1.

1 SOFTWARE SETTING

Make corresponding setting in iTOOL5 after hardware connection.

A）Open iTOOL5 software

B）Setting COM port

Click COM setting icon button in Toolbar.
Or the Setting Option of Interface Menu in Menu bar.

Open COM setting interface and choose the COM terminal number and
baudrate of the computer, and then click Automatic baudrate F11 button
（Validate the baudrate at the same time）
The Auto baudrate Dialog box will disappear automatically after connecting
successfully. At the same time, the COM1，9600，8N1，XONXOFF will appear
below the iTOOL5 interface and click Connect. If the online failed, please
check the COM setting of the computer, iTOOL5 COM terminal choosing, and
connection cable and so on.
C）Open the Terminal Interface

Choose the icon button of console interface in Toolbar or open Terminal

interface of the Program in the Menu bar.
Press ALT+F10 to reset the system in the Terminal interface.
1.2 UPLOAD SYSTEM FILES

Please follow the following order to upload: del.all all application files delete
completely

1.2.1 Upload system bottom files

Open the dialog box of the uploading BRN file by click icon in the toolbar
of the Terminal interface. Choose the uploading file and click “Start Upload” to upload.
Notice：If the system need upload control program, first: backup the original data,
second: delete all the original software, then upload the programs. Press F2 and input
del.all after appearing”*” and then press Y to confirm.

1.2.2 Uploading Control program files

The system will reset automatically after uploading system bottom file SQL1_v311.brn.
Upload control program file after system reset. The method is the same as uploading
system file SQLv311. Choose the uploading file and click Start Upload. The system
will also reset automatically after upload, and carry out “Copy all” operation after
resetting. Click “Copy to EEProm” below “Tools” menu -- “Copy all configurations to
EEProm”, and the system will copy all the configuration files automatically. Reset the
system manually （ALT+F10）after finishing copy.
1.2.3 Uploading LMI files

The same as uploading system file.

1.2.4 Uploading data files

Data files include DAT and TLK. If the data files have converted into BRN files, the
files could be uploaded as above; if not, please do the following methods：

Click the button in Toolbar and open the uploading data interface.
Choose the uploading data files （DAT or TLK）in Source file folder（the sign A）. The
chosen files will be led into the following list automatically（the sign B，the file types in
the list should be coherent, for example, DAT and TLK files cannot be led at the same
time）. Choose the storage location and name of BRN files at Target file（the sign C）;
choose dynamic memory address （the sign D）at “Link to” option，and convert the
data into BRN files by clicking “Start linker”.

The conversion status is the same as being shown in F area of the above picture.
Upload linker file button is in effective status here and the dialogue box of Flashloader
upload will appear by clicking the button.
Upload the BRN files by clicking Start Upload. The real-time uploading status will
appear in Status bar. After uploading, the picture is shown as follows:

The method of uploading DAT and TLK data is the same. Don’t forget to delete the
data in the original list when you want to lead into another data （like TLK）after
finishing uploading one data (like DAT).

Press “T” and then press “Y” to activate Datalog after finish uploading data and reset
the system.

1.2.5 Time and Date Setting

It will record the time and date of failure and overload in the memory of the Data
Recorder, and so please don’t forget to set the correct time and date of the system.
The operation will be completed at iTOOL5.

 Time Setting

Press "F2" and it will appear "*"，input “clockset” + blank key + “hour : minute :second”
after "*" and press Enter to set the system time.

Press ALT+F10 to reset system.

Check whether set time after time setting or not. Press "F2" and it will appear "*"，input
clock after "*" and make the current time of the system.

The current time of the system is 13:50:44 shown as follows:

 Date setting

Press "F2" and it will appear "*"，input “date set” + Blank key +“day-month-year ” and
Enter to set the system date.

For example, if the setting date is 18th, November, 2009, the format is date set
18-11-2009
The order of checking current system date is date. The checking method is the same
as time checking. Press "F2" and it will appear "*"，input date after "*" and Enter to
make the current system date.

1.3 DATA BACKUP

We should backup the original data of the system before we start calibrating data
online and when finish calibrating, or before upload the system program.

 DAT data－including calibration parameter

 TLK data－including load parameter

Pay attention to the follows:

Ensure PC and HC4900 CU are online successfully before backup.

1.4 BACKUP DAT DATA

Click the LMI data backup menu of the Program or click icon on the Toolbar
to enter backup interface. Choose “Data type” as “DAT” data and choose “Download
from” as “dynamic memory address”.
Choose the storage location and click Start to backup.

The showing is as follows after backup:

1.5 BACKUP TLK DATA

The method of backup TLK data is the same as backup DAT. Choose “TLK” data as
“Data type”, choose “Download from” as “dynamic memory address”，choose storage
location and names of files, and click Start to start backup.
1.6 GENERAL DEBUGGING BY ITOOL5

1.6.1 Function key introduction

Enter into iTOOL5 adjustment, there are 4 parts and every part has a particular
function key, adjusting value meaning and unit are as follows:

 Function key “6”: Empty load weight (empty [t]), unit: kg

 Function key “7”: Load percentage (tare [%]), unit: no, percentage
 Function key “8”: Empty load range (empty [m]), unit: cm
 Function key “9”: Load range (with load [m/t]), unit: m/t
 Function key “K”: System confirm receiving, and back to the upper level mode.

1.6.2 ITOOL adjusting procedure diagram

Computer Exam Adjust Adjust

online empty empty load range
load range load
weight

If the adjusting of percentage is

Adjust
over±3 ， re-modify the empty
load
load range and weight
percentag
e

Every boom length has 5 adjusting points, the adjustment begin from bigger angle
and end with smaller angle, and must follow the linearity principle
Press “O” input the password: 6587, then press “A” input password: 6587, go into

calibrate online mode.

Online calibrating includes:

 Empty load weight

 Radius of empty load weight

 Load weight

 Radius of load weight

For every length step, there are five calibrating points which distinguished according
to main boom angle, for example: 80°/75°/65°/45°/20°

1.6.3 Adjust empty load

Press “6” to enter into 1st adjusting point 80°of empty load weight.

If the displayed weight is 0.5t lighter than actual weight, and the original value is 0,
input 500 (original value + calibrated value) and press enter, the value at 80°will
change from 0 to 500, press “K” to confirm, the displayed weight will add 0.5t;.

If the displayed weight is 0.5t heavier than actual weight, input -500 (original value -
calibrated value)and press enter, then press “K” to confirm, the displayed weight will
reduce 0.5t.

Press “6” once again，enter into empty load weight adjusting interface, modify all the
adjusting point data that is smaller than present adjusting point to the same of present
adjusting value. After that, press “K” to confirm the modification and back to the
preparation mode for adjusting.

The present adjusting point of empty load weight is over.

Meanwhile, an examination of whether there’s change between the displayed empty

load range and adjusted empty load range is necessary. If changed, the empty load
range has to be re-modified. And also after the modification, the examination must be
done again, if it is still changing, re-modify again.

After finish the modification of 1st adjusting point 80°, follow the order to adjust other
point which is the same way as that of the 1st one. When all the adjustment being
done, temperately stop the operation of empty load.

Press＂6＂，enter into 1st calibrating point of empty load weight

Enter 500, will add 500kg empty load weight

Press “Enter” the system will receive the value

Then press “Enter” directly to change to the next calibrating point

At last, press “K” to confirm.

1.6.4 Calibrating the radius of empty load

Luffing the boom to 80°（±0.5°is allowed）and measure out actual range. Press “8” to
enter into 1st adjusting point 80°of the empty load radius.
If the displayed radius is 0.25m shorter than actual range and the original value is 0,
input 25 (original value + calibrated value) and press Enter, then press “K” to confirm,
the displayed range will add 0.25m.

If the displayed range is 0.25m longer than actual range, input -25 (original value -
calibrated value) and press Enter, then press “K” to confirm, the displayed range will
reduce 0.25m.

If the modification cannot be finished accurately in one time, you can try several times
till the displayed value is the same as actual value.

Press“8” once again to enter into adjusting interface of empty load radius, modify all
the adjusting point data that is smaller than present adjusting point to the same of
present adjusting value. Then, the present adjusting point of empty load range is over.

1.6.5 Load radius calibration

，press“9” to enter into 2nd

（±0.5°is allowed）
Adjust the boom to 2nd adjusting point75°
adjusting point75°of load radius.

If the displayed range is smaller than actual range, input a suitable positive value and
press Enter，then press “K” to confirm till the displayed value is the same as the actual
value. For the reason of structure, this group of data shall not be negative values.
Press “9” once again to enter into load range adjusting interface, modify all the
adjusting point data that is smaller than present adjusting point to the same of present
adjusting value.

The present adjusting point of load range is over.

1.6.6 Load percentage calibration

Press”7” to enter into 2nd adjusting point 75°, if the displayed weight is smaller than
the actual load capacity, input a exact plus value base on original parameter (count
according to percentage of the weight) and press Enter, then press “K” to confirm.

If the displayed weight is larger than the actual load capacity, input an exact negative
value base on original parameter and press Enter, and then press “K” to confirm till
the displayed value and the actual value are the same.

Press“7” once again to enter into the percentage adjusting interface with load. Adjust
the value of other adjusting point whose angle is smaller than that of current adjusting
point, when it is the same as that of the current adjusting point, After finish the
calibration at 2nd adjusting point 75°, use the same way to adjust values at next other
adjusting point successively. When the calibration at all the adjusting point is finished,
this work is done.

The calibration of with load percentage is over.

Test the displayed value of with load radius and the value after modification, if they are
different, readjust the with load radius. And after the end of radius adjusting with load,
test the displayed value of with load capacity and the value after modification, if they
are different, readjust the with load capacity.

If the adjusted value of with load percentage is over ±3，the value of without load
radius and without load capacity have to be readjusted

After finish the calibration of with load percentage and with load radius，if the modified
value of with load percentage is over±3，adjust that of with load and without load once
again.

1.6.7 Modify the program status

If you calibrate the radius or weight, and you find that the value doesn’t make any
difference, please check whether the data has been locked or not.

At the calibrating terminal (must after press “O” and press “A”), press the letter “O”
then the terminal will show “C NR. 1. 1.1= :”, after it input “1.11” then press “enter”, the
terminal will show “C 1.11.1= XX:”(XX instead of the detailed value), if the XX=8X,
then please input “00” (zero zero) after “C 1.11.1= XX:”, then press “enter”, then
press “K” to save the modify, at this time you could calibrate the parameter again.
1.6.8 Principles of linearity

Generally, the calibration begins from the biggest angle and end to the smallest angle.
When adjust an angle, the value of other adjusting point whose angle is smaller than
that of current adjusting point must be adjusted to be the same to that of the current
adjusting point. This is not just for ensuring accuracy and continuity of data of the five
adjusting point, but also can help us to clearly understand the rules and forecast data
of the next adjusting point to avoid dangerous point.

1.6.9 Notes of calibration

1. To ensure the accuracy of all the point at current OM, we must luffing the boom to
all the angle point to adjust current data.

2. The weight being lifted must bigger than 60% of Max. Load capacity of current
adjusting point at current OM.

3. If the crane is without load, when the displayed value exceeds 80°( larger than 1st
adjusting point, including cylinder overextend),it is not necessary to adjust.

4. After finish the calibration, test the accuracy of the displayed value of the angle
out of the 5 adjusting point

5. During calibration, check if the data is within normal range, if not, please contact
with us, we will help you analyze.

2 Error code
Error Code Error Cause Elimination
* Fallen below the minimum * Luff down the boom to a
radius or gone past the radius or angle specified
Fallen below radius
maximum angle specified in the load chart.
E01 range or angle range
in the respective load
exceeded
chart due to luffing up the
boom too far
* Gone past the maximum * Luff up the boom to a
radius or fallen below the radius or angle specified
Radius range exceeded
minimum angle specified in the load chart.
E02 or fallen below angle
in the respective load
range
chart due to luffing down
the boom too far
Non-permitted slewing * The slewing zone with * Slew to permitted area
E03
zone (no load area) load is not permitted
* A non existing operating
* Set the correct operating
mode has been selectedmode for the operating
Operating mode not
state in question
E04 acknowledged or non
* The boom is in a * Slew the boom to a
permitted slewing zone
non-permitted slewing permitted area.
zone
Error Code Error Cause Elimination
* Boom has been extended * Extend/retract boom to
either too far or not far the correct length
enough, e.g. if it is
prohibited to go beyond a
certain maximum boom
length or with load curves
for jibs where the main
boom has to be extended
to a certain length
* Length sensor adjustment * Retract boom. Check the
has changed, e.g. the pre-sstress of the cable
E05 Prohibited length range cable slid off the length reel (cable must be taut).
sensor reel. Open the length sensor
and carefully turn the
length sensor pot
counterclockwise until the
detent by means of a
screw driver
* Clutch between length * Replace the complete
sensor pot and drive is clutch including drive
defective wheel and adjust length
sensor pot as described
above
* Maximum radius as * Luff the jib to a radius or
Radius range exceeded specified in the load chart angle specified in the load
or fallen below angle exceeded or fallen below chart.
E06
range with luffing jib minimum angle due to
operation luffing down the luffing jib
too far
* Length potentiometer is * Replace length
defective potentiometer
Fallen below lower limit * PDB variable for analog * Setup of correct PDB
value for measuring value not supported variable for analog value
E11
channel "length main in DGA6.i.3
boom" * Electronic component in * Replace sensor unit
the measuring channel is
defective
* Pressure transducer is * Replace pressure
Fallen below the lower
defective. transducer
limit value in the
E12 * PDB variable for analog * Setup of correct PDB
measuring channel
value not supported variable for analog value
"pressure piston side"
in DGA6.i.3
Error Code Error Cause Elimination
* Electronic component in * Replace sensor unit
the measuring channel is
defective.
Fallen below lower limit * refer to E12 * refer to E12
value in the measuring
E13
channel "pressure rod
side"
* Force transducer * Replace force transducer
Fallen below lower limit defective * Replace sensor unit
E14 value in measuring * Electronic component in
channel "force" the measuring channel is
defective.
* Angle potentiometer * Replace angle sensor
defective * Setup of correct PDB
* PDB variable for analog variable for analog value
Fallen below lower limit value not supported in DGA6.i.3
value in measuring * Electronic component in * Replace sensor unit
E15
channel "angle main the measuring channel
boom" defective.
* Electronic component in * Replace sensor unit
the measuring channel
defective
Upper limit value in * refer to E11 * refer to E11
measuring channel
E21
"main boom length" has
been exceeded.
Upper limit value in * refer to E12 * refer to E12
measuring channel
E22
"pressure piston side"
has been exceeded
Upper limit value in * refer to E12 * refer to E12
measuring channel
E23
"pressure rod side" has
been exceeded.
Upper limit value in * refer to E14 * refer to E14
measuring channel
E24
"force" has been
exceeded.
Upper limit value in * refer to E15 * refer to E15
measuring channel
E25
"main boom angle" has
been exceeded.
Error Code Error Cause Elimination
* The system program file * Upload valid system
Error in the system
E31 is defective. software
program
* Flash-EPROM defective Replace central unit
* +UB System not present * +UB System and +UB
at the system start Power must be wired
* +UB System not present separately: +UB System
Error in the power
E32 at the system finish connected direct with the
supply
* Contact problems at +UB crane battery. +UB Power
switch off/on for switch on/off
* +UB switch off/on again
 System program file is  Upload valid system
Error in the logical
E37 defective software
program flow
 Flash-EPROM defective  Replace central unit
* The system program in * Upload valid system
System program and
the SLI does not match to program file or the valid
E38 crane data file do not
the programming in the crane data file
match.
crane data file
* The system program in * Upload valid system
System program and
the SLI and the program file or the valid
E39 load chart file do not
programming in the load load chart file
match
chart file do not match.
Error in the write/read * Write/read memory (RAM) * Replace central unit
E43
memory, (RAM) or central unit defective.
* The CRC sign of the * Restart the SLI
Error in the monitored
monitored write/read * Replace buffer battery on
write/ read memory.
memory is wrong the central unit.
The CRC verification of
E47 * The buffer battery is * Replace central unit
the monitored write/read
decharged (< 2V at
memory provides an
1kOhm).
incoherent result
* Central unit defective.
* No valid data in the crane * Upload valid crane data
Error in the crane data
E51 data file. file
file
* Flash-EPROM defective * Replace central unit
* No valid data in the load * Upload valid load chart
E52 Error in load chart file. chart file file
* Flash-EPROM defective * Replace central unit
Wrong setup of min. * Analog input not * Setup correct Flag in DGA
E53 analog inputs length1, supported 6.i.2
angle1, pressure1
* No valid data in the crane * Restore or upload valid
E56 Error in crane data file. data file during calibration. crane data file
* Flash-EPROM defective * Replace central unit
Error Code Error Cause Elimination
* Calibration data file does * Upload calibration data
Error in serial crane data not contain valid data. file by changing data (OM,
E57
file. * Flash-EPROM defective limits) and save
* Replace central unit
* CAN Bus cable between * Check the connection
the central unit and the between the central unit
sensor unit defective or and the sensor units
Error in the CAN bus
not connected.
E61 data transfer for all CAN
* Can bus port in the central * Replace the central unit
units
unit defective
* Short circuit in a CAN Bus * Replace Can Bus cable
cable
* Cable between the central * Check the cable to the
unit and the sensor unit sensor unit
defective.
Error in the can bus data
* Can bus port in the central * Replace the central unit
E62 transfer of the pressure
unit defective
transducer sensor unit
* Can bus port in the sensor * Replace the sensor unit
unit is defective
* Sensor unit is defective * Replace the sensor unit
Error in the can bus * The analog values of the * Replace the sensor unit
E63 pressure transducer sensor unit are invalid
sensor unit
Error in the can bus data * See E62 * See E62
E64 transfer of the
length/angle sensor unit
Error in the can bus * See E63 * See E63
E65
length/angle sensor unit
Error in the data of the * PDB variable invalid * Change system software
E66
digital I/O MENTOR * Change MENTOR
Error in the can bus data * PDB variable invalid * Connect digtal I/O
E67 transfer of the digital I/O external CAN module
external module
* The selected rigging * Select another rigging
condition is not contained condition
E84 Wrong rigging condition.
in the crane data file. * Check the programming
in the crane data file.
* The computed radius is * Check the programming
Error in the radius
E85 too small (negative in the crane data file.
determination
deflection)
Error Code Error Cause Elimination
* The operating mode on * Select operating mode
Operating mode the console has been without load on the boom
E89
switchover with load. switched over with the
boom loaded.
* SLI processing time limit * Reset system
E98 SLI watchdog activated exceeded * Connect PC terminal and
watch error messages
* Short circuit in the A2B * Replace A2B switch
Short circuit in the A2B
switch * Replace cable to the A2B
EAB switch circuit (not with
* Short circuit in the cable switch
radio A2B)
to the A2B switch
* Disconnected cable in the * Connect or replace cable
A2B switch circuit
A2B switch in the A2B switch
EAC disconnected
* Disconnected cable to the * Connect or replace cable
(not with radio A2B)
A2B switch to the A2B switch
* Sensor wrong function * Replace A2B switch
* CAN bus delay * Replace cable to the A2B
No valid A2B switch * Radio telegram delay switch
EAD
status module (radio A2B) * Replace battery of radio
* Radio telegram ID is module (radio A2B)
invalid * Setup ID in DGA12.9
* Setup of the datalogger is * transfer data and setup
cleared (ser. crane data datalogger again
EDB Datalogger setup error
file or battery buffered
RAM)
* datalogger processing * Reset system
Datalogger watchdog
EDC time limit exceeded * Connect PC terminal and
activated
watch error messages
* Battery check detected a * change batterie, after this
EDD Battery empty
low voltage of the battery setup of RTC
* Not possible to save data * Message disappears after
EDE Record lost because other task saves a few seconds
data at the same time
* Not possible to save any * Message disappears after
EDF Flash block full
more data a few seconds
* a funktion needs more * Message disappears after
EFD SLI Watchdog
than 0.5 sec, e.g. Flash a few seconds
extra time
PROM write