogger x datalogger processing x Reset system time limit exceeded x Connect PC terminal and watch error messages x Battery check detected a x change battery. SkyAzúl. Flash PROM write Note: If an error message is displayed which is not contained in above list.skyazul.com 301-371-6126 .

junction boxes etc.Service Manual 72 iFLEX5 19 TROUBLESHOOTING MOISTURE The PAT iFLEX5 LMI contains electronic components in various locations.com 301-371-6126 . through the use of spray cleaner at short distances. 3) Bent Lid An enclosure will only seal correctly if the lid is not bent. If the lid is bent or damaged. Equipment Solutions www. For this reason.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. If you find water or moisture inside any of the housings. the source for the water ingress has to be detected and corrected to ensure proper operation. 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. it is possible to force water through the gasket or strain relieves. 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. However. SkyAzúl. If no screw is missing. These internal components cannot be designed to withstand exposure to moisture over a longer period of time. To check this. such as rain. such as central unit. take the lid off the box and visually inspect it for deflection. sensors. replace them. the housings of the components are water protected according to IP 65. If there are screws missing. For this reason. 19.skyazul. loosen all screws of the lid. If any were loose. check the tightness. it needs to be replaced. then open all screws and then re-tighten them equally. 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. avoid spraying any components from short distances with spray cleaners.

The gasket needs to be in good condition in order to seal correctly. usually the larger the volume of the box. In this case. to replace a cable. brittle or severely bent. water tightness is not a problem – the box is sealed just fine. Order a new gasket through your PAT representative. If the volume is very small.2 CONDENSATION In a climate with high humidity and rapidly changing temperatures. which is what prevents the trapped air from exiting the box. 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. condensation can happen inside any enclosure. With condensation. Check the tightness by taking the external cable into one hand and carefully trying to turn it. Equipment Solutions www. the only way to get rid of this effect is then to give the box the ability to breath without sacrificing its water tightness. if the cable comes from a connector that is full of water.Troubleshooting Moisture 73 4) Defective Gasket The gasket underneath the lid seals the unit. In example. 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. In this case. If the internal wires turn with the outer cable. Look for damages to the cable itself and inspect the opposite side of the cable. Get a new grommet (insert) through your PAT representative and replace the existing one with the new one. the water will run through the inside of the cable and fill up the central unit. the strain relief is loose. 19. Tighten the strain relief correctly. 2. i. a desiccant bag might be able to soak up the air’s humidity. the more likely. you have to find out why and where water enters the cable. SkyAzúl. The strain relieves have to be correctly tightened in order to do this.skyazul. it needs to be replaced.e. There are two ways to deal with condensation: 1. Note: Whenever a strain relief is opened. water may still enter the box through the inside of the cable.com 301-371-6126 . 5) Loose Strain Relieves The strain relieves allow cabling to enter the box without allowing water to enter it. a new grommet needs to be used. If the effect is more severe. If the gasket is torn. too. water drops build up on the inner components when humid air is trapped inside the box.

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Equipment Solutions www.com 301-371-6126 .skyazul.SkyAzúl.

skyazul. Inc. 2A Middletown.SkyAzúl.com 301-371-6126 . Equipment Solutions www. www. Main Street.skyazul.com SkyAzúl. MD 21769 Phone 301-371-6126 Fax 301-371-0029 info@skyazul.com 200 W. Suite.