You are on page 1of 169

Service Training

Software
Programming
AC - Cranes
Service Training

Version 3.5
2010-08-11

This document describes the complete software programming


procedure for AC cranes equipped with an IC-1 control system.

The training documentation has been designed to accompany


a taught Service Training course and is not suitable for home
study.

In order to be able to use this training documentation


without risk, you will need a fundamental and thorough
grounding in the operation of AC cranes and the IC-1
control system and must also be familiar with the
relevant crane operating manual.

© Terex-Demag 2010, Jürgen Christmann 2


Service Training Contents

Table of Contents
Text accentuation ............................................................................6

1 CRANE UPDATE COMPLETE (E.G. AC 200-1) ................. 7


1.1 Reading out and documenting the current software version ...7

1.2 Dlog project backup ......................................................................7

1.3 Saving the watch lists .................................................................11

1.4 Checking the firmware ................................................................18

1.5 Firmware update CPU, I/O and CGM..........................................20

1.6 Project update: Digsy compact CPU .........................................25


Error messages ............................................................................ 29
Checking the watch lists ............................................................... 30

1.7 Project update, CGM....................................................................33

1.8 Software update, Dlog .................................................................37

1.9 Checking and adapting the crane-specific data .......................43

1.10 Loading new projects as a zipped file on to the Dlog..............43

1.11 Moki project update .....................................................................48


Selecting the crane type (not necessary for updates) .................. 50
Parameter editor ........................................................................... 53

1.12 Backing up the software and parameters of the Mobil


Elektronik system ........................................................................58

1.13 Loading the Mobil Elektronik parameters .................................64

1.14 Mobil Elektronik software flash..................................................67

1.15 Softwareflash Mobil Electronic with *.eea file ..........................70

1.16 Re-loading the backup files ........................................................73

1.17 Programming of the AC55_City steering system .....................78

1.18 Programming of the AC100/4 steering system.........................80

2 REPLACING THE DIGSY COMPACT CPU .......................81


2.1 Unpacking the project .................................................................81

2.2 Loading the project......................................................................82

2.3 Checking the firmware ................................................................84

© Terex-Demag 2010, Jürgen Christmann 3


Service Training Contents

2.4 Firmware update (if necessary)..................................................85

2.5 Loading the crane-specific data.................................................86

3 REPLACING THE DLOG....................................................91


3.1 Loading the operating system and project ...............................91

3.2 Checking and adapting the crane-specific data .......................91

4 CALIBRATING THE PRESSURE TRANSMITTERS ..........98

5 CALIBRATING THE SENSORS .......................................102

6 CHANGING THE JOYSTICK - ID .....................................106

7 CHANGING A CAN - ID....................................................109


7.1 Changing the ID, for example pressure transducer .............. 109

7.2 Reset addressing ...................................................................... 110

8 MOKI .................................................................................112
8.1 Erasing the transmission, ABS and retarder errors.............. 112

8.2 Setting the operating hour counter......................................... 116


Example: Setting 693 hours for carrier ....................................... 118

9 PROGRAMMING OF AC 50-1, AC 80-2 AND AC 100/4 ..119


9.1 PDM Download (Saving) of Projects....................................... 119

9.2 PDM Upload (Updating) of Projects ........................................ 123

9.3 IFM Download of Firmware and Application .......................... 128

9.4 Sensor Calibration .................................................................... 133

9.5 Load Correction ........................................................................ 134

9.6 AC 50-1 / AC 80-2 PWM Menu................................................. 134

9.7 AC100/4 position speed of the telescope............................... 135

10 PROGRAMMING THE CENTRAL COMPUTER AND


THE MOKI AC100/4..........................................................141
10.1 Connecting the laptop to the crane ........................................ 141

10.2 Uploading the software onto the central computer .............. 141

10.3 Uploading parameter set onto ZR32 ....................................... 144

© Terex-Demag 2010, Jürgen Christmann 4


Service Training Contents

10.4 Uploading the EEPROM parameter sets................................. 146

10.5 Parameter editor ....................................................................... 146

11 PROGRAMMING OF THE MOBA EMERGENCY


CONTROL.........................................................................150

12 SOFTWARE-UPDATE MTC .............................................157

13 TABLE OF ILLUSTRATIONS...........................................160

© Terex-Demag 2010, Jürgen Christmann 5


Service Training Text accentuation

Text accentuation
Example Signification

[OK] Button or Key

Project > Option Menu

Postprocessors entry

Dialog Option Name of the dialog

Resources tab Name of the tab

Program Prosyd 1131 Name of the program

AC200_A0701_LMB_V30001 Name

 Remark

Important information

© Terex-Demag 2010, Jürgen Christmann 6


Service Training 1 Crane update complete (e.g. AC 200-1)

1.1 Reading out and documenting the current software version

1 Crane update complete (e.g. AC 200-1)


1.1 Reading out and documenting the current software
version

 Before updating, you will need to acquire the last stored


revision version of the crane from the source archive with all
the projects and watch lists.

 You will need to read out and note the current crane
programming status for documentation purposes.

1. In the Dlog main menu, activate soft button .


The following window is opened:

Fig. 1: List of inputs/outputs

Here you can see the current software version (in this case
Version: 1.215). You can select any of the CPUs from the
selection list (here: CPU A0751 of the AC 60/70).

2. Select all CPUs and note the software version.

1.2 Dlog project backup


For documentation purposes, or for recovering the original
status, you must save the complete Dlog project. The Dlog

© Terex-Demag 2010, Jürgen Christmann 7


Service Training 1 Crane update complete (e.g. AC 200-1)

1.2 Dlog project backup

project also contains the current Digsy compact projects in


zipped form.

1. Connect the laptop using a crossover network cable to the


Dlog.

 Before you launch the upload program on your laptop,


ensure that the Dlog is switched to server mode.

2. In the Dlog main menu, activate soft button .


The following window is opened:

Fig. 2: System

3. Click on Server: [Start].


4. Enter password 1500.
The Dlog switches to the server mode.

5. In your laptop, launch the program Uploader2.5.

© Terex-Demag 2010, Jürgen Christmann 8


Service Training 1 Crane update complete (e.g. AC 200-1)

1.2 Dlog project backup

The software is launched with the following screen:

Fig. 3: IC-1 Uploader 2.5

6. Click on [Connect].
7. Enter password demag and confirm with [OK].

Fig. 4: Password prompt

The laptop connects with the Dlog.

© Terex-Demag 2010, Jürgen Christmann 9


Service Training 1 Crane update complete (e.g. AC 200-1)

1.2 Dlog project backup

Fig. 5: IC-1 Uploader 2.5 connected

Using the Project soft buttons, you can upload complete


projects from the laptop to the crane (1) or download from
the crane to the laptop (2).

8. In order to save the current project, click on soft button (2)

Project: .
This opens the Save Directory dialogue.

Fig. 6: Save directory

9. Select and highlight the storage location.


10. Save the project with [Save Directory].

© Terex-Demag 2010, Jürgen Christmann 10


Service Training 1 Crane update complete (e.g. AC 200-1)

1.3 Saving the watch lists

Download finished successfully.

The file is now located in the selected folder with the day
and time of saving in the file name.

Example: project.jar_20050902_101420
project.jar is the file name,
20050902 means 2 September 2005,
101420 means 10 hours 14 minutes and 20 seconds.

 In order to ensure that the project can be loaded into Dlog,


the suffix must read .jar.

Consequently:

11. Disconnect the Uploader program from the crane by clicking


on [Disconnect], and close the program.
12. Disconnect the laptop from the crane.
13. Rename the file in Windows Explorer to e.g. project_serial
number_date.jar.

1.3 Saving the watch lists

 The crane-specific data in the IC-1 crane control system are


stored as so-called watch lists in the various CPUs:
A0621 as the clutch parameters (AC60 and AC70 only),
A0701 (or A0751 for the AC60/70) are the transmitter
values (length transmitter, angle transmitter, etc.), the
boom section weights, the centres of gravity and the
correction values (pressure sensor, derricking cylinder),
A0703 (or A0753 in the case of the AC60/70) for the
operating hours, the parameters of the slew gear brake and
the PWM parameters (values for the proportional valves).
For subsequent archiving and in order to ensure that the
data are not lost following a software update, you must
ensure that the data are saved. For this, it is vital that you
have the current CPU projects. You can extract the projects
from the previously uploaded Dlog project.

Example: A0701 for an AC200-1:

1. Click with the right mouse button on saved Dlog project


(saved as described under section 1.2 above).
2. Select Open with... from the context menu.

© Terex-Demag 2010, Jürgen Christmann 11


Service Training 1 Crane update complete (e.g. AC 200-1)

1.3 Saving the watch lists

Fig. 7: Open with

3. Select WinZip and confirm with [OK].


The Dlog project is shown in the WinZip window.

4. Double click on the software version relevant to the crane –


in this example SPS_Stand2007_10_31.zip and then click on
[Extract].

Fig. 8: WinZip dialogue

5. Choose the proper folder to save.

© Terex-Demag 2010, Jürgen Christmann 12


Service Training 1 Crane update complete (e.g. AC 200-1)

1.3 Saving the watch lists

6. Launch the program Prosyd 1131 by double clicking on the


project, in this example we want
AC200_A0701_LMB_V30001.pro.

Fig. 9: Open project

The following dialogue is displayed:

Fig. 10: Password for User Group

 The User Group approved for After Sales is Level 5, and the
password reads kudi.

7. Enter the password and confirm with [OK].

© Terex-Demag 2010, Jürgen Christmann 13


Service Training 1 Crane update complete (e.g. AC 200-1)

1.3 Saving the watch lists

You have opened the project AC200_A0701_LMB_V30001.

Fig. 11: Project AC200_A0701_LMB_V30001

8. In order now to go online, connect the laptop to serial


interface X0701 in the superstructure (Ignition ON).
The interfaces are always located in the central electric of
the superstructure or carrier.
9. Click on Online > Login

Fig. 12: Online > Login

The laptop connects with the control system.

© Terex-Demag 2010, Jürgen Christmann 14


Service Training 1 Crane update complete (e.g. AC 200-1)

1.3 Saving the watch lists

 Click on [Cancel] if you see this following message:

Fig. 13: New program load security prompt

This is because the same project must be located in both the


CPU and the laptop.

Check to make sure that you have opened the right project
and are using the correct interface.

The status line shows ONLINE and RUN if the laptop has
been correctly connected to the control system.

Fig. 14: Status = ONLINE RUN

© Terex-Demag 2010, Jürgen Christmann 15


Service Training 1 Crane update complete (e.g. AC 200-1)

1.3 Saving the watch lists

10. Click on the Resources tab.

Fig. 15: Resources tab

11. Click on Watch- und Receipt Manager.


12. Click on the required watch list, in this example Geberwerte
(sensor values).

Watch list in the control system

Watch list on the laptop

Fig. 16: Watch and Receiptmanager, sensor values

 In order to store the watch list currently applicable to the


crane, it is necessary for the data to be read out of the
control system. In Prosyd, this procedure is termed Read
Receipt.

13. Click on e.g. Geberwerte with the right mouse button.

© Terex-Demag 2010, Jürgen Christmann 16


Service Training 1 Crane update complete (e.g. AC 200-1)

1.3 Saving the watch lists

14. In the context menu, select Read Receipt.

Data from laptop to control system

Data from control system to laptop

Fig. 17: Context menu

15. Confirm the dialogue with [Yes].

Fig. 18: Data record read security prompt

Fig. 19: Identical values in Watch- and Receipt Manager

The figure shows identical values on the laptop and in the


control system.

16. In order to store the list on the laptop, click on e.g.


Geberwerte with the right mouse button.

© Terex-Demag 2010, Jürgen Christmann 17


Service Training 1 Crane update complete (e.g. AC 200-1)

1.4 Checking the firmware

17. In the context menu, select Save watch list ...

Fig. 20: Save Watch List

18. Rename the file as e.g. Geberwerte_A701_bn21.


19. Select an appropriate folder and confirm with [Save].

Fig. 21: Save as...

The sensor values list has been saved. You can display the
list in an editor.

20. Repeat this procedure for all lists and corresponding CPUs.

1.4 Checking the firmware


In order to check which firmware is on the control system,
connect the laptop to the control system and launch the
program Prosyd 1131 as described in Section 1.3.

© Terex-Demag 2010, Jürgen Christmann 18


Service Training 1 Crane update complete (e.g. AC 200-1)

1.4 Checking the firmware

1. Click on the Resources tab.

Fig. 22: Checking the firmware

2. Click on the + in front of Global Variables in order to open


the folder.
3. Double click on SYS_VAR (CONSTANT).
4. Click on the + in front of SysIn in order to open the folder.
The interactive window shows the firmware versions of the
CPU and I/O cards, in this example of an A0701 box
belonging to an AC200-1 crane, the versions are 6.4.7 for
the CPU and 6.3.3 for the I/O card.

CPU 6.4.7

I/O 6.3.3

Fig. 23: Firmware

5. Log off and quit Prosyd.


6. Switch off the ignition and switch on again.

© Terex-Demag 2010, Jürgen Christmann 19


Service Training 1 Crane update complete (e.g. AC 200-1)

1.5 Firmware update CPU, I/O and CGM

1.5 Firmware update CPU, I/O and CGM

 The procedure is the same for CPU, I/O, CGM. This


description applies to the software Bootloader 3.2.X. In
cases of doubt, always upload the latest firmware. If a
complete Digsy is being loaded, start with the I/O part.

1. Using a serial cable, connect the laptop to e.g. the control


system CPU.
The interfaces for the CPUs are located in the central electric
of the superstructure or carrier; the interfaces for the CGMs
are in the outrigger control box (unscrew lid); and the
interfaces for the I/O cards must be installed (order in
advance).

2. Launch the Bootloader software by double clicking on the

icon .
3. Using [OK], confirm licence number prompt without making
any inputs.

Fig. 24: Licence number request

4. Switch off the crane ignition.


5. In the InterControlBootloader for ComPorts, quit standard
selection COM1, activate the selection menu for Devices and
select the control system that you want to program – in this
example, the DCE.
DCE = CPU
DIO = I/O
CGM = CGM

© Terex-Demag 2010, Jürgen Christmann 20


Service Training 1 Crane update complete (e.g. AC 200-1)

1.5 Firmware update CPU, I/O and CGM

6. Click on [Login].

Fig. 25: InterControlBootloader

7. Click on [OK] to confirm request Please reset the device.

Fig. 26: Reset device

8. Switch on ignition.

© Terex-Demag 2010, Jürgen Christmann 21


Service Training 1 Crane update complete (e.g. AC 200-1)

1.5 Firmware update CPU, I/O and CGM

The current Bootloader is loaded onto the laptop.

Fig. 27: Loading Bootloader

The Bootloader is loaded and displayed.

Fig. 28: Bootloader Online

Unlike in the case of the earlier Bootloader version, we now


remain logged onto the control system until [Logout] is
activated.

© Terex-Demag 2010, Jürgen Christmann 22


Service Training 1 Crane update complete (e.g. AC 200-1)

1.5 Firmware update CPU, I/O and CGM

9. Click on Download > Firmware.

Fig. 29: Download > Firmware

The Open dialogue is shown.

10. Select the firmware to be loaded – in this example:

cgm_5_3_3.hex for the CGM (Version 5.3.3)


dce_V6_4_7ex for the CPU (Version 6.4.7)
iodce_633.hex for the I/O (Version 6.3.3).

 In cases of doubt, always load the latest version.

© Terex-Demag 2010, Jürgen Christmann 23


Service Training 1 Crane update complete (e.g. AC 200-1)

1.5 Firmware update CPU, I/O and CGM

11. Confirm with [Open].

Fig. 30: Select firmware

Fig. 31: Downloading firmware

The firmware is loaded.

© Terex-Demag 2010, Jürgen Christmann 24


Service Training 1 Crane update complete (e.g. AC 200-1)

1.6 Project update: Digsy compact CPU

12. Confirm success message with [OK].

Fig. 32: Download successful

13. Click on [Logout].


14. Quit the program with [Exit].
15. Switch off ignition and switch on again.

1.6 Project update: Digsy compact CPU

1. Double click on the icon to launch the Prosyd 1131


program.
2. Select File > Open ....

Fig. 33: File > Open…

© Terex-Demag 2010, Jürgen Christmann 25


Service Training 1 Crane update complete (e.g. AC 200-1)

1.6 Project update: Digsy compact CPU

3. Click on the correct project according to the Service Bulletin,


in this example, the project we want is:
AC200_A0701_LMB_V30001.pro.

Fig. 34: Open project

4. Confirm with [Open].


The following dialogue is shown:

Fig. 35: Password for User Group

 The User Group approved for After Sales is Level 5, the


password reads kudi.

5. Enter password and confirm with [OK].

© Terex-Demag 2010, Jürgen Christmann 26


Service Training 1 Crane update complete (e.g. AC 200-1)

1.6 Project update: Digsy compact CPU

You have opened the project AC200_A0701_LMB_V30001.

Fig. 36: Project AC200_A0701_LMB_V30001

6. In order to transfer a project to the control system, connect


the laptop to serial interface X0701 in the superstructure.
The interfaces are always located in the central electric of
the superstructure or carrier.
7. Click on Online > Login.

Fig. 37: Online > Login

The laptop is connected to the control system.

As the project on the laptop and the project in the control


system are not identical, Prosyd 1131 generates a warning
message: The program has been changed. Load new
program?

© Terex-Demag 2010, Jürgen Christmann 27


Service Training 1 Crane update complete (e.g. AC 200-1)

1.6 Project update: Digsy compact CPU

8. Confirm with [Yes].

Fig. 38: Security prompt indicating program change

The project is loaded.

Fig. 39: Load in progress

The window closes automatically once the download has


been completed. The project has now been loaded onto the
control system (ONLINE), but is not yet running (RUN).

Fig. 40: Status indicator

9. Click on Online > Run.

Fig. 41: Project run

The status indicator at the bottom right edge should now


show the following image:

© Terex-Demag 2010, Jürgen Christmann 28


Service Training 1 Crane update complete (e.g. AC 200-1)

1.6 Project update: Digsy compact CPU

Fig. 42: Status bar: Project running

10. In order to check whether the new control system has been
transferred, log off using and then log on again using
.

Fig. 43: Logging off/on

The download was successful if the project launches without


a fault or error message and the status indicator shows both
ONLINE and RUN.

Error messages

 If, after logging on and seeing the message The program


has been changed. Load new program?, you wait more than
10 seconds to confirm, Prosyd 1131 generates the following
time-out message:

Fig. 44: Error message

If you confirm this message with [OK], the download will


commence. When you attempt to launch the software, this
message will appear again.

If you log off and log on again, Prosyd 1131 generates the
following message (No program on the control system! Load
new program?):

Fig. 45: Message and prompt: Download the new program?

If you click on [Yes], the download will begin anew. Then


proceed as described above.

© Terex-Demag 2010, Jürgen Christmann 29


Service Training 1 Crane update complete (e.g. AC 200-1)

1.6 Project update: Digsy compact CPU

Checking the watch lists

The watch lists are essential for crane operation and


crane safety. Consequently, check the watch lists
particularly carefully, as described in the following.

 In order to ensure that the crane-specific data have not


been erased or overwritten, check the data as follows:

1. Click on the Resources tab.

Fig. 46: Resources

2. Double click on Watch- and Receipt Manager.

 Repeat the following steps for all watch lists displayed. The
example describes the procedure for checking the
Geberwerte (Sensor values).

3. Highlight by clicking on the Geberwerte with the left mouse


button.

© Terex-Demag 2010, Jürgen Christmann 30


Service Training 1 Crane update complete (e.g. AC 200-1)

1.6 Project update: Digsy compact CPU

4. Click on Geberwerte with the right mouse button in order to


call up the context menu and load the watch lists saved on
to the laptop into the project as per the description in
section 1.3.

Watch list in the


control system

Watch list on
the Laptop

Fig. 47: Checking the watch lists

5. In the context menu, select Load Watch List….

Save data to hard disc

Open data in Prosyd


Fig. 48: Context menu

6. Click on the previously saved file, in our example


Geberwerte_A0701_bn21.wtc (i.e. the sensor values watch
list for serial number 21) and confirm with [Open].

 The watch list to be loaded and the watch lists that already
exist must not have the same name. Consequently, Prosyd
asks for a new name for the file being loaded. As you have
already changed the name, all you have to do is confirm.

© Terex-Demag 2010, Jürgen Christmann 31


Service Training 1 Crane update complete (e.g. AC 200-1)

1.6 Project update: Digsy compact CPU

7. Enter Name dialogue, confirm the suggested name with


[OK].

Fig. 49: Enter Name

Fig. 50: Comparison of watch lists

The watch list is loaded and is located left in parentheses.

8. If the values on the right agree with the values in


parentheses, repeat the procedure for all watch lists. Then
log off and quit Prosyd.
9. If the values on the right do not agree with the values in
parentheses, click on Geberwerte (Sensor values) as our
example watch list.
10. In the context menu, select Write Receipts.

Fig. 51: Context menu: Write Receipts

The data on the left and right should now agree.

© Terex-Demag 2010, Jürgen Christmann 32


Service Training 1 Crane update complete (e.g. AC 200-1)

1.7 Project update, CGM

11. Then log off and quit Prosyd.


12. Switch off ignition and switch on again.

1.7 Project update, CGM

1. Double click on the icon to launch the program


Prosyd 1131.
2. Select File > Open....

Fig. 52: File > Open…

3. Click on the correct project according to the Service Bulletin,


in this example, the project
AC200_CGM_links_N20_V30000.

Fig. 53: Open project

4. Confirm with [Open].

© Terex-Demag 2010, Jürgen Christmann 33


Service Training 1 Crane update complete (e.g. AC 200-1)

1.7 Project update, CGM

The following dialogue is shown:

Fig. 54: Password for User Group

 The User Group approved for After Sales is Level 5, and the
password is kudi.

5. Enter the password and confirm with [OK].


You have opened the project
AC200_CGM_links_N20_V30000.

6. In order to transfer the project


AC200_CGM_links_N20_V30000, connect the laptop to the
serial interface in the CGM.
7. Click on Online > Login.

Fig. 55: Online > Login

The laptop connects to the control system.

© Terex-Demag 2010, Jürgen Christmann 34


Service Training 1 Crane update complete (e.g. AC 200-1)

1.7 Project update, CGM

As the project on the laptop and the project in the control


system are not identical, Prosyd 1131 generates the
following message:

Fig. 56: Security prompt: Program has changed

8. Confirm with [Yes].


The project is loaded.

Fig. 57: Load in progress

The window closes once the download has been completed.


The project is now loaded on the control system.

In the CGM there are also image files which now have to be
loaded.

© Terex-Demag 2010, Jürgen Christmann 35


Service Training 1 Crane update complete (e.g. AC 200-1)

1.7 Project update, CGM

9. Click on Online > Download Datafile.

Fig. 58: Online > Download Datafile

 A data file is a file with the suffix .ob. There is only one such
file. If there are two CGMs installed in the crane, this file is
loaded onto both sides.

10. Click on the file AC200_CGM_V30000.OB and confirm with


[Open].

Fig. 59: Open data file

The download operation commences.

© Terex-Demag 2010, Jürgen Christmann 36


Service Training 1 Crane update complete (e.g. AC 200-1)

1.8 Software update, Dlog

11. Once the download is successful, click on Online > Run.

Fig. 60: Online > Run

The CGM immediately shows the Terex-Demag logo. As soon


as the bus is running, the CGM shows the normal display for
the outrigger system etc.

12. In order to check whether the new control project has been
transferred, log off with and then log on again with .

Fig. 61: Logging off and on

The download has been successful if the project launches


without an error message and the status indicator shows
both ONLINE and RUN.

1.8 Software update, Dlog

 Within the Dlog, you need to distinguish between the IPC


and the MPC. The operating systems for the IPC and MPC
are different, as can be seen from their names:

project_os_ipc_2_4.jar
means a project based on an OS = operating system type
IPC, Version 2.4, .jar = Java

project_os_mpc_4_5.jar
means a project with an MPC operating system, Version 4.5

 There are applications in the form of projects which run on


both operating systems. There are various versions for these
applications. In the file supplied, e.g.
AC200-1_Varianten_Änderungsliste.pdf,
you can find all the variants listed.

© Terex-Demag 2010, Jürgen Christmann 37


Service Training 1 Crane update complete (e.g. AC 200-1)

1.8 Software update, Dlog

Examples

project_AC55_001_003_009_60815.jar
means a project, variant 1, for the AC55, applicable from
serial number 1, in the version 3.9, dated 15.08.2006. This
project can be loaded on all Dlog systems of the AC55_City.

project_AC200-1_002_007_002_61024.jar
means a project for the AC200-1, variant 2, applicable from
serial number 25, without hydraulic main boom extension, in
the version 7.2, dated 24.10.2006.

In order to connect the laptop to the Dlog, the Dlog must


first be launched in the server mode.

1. In the Dlog main menu, activate the soft button .


The following window is opened:

Fig. 62: System

2. Click on Server: [Start].


3. Enter password.

After saving with , the Dlog switches to the server


mode.

4. Using a crossover network cable, connect the laptop with the


Dlog.
5. Launch the program Uploader 2.5.

© Terex-Demag 2010, Jürgen Christmann 38


Service Training 1 Crane update complete (e.g. AC 200-1)

1.8 Software update, Dlog

The software launches with the following screen:

Fig. 63: IC-1 Uploader 2.5

6. Click on[Connect].
7. Enter password and confirm with [OK].

Fig. 64: Password request

The laptop connects to the Dlog.

© Terex-Demag 2010, Jürgen Christmann 39


Service Training 1 Crane update complete (e.g. AC 200-1)

1.8 Software update, Dlog

You can see that the laptop is connected to the Dlog by the
list of files displayed and the active soft buttons.

Files on the Dlog

Fig. 65: IC-1 Uploader 2.5 connected

Using the Project: soft buttons, you can load complete


projects from the laptop to the crane (1) or from the crane
to the laptop (2).

8. In order to load the new project onto the Dlog, activate soft
button (1).
This opens the dialogue Choose File enabling you to select
the correct project.

Fig. 66: Choose file

9. Highlight the project, in this example


project_AC200-1_002_007_003_70328.jar.

© Terex-Demag 2010, Jürgen Christmann 40


Service Training 1 Crane update complete (e.g. AC 200-1)

1.8 Software update, Dlog

10. Commence the upload by activating [Choose File].


11. Confirm the message Upload finished successfully with
[OK].

Fig. 67: Upload finished successfully

12. Click on [Disconnect] to disconnect the laptop from the


crane.
13. Remove the network cable.
14. Quit Uploader 2.5.

15. Activate on the Dlog in order to exit the server mode.


The Dlog reboots.

 After the Dlog has rebooted, you must set it to a new


operating mode.

16. Modify and save counterweight and rope reeving


arrangement (ideally 9-fall).

 Please do not forget the Info pdf file. This file is always
generated in a new project and contains important
information on the project and operating system.

17. To check which operating system or application is running on

the Dlog, click on in the main menu.

© Terex-Demag 2010, Jürgen Christmann 41


Service Training 1 Crane update complete (e.g. AC 200-1)

1.8 Software update, Dlog

You can read the data off the following screen.

Fig. 68: Readout of the Dlog software versions

As a new operating system is also loaded as a project, the


procedure is identical. If the project and operating system
have to be updated, you can do this in one operation.

During the upload operation, a backup is automatically


created and stored in the source directory under the same
name augmented by the serial number, date and time. In
the source directory, you will now find a file with the name
project_AC55_bn1_v2_1-
50401.jar_15005_20050906_095008

With this file, you can always restore the Dlog to its original
condition.

 In order to ensure that this file is recognised as a Java file


and the project can be loaded into the Dlog, the suffix .jar
must always be provided at the end. Consequently, rename
the file under Windows Explorer, to e.g. project_serial
number_date.jar.

© Terex-Demag 2010, Jürgen Christmann 42


Service Training 1 Crane update complete (e.g. AC 200-1)

1.9 Checking and adapting the crane-specific data

1.9 Checking and adapting the crane-specific data

 After booting the Dlog, there should be no error messages


displayed. In particular, the following messages indicate that
different crane-specific data are located on the Dlog on the
one hand and CPU A0701 and/or A0703 on the other:

E218 S01 for the sensor values


E219 S02 for the options
E220 S03 for the settings
E221 S04 for the correction values

If this should be the case, check the data as described under


section 2.5.

Once the crane is operating properly again:

1. Test the crane and check in particular the radius, load and
angle indicator.
2. Zip the Digsy projects using the WinZip program and load
onto Dlog (see section 1.10).
3. Following successful testing, save the Dlog project (see
section 1.2).
4. Send the zipped Dlog project to Zweibrücken for archiving.
5. If it was necessary to carry out a calibration procedure, you
will also need to save the corresponding watch lists (see
section 1.3) and send these to Zweibrücken for archiving.
6. Complete the software record.

1.10 Loading new projects as a zipped file on to the Dlog


In order to make newly loaded CPU projects accessible for
subsequent applications on the Dlog, you can load the files
in zipped form onto the Dlog (where the files do not already
exist on the Dlog).

1. Using a crossover network cable, connect the laptop to the


Dlog.

 Before you launch the program on the laptop, make sure


that the Dlog is switched to server mode.

2. In the Dlog main menu, activate the soft button .

© Terex-Demag 2010, Jürgen Christmann 43


Service Training 1 Crane update complete (e.g. AC 200-1)

1.10 Loading new projects as a zipped file on to the Dlog

The following window is opened:

Fig. 69: System

3. Click on Server: [Start].


4. Enter password.
Server starts up.

5. Start up laptop program Uploader 2.5.

© Terex-Demag 2010, Jürgen Christmann 44


Service Training 1 Crane update complete (e.g. AC 200-1)

1.10 Loading new projects as a zipped file on to the Dlog

Software launches with the following screen:

Fig. 70: IC-1 Uploader 2.5

6. Click on [Connect].
7. Enter password and confirm with [OK].

Fig. 71: Password request

The laptop connects to the Dlog.

© Terex-Demag 2010, Jürgen Christmann 45


Service Training 1 Crane update complete (e.g. AC 200-1)

1.10 Loading new projects as a zipped file on to the Dlog

8. Click on Config:sps.
9. Click on [New].

Fig. 72: Config:sps

10. In the Choose File dialogue, click on the zip file, in this
example SPS_Stand2007_10_31.zip.
11. Upload to the Dlog by clicking on [Choose File].

Fig. 73: Choose File

© Terex-Demag 2010, Jürgen Christmann 46


Service Training 1 Crane update complete (e.g. AC 200-1)

1.10 Loading new projects as a zipped file on to the Dlog

12. Confirm message File creation finished successfully with


[OK].

Fig. 74: File creation finished successfully

The loaded file is displayed under Config:sps .

Fig. 75: Config:sps loaded

13. Disconnect the laptop from the crane by clicking on


[Disconnect].
14. Remove network cable.
15. Quit Uploader 2.5.

16. Exit the Dlog server mode by clicking on .


Dlog reboots.

© Terex-Demag 2010, Jürgen Christmann 47


Service Training 1 Crane update complete (e.g. AC 200-1)

1.11 Moki project update

1.11 Moki project update

Check the connection with the central computer with


onlinetest (see chapter 7) before update.
Only start programming if a connection is built up
because you, otherwise, delete the central computer.

1. Copy the update files to the directories shown:


33K10507.PRG in KIBES_RT\PST\,
33_K2_K3_0507_32Bit.zip in CAVTAN\PROJECTS\.
2. Connect the laptop using the K-Line Adapter (42377012) to
the J1939 diagnostics interface in the superstructure or
carrier.
3. Launch the software KIBES Runtime by double clicking on
the icon or on KS.bat.
\\KIBES_RT\PST\

Fig. 76: KIBES Runtime

4. Press any key.

 Using the cursor keys, select an entry and confirm your


selection with [Enter].

© Terex-Demag 2010, Jürgen Christmann 48


Service Training 1 Crane update complete (e.g. AC 200-1)

1.11 Moki project update

5. Select Postprocessors.

Fig. 77: KIBES postprocessors

6. Select Communication and confirm with [Enter].

Fig. 78: KIBES communication

7. Select Load PLC Prog. and confirm with [Enter].


8. Show the list of projects with [Enter].

© Terex-Demag 2010, Jürgen Christmann 49


Service Training 1 Crane update complete (e.g. AC 200-1)

1.11 Moki project update

9. Using the cursor keys, select the correct project and load
onto the Moki with [Enter].

Fig. 79: KIBES load PLC program

10. Once the download has been 100% completed, quit


Communication by confirming End with [Enter].

Fig. 80: Load in progress, PLC program to central computer

Selecting the crane type (not necessary for updates)

 The projects 33K10502.prg, 33K10507.prg and so on apply


to all IC-1 cranes apart from the AC60 and AC70.
Consequently, you will need to select the appropriate crane
type once the download has been completed.

1. Staying in KIBES_RT from project 33K10507.prg, select the


crane type.

© Terex-Demag 2010, Jürgen Christmann 50


Service Training 1 Crane update complete (e.g. AC 200-1)

1.11 Moki project update

2. Select Online Test and confirm with [Enter].

Fig. 81: Online test

3. Confirm message Onlinetest by pressing the [Y] for Yes on


the keyboard.

Fig. 82: Licence message, online test

4. Click with left mouse button.

Fig. 83: Continue with left click

5. Using the cursor keys, scroll the highlighting in the list of


contents at Sheet forward.

© Terex-Demag 2010, Jürgen Christmann 51


Service Training 1 Crane update complete (e.g. AC 200-1)

1.11 Moki project update

6. Using [Enter], scroll on to the page 2.Config Gerätetyp.

Fig. 84: Selection Config Gerätetyp

7. Select Def & Run and confirm with [Enter].

 You can move the violet cursor over the screen using the
cursor keys.

8. Move the cursor on to the crane type to be selected, in this


example: TB_AC200-1.

Fig. 85: Selecting the crane type

© Terex-Demag 2010, Jürgen Christmann 52


Service Training 1 Crane update complete (e.g. AC 200-1)

1.11 Moki project update

9. Confirm selection with [Enter].


KIBES highlights the associated information.

Fig. 86: Selection check

10. Select TB_AC200-1 again by clicking on [Enter] in order to


cancel the entry highlight.

Fig. 87: Entry highlight cancelled

The crane type is now set and is shown in the Moki system.

 Keep pressing [Esc] – you can quit the software program by


confirming each message with [Y] for Yes.

Parameter editor

 There are two parameter editors, a 16-bit and a 32-bit


version. Newer cranes are only supplied with the 32-bit
version.

© Terex-Demag 2010, Jürgen Christmann 53


Service Training 1 Crane update complete (e.g. AC 200-1)

1.11 Moki project update

1. Launch the parameter editor by double clicking on the icon.


The example shows the 32-bit parameter editor.

Fig. 88: Software icons

The program opens the following screen:

Fig. 89: Starting screen, Parameter Editor 32bit

2. Click on File > Load project.

Fig. 90: Load project

© Terex-Demag 2010, Jürgen Christmann 54


Service Training 1 Crane update complete (e.g. AC 200-1)

1.11 Moki project update

3. Select the correct project – in this example


33_K2_K3_0507_32Bit.zip, and load with [Open].

Fig. 91: Load project

Fig. 92: Parameter Editor with project

4. To check the speed display in the project menu, click on


Basiskombi > Anpassung Drehzahl.
The adaptation factor shown in the project working window
should read 21.800 or 21.8.

If this is not the case, double click on the figure and change
the numbers.

© Terex-Demag 2010, Jürgen Christmann 55


Service Training 1 Crane update complete (e.g. AC 200-1)

1.11 Moki project update

Fig. 93: Speed adaptation

5. Click on Communication> Load application and


parameter.

Fig. 94: Load application and parameter

© Terex-Demag 2010, Jürgen Christmann 56


Service Training 1 Crane update complete (e.g. AC 200-1)

1.11 Moki project update

6. Consider the prompt and monitor the download process.

Fig. 95: Do not cut off power

Fig. 96: Download in progress

7. In the following dialogue, select all cranes by clicking on the


chevron.

Fig. 97: Select devices

8. Confirm the device selection with [OK].

© Terex-Demag 2010, Jürgen Christmann 57


Service Training 1 Crane update complete (e.g. AC 200-1)

1.12 Backing up the software and parameters of the Mobil Elektronik system

 The AC55_City and the AC70_City with the new cabin do not
have a “Basiskombi”. Cancel the error message with [OK].

9. Click on File> Quit in order to exit the program.


10. Disconnect the laptop from the interface.
11. Switch the ignition off and then on again.

1.12 Backing up the software and parameters of the Mobil


Elektronik system

 Prerequisite: Mobil Elektronik Toolbox min. Version 1.0.5.0.


installed.
With this function, you save the data of the computers prior
to an update and ensure that you can reinstate the crane’s
systems in accordance with the original condition.

You can also use this function in order to save the data on a
computer prior to replacing it, and then uploading that data
to the new, unprogrammed computer. This eliminates the
need for wheel alignment.

1. Connect the laptop via a serial null modem cable to the


control system to be programmed.
The interfaces for the steering computers are always located
in the central electric in the substructure and are clearly
marked with e.g. X4200 for computer A4200.

2. Switch on ignition.
3. Launch program WinEEA.

© Terex-Demag 2010, Jürgen Christmann 58


Service Training 1 Crane update complete (e.g. AC 200-1)

1.12 Backing up the software and parameters of the Mobil Elektronik system

4. In the tab Read C16x Flash, click on [Connect].

Fig. 98: WinEEA connection

5. Click on [Read Flash].

Fig. 99: Read Flash

© Terex-Demag 2010, Jürgen Christmann 59


Service Training 1 Crane update complete (e.g. AC 200-1)

1.12 Backing up the software and parameters of the Mobil Elektronik system

 It must be clearly identifiable from the file name which


computer and crane the data has been loaded from and
which of the files it actually belongs to – in this example
A4200_Flash_33478.hex.

 If connection breaks up, change baud rate to 9600.

6. Provide the file to be stored with a discrete name and click


on [Save].

Fig. 100: Save flash

The software of the crane is uploaded and stored in the


selected directory.

© Terex-Demag 2010, Jürgen Christmann 60


Service Training 1 Crane update complete (e.g. AC 200-1)

1.12 Backing up the software and parameters of the Mobil Elektronik system

Fig. 101: Flash read in progress

The checksum is verified and, if correct, displayed.

7. Confirm the checksum with [OK].

Fig. 102: Checksum verification

© Terex-Demag 2010, Jürgen Christmann 61


Service Training 1 Crane update complete (e.g. AC 200-1)

1.12 Backing up the software and parameters of the Mobil Elektronik system

8. Switch to the tab C16x-E2Prom Read/Write.


9. Click on [Connect].

Fig. 103: E2Prom Read/Write

10. Click on [Read E2Prom].

Fig. 104: Read E2Prom

© Terex-Demag 2010, Jürgen Christmann 62


Service Training 1 Crane update complete (e.g. AC 200-1)

1.12 Backing up the software and parameters of the Mobil Elektronik system

 It must be clearly identifiable from the file name from which


computer and crane the file has been loaded and what file it
actually is. In this example: A4200_E2prom_33478.hex

11. Give the file being stored a discrete name and click on
[Save].

Fig. 105: E2Prom save

The content of the E2Prom (parameters, error memory and


the wheel alignment data) are loaded and stored n the
selected directory.

Fig. 106: E2Prom read in progress

The checksum is verified and, if correct, displayed.

© Terex-Demag 2010, Jürgen Christmann 63


Service Training 1 Crane update complete (e.g. AC 200-1)

1.13 Loading the Mobil Elektronik parameters

12. Confirm checksum with [OK].

Fig. 107: Checksum

 Repeat this procedure for every Mobil Elektronik computer.


For example, on the AC55_C, there are 8 files with the suffix
.hex.

Please note: If the files are not clearly and discretely named,
you may load an incorrect file.

1.13 Loading the Mobil Elektronik parameters


1. Using a serial null modem cable, connect the laptop to the
control system to be programmed.
The interfaces for the steering computers are located in the
central electric of the carrier and are clearly marked with,
e.g. X4200 for computer A4200.

2. Switch on the ignition.


3. Launch the program WinPCS by double clicking on the icon.
The connection is automatically established.
4. Click on [Select Project].

Fig. 108: Project selection

© Terex-Demag 2010, Jürgen Christmann 64


Service Training 1 Crane update complete (e.g. AC 200-1)

1.13 Loading the Mobil Elektronik parameters

5. In the Choose Project dialogue, select the standard project


CraneSteering.INI or CraneSteering2.ini for AC 100/4 e.g.

Fig. 109: Choose Project dialogue

The window automatically closes once the selection has been


made.

6. Click on [Edit Parameters].

Fig. 110: Edit parameters

© Terex-Demag 2010, Jürgen Christmann 65


Service Training 1 Crane update complete (e.g. AC 200-1)

1.13 Loading the Mobil Elektronik parameters

7. In the Parameter dialogue click on [Load].

Fig. 111: Parameter dialogue

8. In the Open dialogue select the file to be loaded and click on


[Open].

Fig. 112: Select file

You will be able to see from the file name the control system
for which the file is designated, in this example 019410 for
the A4200 (SLC 1) of e.g. an AC200-1.

The values are indicated on the left of the Parameter


dialogue.

© Terex-Demag 2010, Jürgen Christmann 66


Service Training 1 Crane update complete (e.g. AC 200-1)

1.14 Mobil Elektronik software flash

9. Click on [Download].

Fig. 113: Parameter values

10. Confirm security prompt with [Yes].

Fig. 114: Security prompt

The parameters are loaded onto the control system.

Fig. 115: Parameter Download

Following an automatic restart of the control system, the


download process is completed.

11. In the Parameter dialogue, click on [ESC].


12. Close the WinPCS software with [Exit].
13. Disconnect the laptop from the computer.
14. Switch the ignition off and then on again.

1.14 Mobil Elektronik software flash


1. Using a serial null modem cable, connect the laptop to the
control system to be programmed.

© Terex-Demag 2010, Jürgen Christmann 67


Service Training 1 Crane update complete (e.g. AC 200-1)

1.14 Mobil Elektronik software flash

The interfaces for the steering computers are located in the


central electric of the carrier and are clearly marked with
e.g. X4200 for computer A4200.

2. Switch ignition on.


3. Launch the WinEEA program.
4. Click on [Connect].

Fig. 116: WinEEA connection

© Terex-Demag 2010, Jürgen Christmann 68


Service Training 1 Crane update complete (e.g. AC 200-1)

1.14 Mobil Elektronik software flash

5. Click on [Program].

Fig. 117: WinEEA programming

6. Click on the file to be loaded.


You can tell from the file name for which control system the
file is designated – in this example 019410 for the A4200
(SLC 1) of e.g. an AC200-1.

7. Confirm with [Open].

Fig. 118: Select Hex-file…

The software begins immediately with deletion of the


Eeprom and then with loading of the new function software.

© Terex-Demag 2010, Jürgen Christmann 69


Service Training 1 Crane update complete (e.g. AC 200-1)

1.15 Softwareflash Mobil Electronic with *.eea file

 If the error message Not ready for programming is shown,


click on [Delete All] in order to delete the Eeprom prior to
programming.

Fig. 119: Programming flash…

The message Success indicates that the software has been


successfully loaded.

Fig. 120: Flash programmed

8. Confirm with [OK].


9. Click on [Software reset].
10. Quit the software with [Close].
11. Switch the ignition off and then on again.

1.15 Softwareflash Mobil Electronic with *.eea file


1. Connect the laptop via a serial null modem cable to the
control system to be programmed.
The interfaces for the steering computers are always located
in the central electric in the substructure and are clearly
marked with e.g. X4200 for computer A4200.

© Terex-Demag 2010, Jürgen Christmann 70


Service Training 1 Crane update complete (e.g. AC 200-1)

1.15 Softwareflash Mobil Electronic with *.eea file

2. Switch on ignition.
3. Click on the file to be loaded.

Fig. 121: Choose File

4. Confirm with [OK].

Fig. 122: WinEEA Pause OK

© Terex-Demag 2010, Jürgen Christmann 71


Service Training 1 Crane update complete (e.g. AC 200-1)

1.15 Softwareflash Mobil Electronic with *.eea file

Automated displays are following:

Fig. 123: Erase Flash

Fig. 124: Programming Flash

© Terex-Demag 2010, Jürgen Christmann 72


Service Training 1 Crane update complete (e.g. AC 200-1)

1.16 Re-loading the backup files

Fig. 125: Executed Action

5. Quit the software with [Close].


6. Switch the ignition off and then on again.

1.16 Re-loading the backup files

 If you should encounter problems with the steering after an


update or after changing a computer, you can re-load the
previously stored files and restore the system to its original
condition.

1. Connect the laptop to the control system using a serial null


modem cable, and launch the WinEEA software.

© Terex-Demag 2010, Jürgen Christmann 73


Service Training 1 Crane update complete (e.g. AC 200-1)

1.16 Re-loading the backup files

2. Click on the tab Program C16x-Flash and then on


[Connect].

Fig. 126: Connection

3. Click on [Program].

Fig. 127: Program

© Terex-Demag 2010, Jürgen Christmann 74


Service Training 1 Crane update complete (e.g. AC 200-1)

1.16 Re-loading the backup files

4. Click on the file to be programmed – in this example the


flash file of crane 33478, and confirm with [Open].

Fig. 128: Hex file selection …

The file is loaded. The checksum is verified and, if correct,


displayed.

Fig. 129: Loading

© Terex-Demag 2010, Jürgen Christmann 75


Service Training 1 Crane update complete (e.g. AC 200-1)

1.16 Re-loading the backup files

5. Click on [OK].

Fig. 130: Load in progress and checksum Flash

6. Click on [Software reset].


7. Switch to the tab C16x-E2prom Read/Write.
8. Click on [Connect].

Fig. 131: C16x E2prom Read/Write

© Terex-Demag 2010, Jürgen Christmann 76


Service Training 1 Crane update complete (e.g. AC 200-1)

1.16 Re-loading the backup files

9. Click on [Write E2-Prom].

Fig. 132: E2Prom write

10. Click on the file to be programmed – in this example the


E2Prom file of crane 33478, and confirm with [Open].

Fig. 133: Select Hex file…

The download commences. The file is loaded. The checksum


is verified and, if correct, displayed.

© Terex-Demag 2010, Jürgen Christmann 77


Service Training 1 Crane update complete (e.g. AC 200-1)

1.17 Programming of the AC55_City steering system

Fig. 134: Load in progress and checksum E2Prom

11. Click on [Software reset].


12. Switch the ignition off and then on again.

 This returns the computer to its original condition which


means that the old errors are also back in the memory.

1.17 Programming of the AC55_City steering system


There are four steering computers installed on the AC55_C.

In one computer are the following:


A4200-1: Backup computer for the main circuit
A4200-2: Functional computer for the main circuit

In the other computer are located the following:


A4201-1, Backup computer for the auxiliary circuit
A4201-2, Functional computer for the auxiliary circuit

The software for the update comprises the following


programs:
For the backup computers: e.g. 018302SR_V0105.HEX
For the functional computers: e.g. 018302FR_V0105.HEX,

© Terex-Demag 2010, Jürgen Christmann 78


Service Training 1 Crane update complete (e.g. AC 200-1)

1.17 Programming of the AC55_City steering system

The abbreviation SR means backup computer and FR means


functional computer.

The parameters for the A4200 or A4201 can be identified


from the name, e.g. 018302_4200_v103_B14.par for the
A4200.

Programming procedure:

1. Uploading the parameters with the software package


WinPCS.
The parameters only have to be loaded into the backup
computers, i.e. the A4200-1 and A4201-1.

 Make sure that you load the correct software in accordance


with the abbreviations SR for back up or FR for functional
computer.

2. Load the software onto the computers in the following


sequence:
SR A4200-1,
FR A4200-2,
SR A4201-1,
FR A4201-2.
3. After the upload, click on [Software Reset].
4. Once the update has been completed, switch the ignition off
and then on again.
All the computers must boot up simultaneously, otherwise
U-errors will occur. During the booting process, the
parameters are copied from the SR backup computers to the
FR functional computers.

 The sequence described above – first the parameters, then


the software – is recommended because otherwise the
parameters are not copied and error messages occur if you
do not switch the ignition off and then on again prior to
parameter upload.

 If something should go wrong during the updating process,


e.g. someone switches the ignition off during the
programming operation, the control system will respond to
this with a U-error. This may result in it no longer being
possible to connect to the computer. If this happens, switch
off the ignition and set the Bootloader DIP switch to On. It
should then be possible to re-establish the connection. Once
the programming operation has been completed, switch the
ignition off and set the DIP switch to Off.

© Terex-Demag 2010, Jürgen Christmann 79


Service Training 1 Crane update complete (e.g. AC 200-1)

1.18 Programming of the AC100/4 steering system

 The emergency hydraulic control system on the AC55_City


functions differently from the usual manner. You cannot
operate the proportional valve with your finger. If you
remove the protective cap from the valve, you can see a
hexagonal socket screw. This screw has a hole (approx. 2
mm). You can operate the spool by inserting a sharp
implement into the hole. Under no circumstances should you
turn the hexagonal socket screw because this changes the
zero position and the preload of the valve.

1.18 Programming of the AC100/4 steering system


For the new generation of steering computers a new project
cranesteering2.ini is needed (see also capture 1.13 Loading
the Mobil Elektronik parameters, Fig. 108). This project
enables the access to both steering computers over only one
interface, e.g. X4200A.

 When loading a new parameter set, pay attention that the


proper Can-Member is chosen in the CANopen-Members
screen. In doubts, take the plug off of one computer. The
address is in the parameter set. For downloading the
parameter code 7101 is needed.

If a new computer has to be programmed, first flash with


WinEEA and then download the parameter.

© Terex-Demag 2010, Jürgen Christmann 80


Service Training 2 Replacing the Digsy compact CPU

2.1 Unpacking the project

2 Replacing the Digsy compact CPU


The replacement CPU is supplied unprogrammed from our
spare parts centre.

2.1 Unpacking the project


1. Load the requisite project(s) from the Dlog (see section 1.2,
Dlog project ).
2. Rename the file ensuring that the suffix is .jar.
3. Click on the file with the right mouse button.
4. In the context menu, select Open with....

Fig. 135: Open with

5. Select WinZip and confirm with [OK].


The Dlog project is opened in the WinZip window.

© Terex-Demag 2010, Jürgen Christmann 81


Service Training 2 Replacing the Digsy compact CPU

2.2 Loading the project

6. Click on the software version being used by the crane – in


this example SPS_Stand2007_10_31.zip – and then click on
[Extract].

Fig. 136: WinZip dialogue

The project is automatically saved in a Config subdirectory.

7. Click on the project with the right mouse button and extract
to the desired directory using WinZip.

Fig. 137: Explorer Config\sps

2.2 Loading the project


1. Load the project in accordance with the as-delivered list or
the last version issued by After Sales (see section 1.6 and
1.7)

 If the control system has never been loaded with the


project, you will need to change the communication
parameters for the first programming operation.

© Terex-Demag 2010, Jürgen Christmann 82


Service Training 2 Replacing the Digsy compact CPU

2.2 Loading the project

2. Launch Prosyd 1131.


3. Open the required project and, in the menu, click on Online
> Communication Parameters.
4. Double-click on the Baud rate 57600 until you see 19200.
5. Confirm with [OK].

Fig. 138: Baud rate 57600

Fig. 139: Baud rate 19200

6. As described in section 1.6 and 1.7, establish the connection


and load the project.

 When the Box A0701 was changed a table transfer need to


be done.

7. On the Dlog modify and save counterweight and rope


reeving arrangement.
Once the update has been completed, the control system will
show one or several of the errors of the type E218 S01 –
E221 S04 described in the section 1.9. This means that
different data are stored on the Dlog as compared to one or
several of the CPUs.

© Terex-Demag 2010, Jürgen Christmann 83


Service Training 2 Replacing the Digsy compact CPU

2.3 Checking the firmware

2.3 Checking the firmware


1. Connect the laptop to the control unit and launch the
program Prosyd 1131 as described in the section 1.3.
2. Click on the Resources tab.

Fig. 140: Checking the firmware

3. Click on the + in front of Global Variables in order to open


the file.
4. Double-click on SYS_VAR (CONSTANT).
The working window shows the firmware versions of the CPU
and I/O cards, in this example relating to an A0701 box of
an AC200-1, version 6.4.7 for the CPU and 6.3.3 for the I/O
cards.

© Terex-Demag 2010, Jürgen Christmann 84


Service Training 2 Replacing the Digsy compact CPU

2.4 Firmware update (if necessary)

CPU 6.4.7

I/O 6.3.3

Fig. 141: Prosyd 1131 firmware

2.4 Firmware update (if necessary)


1. The firmware checked in the previous section needs to be
compared to the as-delivered condition or the last version
reported by After Sales.

 If the control system has a newer firmware version than


indicated in the record, there is no need to change anything.

However, if the control system has an older firmware version


than shown in the record, you must at least update it to the
version in the record. In cases of doubt, always use the
latest firmware version.

In our example, the firmware is to be updated. The


procedure is as described in section 1.5.

 If the origin of a CPU to be replaced is unknown, or an


A0703 is to be reprogrammed as an A0701, before
commencing the programming operation you will need to
delete the retain data.

2. Once Bootloader has been launched and logged in, in the


menu click on Erase >Retain_Data.

© Terex-Demag 2010, Jürgen Christmann 85


Service Training 2 Replacing the Digsy compact CPU

2.5 Loading the crane-specific data

Fig. 142: Retain_Data

The data are erased. This ensures that there are no incorrect
data in the memory.

Fig. 143: Success message

Erasure has been successful.

Now the firmware can be loaded.

2.5 Loading the crane-specific data


As a new CPU has now been installed, the crane-specific
data are no longer available and have to be re-loaded.

1. A0701: Use the Superpin function to activate the Dlog.

© Terex-Demag 2010, Jürgen Christmann 86


Service Training 2 Replacing the Digsy compact CPU

2.5 Loading the crane-specific data

Fig. 144: Dlog crane setup

2. Select all the menu items such as Auslegersystem (Boom


system), Längen (Lengths) and click on .
3. In the Abnahme (Acceptance) menu, set the correction
values to ON and save by clicking on .
4. Quit the Superpin menu.
If a correct length code has been adopted, i.e. the length
code is green, the Quick Menu shows the soft button [KW].

Fig. 145: Quick menu

5. Click on [KW].
The correction values for the derricking cylinder pressure
transmitter are shown.

In order to delete the error E221 S04, you will need to load
the values onto box A0701.

6. In this example, you will need to click on the K80 [500].

© Terex-Demag 2010, Jürgen Christmann 87


Service Training 2 Replacing the Digsy compact CPU

2.5 Loading the crane-specific data

Fig. 146: Correction (K) values

7. Enter the same value, in this example 500, and save by

clicking on .

Fig. 147: Value entry

Error E221 S04 should now have disappeared.

8. In the menu, switch to manual telescope.

© Terex-Demag 2010, Jürgen Christmann 88


Service Training 2 Replacing the Digsy compact CPU

2.5 Loading the crane-specific data

9. Click on to switch to the teach menu.

Fig. 148: Manual telescope menu

10. Set the current telescope configuration and save with


[Teach].

Fig. 149: TeleTeach

The crane should now function properly again.

11. Test the crane, in particular check the radius, load and angle
display.
12. A703: Save all solenoid valve values, including e.g. those of
the slewing gear brake.

© Terex-Demag 2010, Jürgen Christmann 89


Service Training 2 Replacing the Digsy compact CPU

2.5 Loading the crane-specific data

 The operating hours cannot be re-loaded.

13. A0621: (AC60/70 only) Save the values for the clutch.

© Terex-Demag 2010, Jürgen Christmann 90


Service Training 3 Replacing the Dlog

3.1 Loading the operating system and project

3 Replacing the Dlog


The Dlog is supplied unprogrammed by our Spare Parts
Centre. Prior to the update, retrieve the last-saved crane
status data from the Worm Backup or, if possible, back up
the old Dlog project (see section 1.2)

3.1 Loading the operating system and project


If you launch a new, unprogrammed Dlog, the first thing you
see is the Server menu. You can read off the current
operating system from this menu. If an older version of the
operating system is present, this will need to be updated.

1. Update the operating system as described in section 1.8.


The file name of the project must contain the letters OS, e.g.
project_os_mpc_1_9.jar indicates a project whereby the
operating system (os) is MPC, Version 1.9; .jar = Java.

Once the operating system has been loaded, the project can
be immediately transferred from the Worm Backup, or the
saved project can be uploaded from the old Dlog.

 If there are further extensions behind the file name, e.g.


project_AC55_bn1_v2_1-50401.jar_15005_20050906
_095008 you will need to rename the file and write .jar at
the end, for example
project_AC55_bn1_v2_150401_15005_20050906
_095008.jar, as otherwise the project will not be recognised
by the program Uploader 2.5.

3.2 Checking and adapting the crane-specific data


1. Activate the Dlog using the Superpin function.

© Terex-Demag 2010, Jürgen Christmann 91


Service Training 3 Replacing the Dlog

3.2 Checking and adapting the crane-specific data

2. Check the values in the various menus and correct as


necessary.

Fig. 150: Value correction

3. Compare the values under Eigenschaften (Characteristics)


and Optionen (Options) with the as-delivered condition
shown in the record.

 If the data do not agree, check whether there have been


changes to the as-delivered condition of the crane.

For safety reasons, only save if you are sure, that the
values are corresponding with the conditions of the
crane.

© Terex-Demag 2010, Jürgen Christmann 92


Service Training 3 Replacing the Dlog

3.2 Checking and adapting the crane-specific data

4. Click on in order to save the values to the CPU.

Fig. 151: Comparison of characteristics

Fig. 152: Comparison of options

5. To adjust the sensor values, click on Geberwerte (Sensor


Values) > Get SPS in the menu.
This loads the data from the CPU to the Dlog.

© Terex-Demag 2010, Jürgen Christmann 93


Service Training 3 Replacing the Dlog

3.2 Checking and adapting the crane-specific data

6. Click on [save on IPC].

Fig. 153: Adjusting the transmitter values

7. In the Abnahme (Acceptance) menu, activate the correction

values and click on .


8. Quit the Superpin menu.
If a correct Length code is adopted, i.e. the Length code is
green in the Dlog, the crane menu shows the soft button
[KW].

9. Click on [KW Korrektur].

Fig. 154: Quick menu with KW

The correction data of the derricking cylinder pressure


transmitter are shown.

© Terex-Demag 2010, Jürgen Christmann 94


Service Training 3 Replacing the Dlog

3.2 Checking and adapting the crane-specific data

10. Click on [get SPS].

Fig. 155: Loading the correction values

The values are transferred from the CPU to the Dlog.

11. Save by clicking on .


12. Switch off the ignition.
13. Completely switch off the Dlog using the Off Button (MPC)
or the Reset Button (IPC).
14. Switch on the ignition.

 After booting the Dlog, there should be no further error


messages. In particular, the messages

 E218 S01 for the sensor values


E219 S02 for the options
E220 S03 for the settings
E221 S04 for the correction values
must have been rectified following correction of the crane-
specific data on the Dlog and the CPUs.

If one of the errors should nevertheless occur, this indicates


that different data are stored on the Dlog than on one of the
CPUs. In this case, the corresponding data will need to be
modified in accordance with the previously described
procedure.

 If, after rebooting, adjustment and confirmation of the crane


configuration, an overload condition should be shown, you
will need to teach the telescopic system.

© Terex-Demag 2010, Jürgen Christmann 95


Service Training 3 Replacing the Dlog

3.2 Checking and adapting the crane-specific data

15. In the menu, switch to manual telescope.

16. Click on to switch to the teach menu.

Fig. 156: Manual telescope menu

17. Set the current telescope configuration and save with


[Teach].

Fig. 157: TeleTeach

The crane should now function properly again.

18. Test the crane, in particular check the radius, load and angle
display.
19. Once the test has been completed, save the Dlog project
(see section 1.1) and send to Zweibrücken for archiving.

© Terex-Demag 2010, Jürgen Christmann 96


Service Training 3 Replacing the Dlog

3.2 Checking and adapting the crane-specific data

20. If it was necessary to perform a calibration operation, the


corresponding watch lists must also be saved (see section
1.3) and send to Zweibrücken for archiving.
21. Fill in the software record.

© Terex-Demag 2010, Jürgen Christmann 97


Service Training 4 Calibrating the pressure transmitters

4 Calibrating the pressure transmitters

 When replacing a pressure transducer and/or derricking


cylinder, it may be necessary to readjust the empty load
moment at the Dlog. For this, several angle points will need
to be adopted and the empty load moment adapted in each
case rather than teaching-in the zero point of the pressure
transmitter.

1. Set up the crane in accordance with the operating manual


(without any main boom extension), apply a two-fall reeving
arrangement, derrick out to maximum reach and adjust and
adopt the following LK values:

AC 50-1 LK 9
AC 55 LK 38
AC 70 LK 39
AC 80-2 LK 4
AC 100/4 LK 12
AC 100/4L LK 20
AC 100/5 LK 23
AC 120-1 LK 15
AC 140 LK 15
AC 160 LK 15
AC 200-1 LK 18
AC 250-1 LK 18
AC 300/6 LK 26
AC 350/6 LK 26
AC 500-2 LK 32
AC 1000/9 LK 31 / LK 251

© Terex-Demag 2010, Jürgen Christmann 98


Service Training 4 Calibrating the pressure transmitters

2. In the Dlog, activate the Korrektur (Correction) menu


using the Superpin function.

Fig. 158: Crane setup, Diverses > Correction on

3. Save and quit the Superpin menu.


4. Switch to the crane screen.
5. Click on [KW Korrektur].

Fig. 159: Crane screen > KW Korrektur

© Terex-Demag 2010, Jürgen Christmann 99


Service Training 4 Calibrating the pressure transmitters

Fig. 160: Correction values

The correction values are shown in mbar against the


corresponding boom angles, for example 500 mbar as the
correction at an angle of 80 degrees (K80).

6. To retrieve the control system values, click on [Get SPS].


The currently saved values are displayed under K10, K20
etc.

7. Let the hook block down to just above ground level.

 Always move to the angle from above, i.e. from steep to


shallow.

8. Derrick the boom to 80 degrees.


9. Wait until the load display is roughly stable, compare the
LAST (t) value with the actual weight of the hook block, and
correct as necessary.

 Displayed load > Actual load: Reduce correction value.


Displayed load < Actual load: Increase correction value.

Example: The hook block weighs 300 kg, the load display
shows 0.4t. The preset K80 value is 500 mbar (see Fig.
155). In order to reduce the load value displayed, correct
the value in the downward direction, i.e. enter 400, and
save. If the load display has not changed, enter 350, and so
on, until the load display and the actual weight agree.

10. Move to the next boom angle (75 degrees) and repeat the
procedure for this angle.
11. Once all the angles have been covered, perform another
complete derricking cycle and check the values.

© Terex-Demag 2010, Jürgen Christmann 100


Service Training 4 Calibrating the pressure transmitters

12. Save the watch list (see 1.3 Saving the watch lists) and send
it to Wolfram.Kerth@terex.com.

 Special case AC 55:


In the case of the AC55, it can take up to 4 minutes until the
load display is more or less constant. If the correction
feature is active, the actual load is shown in kg (without an
average value) in the window for the maximum load, for
example 80.0 for 800 kg.

The maximum main boom (HA) angle is less than 80


degrees. Nevertheless, the correction value 80 has been
retained.

When calibrating the system, move the boom to the steepest


possible value below the mechanical limit.

In order to determine the correction value, always change


two values simultaneously by the same amount until the
load display shows the correct values – for example K80 and
K75. After derricking down, also change the next smallest
correction value in each case.

Otherwise, proceed as described above.

13. Following completion of the calibration procedure, switch the


ignition off and then on again.
14. Pick up a load and move to various radius and length points,
and check the display readings.
15. Save the watch list (see 1.3 Saving the watch lists) and send
it to Wolfram.Kerth@terex.com.

© Terex-Demag 2010, Jürgen Christmann 101


Service Training 5 Calibrating the sensors

5 Calibrating the sensors

 Once a component such as an angle transmitter, a length


transmitter etc. has been replaced, that transmitter has to be
recalibrated.

1. In the Dlog, activate the Kalibrierung (Calibration) menu


using the Superpin function.

Fig. 161: Crane setup, Diverses > Calibration on

2. Save and exit the Superpin menu.


3. Switch to the crane screen.

© Terex-Demag 2010, Jürgen Christmann 102


Service Training 5 Calibrating the sensors

4. Click on [KA Kalibrierung].

Fig. 162: Crane screen, KA Kalibrierung

5. Using Druckaufnehmer, select the sensor to be calibrated.

Fig. 163: Pressure transmitter calibration

© Terex-Demag 2010, Jürgen Christmann 103


Service Training 5 Calibrating the sensors

Fig. 164: Example of an external length transmitter

6. Completely retract the main boom.


7. Click on [Teach].

Fig. 165: Telescope length Teach function

 If the error message E218 S01 should now be shown, update


the sensor values in the Dlog.

8. In the Dlog, switch to the transmitter values using the


Superpin function.
9. Scroll down and click on [Get SPS].

© Terex-Demag 2010, Jürgen Christmann 104


Service Training 5 Calibrating the sensors

10. Scroll up and click on [save on IPC].

Fig. 166: Get SPS

11. Confirm the security prompt with [OK].


12. Quit the Superpin menu.
13. Switch the ignition off and then on again.
[KA Kalibrierung] and the error E218 S01 are no longer
displayed.

14. Save the watch list sensor values (see 1.3 Saving the watch
lists) and send it to Wolfram.Kerth@terex.com.

© Terex-Demag 2010, Jürgen Christmann 105


Service Training 6 Changing the joystick - ID

6 Changing the joystick - ID


When installing a new joystick, you will need to reprogram its
address. If a joystick is defective, you can perform functions
not available by reprogramming the address of the still
functional joystick.

In this example, a right-hand joystick is to be reprogrammed


as the left-hand joystick.

1. Switch off the ignition and disconnect from the bus the
joystick that is not to be programmed (disconnect bus cable).
2. Switch on the ignition and, in the Dlog, switch to the main
menu.
3. Click on [Joystick].

Fig. 167: Dlog main menu

4. Click on [Setup].

© Terex-Demag 2010, Jürgen Christmann 106


Service Training 6 Changing the joystick - ID

Fig. 168: Joystick dialogue

5. In the Info window, click on [Continue] and then enter the


code 8315.

Fig. 169: Only for Terex-Demag personnel

The soft buttons [R ---> L] and [L ---> R] are used for


changing the address.

6. In our example, click on [R --> L].

Fig. 170: Joystick Setup

7. Switch the ignition off, connect the Bus to the joystick and
switch the ignition on again.
The joystick has now been reprogrammed.

© Terex-Demag 2010, Jürgen Christmann 107


Service Training 6 Changing the joystick - ID

8. To check, click on Diagnose > .


The Joystick window shows your motions on screen.

Fig. 171: Joystick

© Terex-Demag 2010, Jürgen Christmann 108


Service Training 7 Changing a CAN - ID

7.1 Changing the ID, for example pressure transducer

7 Changing a CAN - ID
7.1 Changing the ID, for example pressure transducer
1. In the Dlog main menu click on [CAN?].

Fig. 172: Dlog main menu

2. Click on [Can-ID] and enter a superpin.

Fig. 173: CAN-ID - Superpin

© Terex-Demag 2010, Jürgen Christmann 109


Service Training 7 Changing a CAN - ID

7.2 Reset addressing

The overview of all CAN participants with the associated Node-


ID shows in black font participants who are not addressed.

Fig. 174: Set Node ID

In our Example Druckmesser 1 and Druckmesser 2 are not


addressed.

 Only one participant can be addressed at once because CAN


spare parts of the same type come with the same Node ID.

3. Disconnect one pressure transducer from the CAN-Bus.


4. Click on [(9)Druckmesser 1] or [(10)Druckmesser 2] to
address the connected pressure transducer.
5. Switch off ignition.
6. Connect the disconnected pressure transducer to the CAN-
Bus.
7. Switch on ignition.
8. Repeat this procedure.

7.2 Reset addressing

 If a participant was wrong addressed or an addressed


participant should be inserted at another place, the address of
this participant must be reset.

© Terex-Demag 2010, Jürgen Christmann 110


Service Training 7 Changing a CAN - ID

7.2 Reset addressing

1. Click [Set Default].

Fig. 175: Set Default

2. Click the participant you want to reset.


Font changes from black to grey.

Fig. 176: Reset pressure transducer 1

3. Click on the Dlog in order to exit.


4. Switch off ignition and switch on again.
5. Address the new participant.

© Terex-Demag 2010, Jürgen Christmann 111


Service Training 8 Moki

8.1 Erasing the transmission, ABS and retarder errors

8 Moki
8.1 Erasing the transmission, ABS and retarder errors
1. Launch the software KIBES Runtime by double clicking on the
icon or on KS.bat.

Fig. 177: KIBES Runtime

2. Press any key.

 Using the cursor keys, select an entry and confirm your


selection with [Enter].

3. Select Post Processors.

Fig. 178: Postprocessors

4. Select Online Test.

© Terex-Demag 2010, Jürgen Christmann 112


Service Training 8 Moki

8.1 Erasing the transmission, ABS and retarder errors

Fig. 179: Online test

5. Confirm message Online-Test with [Y] for Yes.

Fig. 180: Online test licence message

6. Click with left mouse button.

Fig. 181: List of contents

7. Using the cursor keys, click on Sheet forward to move the


highlight in the list of contents.
8. Using [Enter], scroll to page 6: fault mem clear.

© Terex-Demag 2010, Jürgen Christmann 113


Service Training 8 Moki

8.1 Erasing the transmission, ABS and retarder errors

9. Select Def and Run and confirm with [Enter].

Fig. 182: fault mem clear

10. Using the cursor keys, move to TB_ALL_ECU and confirm with
[Enter].
The faults in the ABS, retarder and transmission unit are
deleted.

Fig. 183: TB_ALL_ECU ON

© Terex-Demag 2010, Jürgen Christmann 114


Service Training 8 Moki

8.1 Erasing the transmission, ABS and retarder errors

11. Select TB_ALL_ECU using [Enter] in order to remove the


highlighting made at the input.

Fig. 184: TB_ALL_ECU OFF

12. Click on [ESC] twice.

13. Quit the online test by pressing [Y] for Yes.

Fig. 185: Terminate online test

© Terex-Demag 2010, Jürgen Christmann 115


Service Training 8 Moki

8.2 Setting the operating hour counter

14. To reboot the central computer, click on [Y] for Yes.

Fig. 186: Finishing Onlinetest, Reboot CC2

15. Quit KIBES_Runtime.


16. Switch the ignition off and then on again.

8.2 Setting the operating hour counter

 After the MOKI central computer has been replaced, the


operating hour reading has to be reset.

1. Engage the handbrake.


2. Launch the software KIBES Runtime by double clicking on the
icon or KS.bat.
3. Press any key.
4. Select Online Test.
5. Select Config, (normally page 4).

Fig. 187: Config

6. Select Def & Run.


7. Using the cursor keys, move to TB_Call_Special and confirm
with [Enter].

© Terex-Demag 2010, Jürgen Christmann 116


Service Training 8 Moki

8.2 Setting the operating hour counter

The blue line is highlighted.

Fig. 188: TB_Call_Special

8. Click on [ESC].
9. Move the cursor to Sheet Contents and confirm with
[Enter].
10. Move the cursor to Set Zähler, in this example on page 150,
and confirm with [Enter].
11. Select Def & Run.

Fig. 189: Setting the counter

© Terex-Demag 2010, Jürgen Christmann 117


Service Training 8 Moki

8.2 Setting the operating hour counter

Setting the operating


hours, superstructure

Setting the operating


hours, carrier

Setting the operating


hours, superstructure
and carrier

Fig. 190: Example for carrier operating hours

Example: Setting 693 hours for carrier


1. Move the cursor to TB_RESET_UW and click on [Enter].
The operating hours shown by the Moki are set to zero.

2. Move the cursor to the 0 (inp. Dig1) below TB_UW_Digit_6-3 ,


confirm with [Enter] and enter 3.
3. Move the cursor to the 0 (inp. Dig2) below TB_UW_Digit_6-3,
confirm with [Enter] and enter 9.
4. Move the cursor to the 0 (inp. Dig3) below TB_UW_Digit_6-3,
confirm with [Enter] and enter 6.
5. Move the cursor to TB_UW_Digit_1 and confirm with [Enter].
6. Move the cursor to TB_SET_UW and confirm with [Enter].
The Moki shows 3 operating hours.

7. Switch off TB_UW_Digit_1 and TB_SET_UW with [Enter].


8. Move the cursor to TB_UW_Digit_2 and confirm with [Enter].
9. Move the cursor to TB_SET_UW and confirm with [Enter].
The Moki now shows 93 operating hours.

10. Switch off TB_UW_Digit_2 and TB_SET_UW with [Enter].


11. Move the cursor to TB_UW_Digit_3 and confirm with [Enter].
12. Move the cursor to TB_SET_UW and confirm with [Enter].
The Moki now shows 693 operating hours.

13. Switch off TB_UW_Digit_3 and TB_SET_UW with [Enter].


14. Click on [ESC].
15. Return to the Config page via the list of contents.
16. Switch off TB_CALL_SPEZIAL with Def & Run and [Enter].
17. Quit the program by clicking on [ESC] several times and
confirm all windows with [Yes].
18. Disconnect from the system.
19. Switch the ignition off and then on again.

© Terex-Demag 2010, Jürgen Christmann 118


Service Training 9 Programming of AC 50-1, AC 80-2 and AC 100/4

9.1 PDM Download (Saving) of Projects

9 Programming of AC 50-1, AC 80-2 and


AC 100/4
9.1 PDM Download (Saving) of Projects
In order to connect the laptop with the PDM, the PDM must
first be started in the server mode.

1. Select the symbol in the main menu.


2. Select the Start symbol in the following menu under server.

Fig. 191: Menu PDM

3. Enter the password and press the [F6] key.


The PDM switches to server mode.

Fig. 192: Server mode

4. Press the [F2] key to start the DHCP server.

© Terex-Demag 2010, Jürgen Christmann 119


Service Training 9 Programming of AC 50-1, AC 80-2 and AC 100/4

9.1 PDM Download (Saving) of Projects

5. Wait for the message serverPDM: waiting for connection.

Fig. 193: Connection not possible

The mask automatically changes:

Fig. 194: Waiting for connection

6. Using a cross over network cable, connect the laptop with the
PDM (interface on the dashboard).
7. Start the program Uploader 2.5.

© Terex-Demag 2010, Jürgen Christmann 120


Service Training 9 Programming of AC 50-1, AC 80-2 and AC 100/4

9.1 PDM Download (Saving) of Projects

8. Press the [Connect] key.

Fig. 195: Uploader, connect

9. Enter the password.

Fig. 196: Enter password

10. Click on [OK].


The laptop connects to the PDM.

© Terex-Demag 2010, Jürgen Christmann 121


Service Training 9 Programming of AC 50-1, AC 80-2 and AC 100/4

9.1 PDM Download (Saving) of Projects

11. In order to save the project on the PDM, press

Fig. 197: Uploader, save

12. In the following window, select the correct folder, in this case
D:\Backup AC50-1\PDM.

Fig. 198: Save Directory

13. Click on [Save Directory].


The project is loaded onto the laptop. The message indicates
that the download was successful.

© Terex-Demag 2010, Jürgen Christmann 122


Service Training 9 Programming of AC 50-1, AC 80-2 and AC 100/4

9.2 PDM Upload (Updating) of Projects

Fig. 199: Confirmation of successful download

14. Confirm with [OK].


15. Disconnect from the crane with [Disconnect].
16. Remove the network cable.
17. Finish the Uploader 2.5 program.
The PDM starts again.

 There is now a file listed as e.g. pdm.tar_20070601_140450


in the folder Backup AC50-1\PDM\, carrying the date
(yyyymmdd) and the time (hhmmss) of saving. In order to be
able to load this file onto the PDM again, the extension .tar
must be at the end of the file name, i.e.
pdm_20070601_140450.tar. Only then does the Uploader
recognise the file.

If you want to load the backup file again in the PDM,


you have to rename it.

9.2 PDM Upload (Updating) of Projects

 The software is available in 2 different versions:

pdm_default_AC80_001_002.tar a default project for any


AC80-2 which does not yet have any crane-specific data
saved.

pdm_update_AC80_001_002.tar an update project for a


crane which has been approved and set, i.e. the crane-specific
data are not overwritten.

 The server has to be restarted!

1. Select the symbol in the main menu.

© Terex-Demag 2010, Jürgen Christmann 123


Service Training 9 Programming of AC 50-1, AC 80-2 and AC 100/4

9.2 PDM Upload (Updating) of Projects

2. Select the [Start] symbol in the following menu under server.

Fig. 200: Menu PDM

3. Enter the password and press the [F6] key.


4. Press [Start DHCP].

Fig. 201: Server mode

The PDM switches to server mode.

© Terex-Demag 2010, Jürgen Christmann 124


Service Training 9 Programming of AC 50-1, AC 80-2 and AC 100/4

9.2 PDM Upload (Updating) of Projects

5. Wait for the message serverPDM: waiting for connection.

Fig. 202: Connection not possible

The mask automatically changes:

Fig. 203: Waiting for connection

6. Using a cross over network cable, connect the laptop with the
PDM (interface on the dashboard).
7. Start the program Uploader 2.5.

© Terex-Demag 2010, Jürgen Christmann 125


Service Training 9 Programming of AC 50-1, AC 80-2 and AC 100/4

9.2 PDM Upload (Updating) of Projects

8. Press the [Connect] key.

Fig. 204: Uploader connect

9. Enter the password.

Fig. 205: Enter Password

10. Click on [OK].


The laptop connects to the PDM.

© Terex-Demag 2010, Jürgen Christmann 126


Service Training 9 Programming of AC 50-1, AC 80-2 and AC 100/4

9.2 PDM Upload (Updating) of Projects

11. In order to load the update project onto the PDM, press

Fig. 206: Uploader load

A window is opened in which the correct project can be


selected.

Fig. 207: Choose File

 So that the crane-specific files are not overwritten, you must


click on the project pdm_update_AC80_001_002.tar.

12. Select a file and click [Choose File].


The upload starts.

© Terex-Demag 2010, Jürgen Christmann 127


Service Training 9 Programming of AC 50-1, AC 80-2 and AC 100/4

9.3 IFM Download of Firmware and Application

A message indicates that the upload was successful.

Fig. 208: Confirmation of successful upload

13. Confirm with [OK].


14. Disconnect from the crane with [Disconnect].
15. Remove the network cables.
16. Finish the Uploader 2.5 program.
The PDM starts again.

 A backup is automatically created during an upload and filed


under the same name in the index; the name is extended by
date and time. Using this file it is possible to return the PDM
back to its original state at any time. If the file is to be loaded
into the PDM, .tar must be at the end of the name in order for
the uploader to recognise this file.

If you want to load the backup-file again in the PDM,


you have to rename it.

9.3 IFM Download of Firmware and Application


1. Switch ignition off.
2. Connect the laptop with the control system using a serial
cable. The interface is on the dashboard.
3. Press switch [S781] (ECU).
4. Switch ignition on.
5. Start the download tool of IFM (from version 5.10.03).
6. In order to set the new baud rate 57600, click [Interface
parameter].

Fig. 209: IFM Download tool

Ex works, there is no firmware in the control system and the


baud rate is set to 9600.

© Terex-Demag 2010, Jürgen Christmann 128


Service Training 9 Programming of AC 50-1, AC 80-2 and AC 100/4

9.3 IFM Download of Firmware and Application

7. Click on 57600 in this case and confirm with [Set PLC].

Fig. 210: Interface RS232

8. Click on [Get Identity] in order to check whether the


connection to the control system can be made.

Fig. 211: Checking connection

You have the current status displayed.

9. Exit with [OK].

Fig. 212: Announcement Call sign

© Terex-Demag 2010, Jürgen Christmann 129


Service Training 9 Programming of AC 50-1, AC 80-2 and AC 100/4

9.3 IFM Download of Firmware and Application

10. Click [Open file] in order to load the desired firmware.

Fig. 213: IFM Download

 Because the firmware delete the application, the order is


important: First load the firmware then the application!

11. Select the correct file, in this case ifm_CR0020_V040000.H86.


12. Confirm with [Open].

Fig. 214: Open firmware

13. Click on [Download].

Fig. 215: IFM Download firmware

The firmware is loaded.

© Terex-Demag 2010, Jürgen Christmann 130


Service Training 9 Programming of AC 50-1, AC 80-2 and AC 100/4

9.3 IFM Download of Firmware and Application

Fig. 216: IFM Download progress announcement

Download successful is displayed.

14. Click [OK].

Fig. 217: Download successful

15. Repeat the same procedure for the application, beginning with
Step 8.
In this case, the file Cr0020_AC50_80_V1002.H86, for
example, must be selected.

Fig. 218: Open application

The remainder of the procedure is identical.

© Terex-Demag 2010, Jürgen Christmann 131


Service Training 9 Programming of AC 50-1, AC 80-2 and AC 100/4

9.3 IFM Download of Firmware and Application

16. After loading click [RUN] to start the control system

Fig. 219: Starting the control system

17. Confirm with [OK].

Fig. 220: Announcement after the start

18. Click [Get Identity] to check whether the control system is


running properly.

Fig. 221: Get Identity

19. Confirm with [OK].

Fig. 222: Announcement Call sign

20. Exit the program with [Exit].


21. Switch ignition off.
22. Switch off [S781] (ECU) again.

© Terex-Demag 2010, Jürgen Christmann 132


Service Training 9 Programming of AC 50-1, AC 80-2 and AC 100/4

9.4 Sensor Calibration

 If you try to load the application without firmware, the


following message appears:

Fig. 223: Error message without firmware

After confirmation with [OK], the following message appears:

Fig. 224: Error message Download

9.4 Sensor Calibration

 The symbol service must be enabled. If not, you have


to use in the system menu the Demag-Pin (Super-Pin) or
release it permanently in the authorisation menu.

1. Call up the service menu using the Service button from


the crane mask.
2. Enter the calibration menu using the Sensor calibration button
.

Fig. 225: Sensor calibration

Basic case angle sensor:


Is only taught in the 0° position. The sensor must be slewed

© Terex-Demag 2010, Jürgen Christmann 133


Service Training 9 Programming of AC 50-1, AC 80-2 and AC 100/4

9.5 Load Correction

mechanically at the front stop (to the right), so that negative


angles can also be displayed.

Length transducers tele 1 and 2 (AC80-2: tele 3 in


addition):
Are taught when completely retracted (LK 1) and when
completely extended (AC 50-1: LK7, AC80-2: LK18).

Slew ring sensor:


Is taught in the 180° position (pinned to the front).

Length transducer hydraulic MBE:


(Not realised)

9.5 Load Correction

 Load correction works in the same way as all newer IC-


1 cranes by running through the luffing cylinder identification
line from 80° to 10°.

The calibration length code is


AC 50-1: 0-54-54-54 (LK9)
AC 80-2: 0-34-34-34-34 (LK4)

A new characteristic of this crane is the fact that the angle


between the individual sections can be set.

Using the angle button , you enter the setting menu for
the differential angle between the individual sections.

This setting possibility should not be changed. It serves only


as a correction method in case there is a large change in the
boom angle between the sections.

9.6 AC 50-1 / AC 80-2 PWM Menu


1. Enter the PWM menu using the PWM parameters button

.
In this menu, the characteristic lines for the proportional
valves and the slewing gear brake are set. The only value that
should be adjusted is Y2 (entry point of the movement and /
or brake closed).

© Terex-Demag 2010, Jürgen Christmann 134


Service Training 9 Programming of AC 50-1, AC 80-2 and AC 100/4

9.7 AC100/4 position speed of the telescope

Fig. 226: Pulse Width Modulation

2. In order to determine the correct current value, press [F2] for

the Set button


3. Change the current value (yellow display in the figure) using
the adjusting knob or the arrow keys for quick changes until
you have found the best value.

 The slewing gear must be controlled using the maximum


joystick movement in order to set the pilot control pressure
and the slewing gear reduction must be fully open. The
current must be reduced during the setting procedure to avoid
hysteresis effects, i.e. the current (or the slewing movement)
must be reduced until the slewing gear almost comes to a
standstill.

In contrast to other machines, a minimum movement must


still be permitted with Y2. You must also drive against the
brake until the movement almost stops, in order to set the
optimum braking point.

4. Once the optimum point has been found, press [F2] for Set
again.
5. Enter Y2.
6. In order to save the current values, turn the adjusting knob
up to the Exit key , press once.

7. Confirm with Save .


The parameters are then written in a parameter file. Driver-
specific settings have no function in this case.

9.7 AC100/4 position speed of the telescope


If you want to set speed for tele extend, than put main boom
in a steep position, choose LK2 and extend telescope 1
approx. half a meter.

© Terex-Demag 2010, Jürgen Christmann 135


Service Training 9 Programming of AC 50-1, AC 80-2 and AC 100/4

9.7 AC100/4 position speed of the telescope

If you want to set speed for tele retract, than put main boom
in a flat position.

While adjusting, the telescope is moving, so lower the


hook block accordingly.

1. Using superpin, change to the crane-setup screen. Switch on


the PWM Parameter and push the save button.

Fig. 227: PWM Parameter on

© Terex-Demag 2010, Jürgen Christmann 136


Service Training 9 Programming of AC 50-1, AC 80-2 and AC 100/4

9.7 AC100/4 position speed of the telescope

2. Change to the main menu and push the button for parameter

settings Service > .

Fig. 228: Service > Parameter settings

3. Push .

Fig. 229: Parameter settings

© Terex-Demag 2010, Jürgen Christmann 137


Service Training 9 Programming of AC 50-1, AC 80-2 and AC 100/4

9.7 AC100/4 position speed of the telescope

4. Push Y8111.

Fig. 230: Y8111

5. Change the screen to vTele extend.


6. To set the speed of 10 mm/s, push [SET].

Fig. 231: SET v Tele extend

7. Push the dead man switch and move the joystick tele extend.

© Terex-Demag 2010, Jürgen Christmann 138


Service Training 9 Programming of AC 50-1, AC 80-2 and AC 100/4

9.7 AC100/4 position speed of the telescope

8. Observe the actual speed in the right screen v SVE(mm/s).

Fig. 232: Tele speed

 If pushing the double arrow up, the value of the mA will be


increased in big steps, if turning the knob the mA value will be
increased in small steps.

9. Use the double arrow and / or the turning knob till the
telescope moves a little faster then 10 mm/s.
10. Decrease the speed to 10 mm/s using the turning knob.

© Terex-Demag 2010, Jürgen Christmann 139


Service Training 9 Programming of AC 50-1, AC 80-2 and AC 100/4

9.7 AC100/4 position speed of the telescope

11. Enter the value over the set button, displayed at 10 mm/s,
into the “v 10 mm/s” field.

Fig. 233: Set value

12. Repeat the same operation for 20 mm/s and tele retract if
necessary.

© Terex-Demag 2010, Jürgen Christmann 140


Service Training 10 Programming the central computer and the Moki AC100/4

10.1 Connecting the laptop to the crane

10 Programming the central computer and


the Moki AC100/4
10.1 Connecting the laptop to the crane
1. Connect the laptop using an ISO/SAE interface cable plugged
into diagnostics socket X0817 (Central electrics cubicle, carrier
cabin)
2. Switch on ignition.
3. Insert USB dongle.
4. Launch the logiCAD program.

10.2 Uploading the software onto the central computer


1. Click on and mark Open project and then click on [Next >].

Fig. 234: logiCAD Project Wizard (Open project)

© Terex-Demag 2010, Jürgen Christmann 141


Service Training 10 Programming the central computer and the Moki AC100/4

10.2 Uploading the software onto the central computer

2. Click on [ … ] to open Select project dialogue.

Fig. 235: logiCAD Project Wizard (Project)

3. Select the correct directory (in this example


D:\a_Produkte\AC100-4\Software\UW\ZR32) and mark the
current/applicable project (in this example P10000_v1.02).
Then click on [OK] to open.

Fig. 236: Select project dialogue

© Terex-Demag 2010, Jürgen Christmann 142


Service Training 10 Programming the central computer and the Moki AC100/4

10.2 Uploading the software onto the central computer

4. Click on [Finish].

Fig. 237: logiCAD Project Wizard (Finish)

5. Click on the + in front of Configuration.


6. Right-click on ZR32-A to open the context menu.
7. Click on Download to commence programming.

Fig. 238: Start download

© Terex-Demag 2010, Jürgen Christmann 143


Service Training 10 Programming the central computer and the Moki AC100/4

10.3 Uploading parameter set onto ZR32

8. Confirm message Download successfully finished! by clicking


on [OK].

Fig. 239: Download successfully finished!

10.3 Uploading parameter set onto ZR32


1. Right-click on ZR32-A to open the context menu.
2. Click on Configuration-Manager to open a new window.

Fig. 240: Open Configuration-Manager

© Terex-Demag 2010, Jürgen Christmann 144


Service Training 10 Programming the central computer and the Moki AC100/4

10.3 Uploading parameter set onto ZR32

3. Click to select Target > Parameter Sets.

Fig. 241: Open Target System Parameter Sets

The Target System Parameter Sets dialogue is opened.

4. If necessary, click on [ >> ] all languages in the Language to


Generate text field and transfer all parameter sets to the
Parameter Set to Generate text field.
5. Click on [Download].

Fig. 242: Download target system parameter sets

© Terex-Demag 2010, Jürgen Christmann 145


Service Training 10 Programming the central computer and the Moki AC100/4

10.4 Uploading the EEPROM parameter sets

10.4 Uploading the EEPROM parameter sets


1. Click to select Target > EEPROM.

Fig. 243: Open EEPROM Target System Parameter Sets

The EEPROM Target System Parameter Sets is opened.

2. If necessary, click on [ >> ] all parameter sets and transfer


to the EEPROM Parameter Set to Generate text field.
3. Click on [Download].

Fig. 244: Download EEPROM target system parameter sets

4. Close Configuration-Manager.

10.5 Parameter editor


1. Launch the parameter editor 32-bit by double clicking on the
icon.

Fig. 245: Software icons

© Terex-Demag 2010, Jürgen Christmann 146


Service Training 10 Programming the central computer and the Moki AC100/4

10.5 Parameter editor

The program opens the following screen:

Fig. 246: Starting screen, Parameter Editor 32bit

2. Click on File > Load project.

Fig. 247: Load project

3. Select the correct project – in this example P1000_v0100.ZIP,


and load with [Open].

© Terex-Demag 2010, Jürgen Christmann 147


Service Training 10 Programming the central computer and the Moki AC100/4

10.5 Parameter editor

Fig. 248: Parametereditor with project

4. Click on Communication> Load application and


parameter.

Fig. 249: Load application and parameter

5. Consider the prompt and monitor the download process.

Fig. 250: Do not cut off power

© Terex-Demag 2010, Jürgen Christmann 148


Service Training 10 Programming the central computer and the Moki AC100/4

10.5 Parameter editor

Fig. 251: Download in progress

6. In the following dialogue, select all devices by clicking on the


chevron.

Fig. 252: Select devices

7. Confirm the device selection with [OK].


8. Click on File > Quit in order to exit the program.
9. Disconnect the laptop from the interface.
10. Switch the ignition off and then on again.

© Terex-Demag 2010, Jürgen Christmann 149


Service Training 11 Programming of the MOBA emergency control

11 Programming of the MOBA emergency


control
1. Connect the programming lead, which is attached to the cable
for the emergency control system, to the serial interface of
the notebook.

Fig. 253: Programming lead attached to the cable for the emergency
control system

2. In Explorer, launch the application MCan2Flash.exe or double

click on the link on the desktop.

Fig. 254: MCan2Flash launch

© Terex-Demag 2010, Jürgen Christmann 150


Service Training 11 Programming of the MOBA emergency control

3. Click on Connect in order to create the connection to the


control system.

Fig. 255: Connect

4. Note the transmission parameters for the serial interface.

Fig. 256: Transmission parameters

5. Click on Detect modules in order to establish


communication with the emergency control system and to
determine the version of the installed software.

Fig. 257: Detect modules

Once the connection has been established and is stable, the


status line will show .

© Terex-Demag 2010, Jürgen Christmann 151


Service Training 11 Programming of the MOBA emergency control

If the connection has failed, MOBA CAN2Flash will show the


following message:

Fig. 258: Failed connection

 This may indicate that the lead has not been plugged in
properly or is defective.
Caution: The serial download channel only uses the Rx, Tx and
Ground conductors, Pins 2, 3 and 5 on the 9-pin SUB-D
connector.

Once the control system has been detected, module 34 shows


the information relating to the operating system and module
35 shows the information relating to the application (PLC
program).

Fig. 259: Operating system and application recognised

© Terex-Demag 2010, Jürgen Christmann 152


Service Training 11 Programming of the MOBA emergency control

If no application has yet been uploaded, the following


message appears:

Fig. 260: No application

6. To upload the application, click on Module 35 in order to select


the destination for program transfer.

Fig. 261: Program transfer destination

7. Click on the Application menu in order to select the HEX file of


the PLC program to be uploaded.
8. Click on the Option submenu.

Fig. 262: Application > Option

© Terex-Demag 2010, Jürgen Christmann 153


Service Training 11 Programming of the MOBA emergency control

9. In the Options window, click on in order to select the


directory and the file for uploading.

Fig. 263: Find and select file

10. Open the files to be uploaded.

Fig. 264: Open file

11. Click on program button in order to initiate the program


transfer operation.

Fig. 265: Initiate program transfer.

The progress bar shows the rate at which the application (HEX
file) is being transferred.

© Terex-Demag 2010, Jürgen Christmann 154


Service Training 11 Programming of the MOBA emergency control

Fig. 266: Progress bar

Once the application has been successfully transferred, the


MOBA CAN2Flash shows the following message:

Fig. 267: Application after transfer

12. Click on the Module menu.


13. Click on the submenu Reset module.

Fig. 268: Reset module

The previously programmed module (in this case Module 35)


is reset and the power supply to the PLC is briefly
disconnected and then re-connected.

The application launches. The word tYPE appears on the


display of the hand-held emergency control unit and the
illumination flashes.

14. In order to check which software version is on the PLC, set


operating mode 0 at the emergency control operating unit.

© Terex-Demag 2010, Jürgen Christmann 155


Service Training 11 Programming of the MOBA emergency control

15. Simultaneously depress the pushbuttons [Enable] and


[Pressure indication] (bottom left pushbutton 123).

Fig. 269: MOBA control (detail)

The current software version of the application is then


displayed.

© Terex-Demag 2010, Jürgen Christmann 156


Service Training 12 Software-Update MTC

12 Software-Update MTC

 The crane ignition is switched off.

1. Press and hold down [Enter] on MTC.

Fig. 270: MTC

2. Switch on ignition on superstructure and hold down [Enter]


on MTC, until in the user field the LED-1 is shining red.
The server is starting.

3. Wait for 1 minute till the server is ready.


4. Using a crossover network cable, connect the laptop to the
programming interface RJ45
5. Launch the program Uploader 2.5.

© Terex-Demag 2010, Jürgen Christmann 157


Service Training 12 Software-Update MTC

6. Click on [Connect].

Fig. 271: IC-1 Uploader 2.5

7. Enter password and confirm with [OK]

Fig. 272: Password request

The laptop connects to the MTC.

Fig. 273: IC-1 Uploader 2.5 connected with MTC

© Terex-Demag 2010, Jürgen Christmann 158


Service Training 12 Software-Update MTC

8. In order to load the new project onto the MTC, click


(from the laptop to the crane).
This opens the dialogue Choose File enabling you to select the
correct project.

Fig. 274: Choose File

9. Highlight the project, in this example


mtc_update_AC300_6_001_050.tar.
10. Commence the upload by activating [Choose File].
If the Upload is done, you see the message Transfer 100%

Fig. 275: Upload done

11. Click on [Disconnect] to disconnect the laptop from the


crane.
12. Remove the network cable.
13. Quit Uploader 2.5.
14. Switch off ignition and switch on again.

© Terex-Demag 2010, Jürgen Christmann 159


Service Training 13 Table of Illustrations

13 Table of Illustrations
Fig. 1: List of inputs/outputs ............................................... 7

Fig. 2: System .................................................................. 8

Fig. 3: IC-1 Uploader 2.5 ................................................... 9

Fig. 4: Password prompt .................................................... 9

Fig. 5: IC-1 Uploader 2.5 connected....................................10

Fig. 6: Save directory .......................................................10

Fig. 7: Open with .............................................................12

Fig. 8: WinZip dialogue .....................................................12

Fig. 9: Open project .........................................................13

Fig. 10: Password for User Group .......................................13

Fig. 11: Project AC200_A0701_LMB_V30001........................14

Fig. 12: Online > Login .....................................................14

Fig. 13: New program load security prompt .........................15

Fig. 14: Status = ONLINE RUN ...........................................15

Fig. 15: Resources tab ......................................................16

Fig. 16: Watch and Receiptmanager, sensor values ...............16

Fig. 17: Context menu ......................................................17

Fig. 18: Data record read security prompt ...........................17

Fig. 19: Identical values in Watch- and Receipt Manager........17

Fig. 20: Save Watch List ...................................................18

Fig. 21: Save as...............................................................18

Fig. 22: Checking the firmware ..........................................19

Fig. 23: Firmware.............................................................19

Fig. 24: Licence number request ........................................20

Fig. 25: InterControlBootloader ..........................................21

Fig. 26: Reset device ........................................................21

Fig. 27: Loading Bootloader ...............................................22

© Terex-Demag 2010, Jürgen Christmann 160


Service Training 13 Table of Illustrations

Fig. 28: Bootloader Online .................................................22

Fig. 29: Download > Firmware ...........................................23

Fig. 30: Select firmware ....................................................24

Fig. 31: Downloading firmware...........................................24

Fig. 32: Download successful .............................................25

Fig. 33: File > Open… .......................................................25

Fig. 34: Open project........................................................26

Fig. 35: Password for User Group .......................................26

Fig. 36: Project AC200_A0701_LMB_V30001........................27

Fig. 37: Online > Login .....................................................27

Fig. 38: Security prompt indicating program change..............28

Fig. 39: Load in progress...................................................28

Fig. 40: Status indicator....................................................28

Fig. 41: Project run ..........................................................28

Fig. 42: Status bar: Project running ....................................29

Fig. 43: Logging off/on .....................................................29

Fig. 44: Error message .....................................................29

Fig. 45: Message and prompt: Download the new program? ...29

Fig. 46: Resources ...........................................................30

Fig. 47: Checking the watch lists ........................................31

Fig. 48: Context menu ......................................................31

Fig. 49: Enter Name .........................................................32

Fig. 50: Comparison of watch lists ......................................32

Fig. 51: Context menu: Write Receipts ................................32

Fig. 52: File > Open… .......................................................33

Fig. 53: Open project........................................................33

Fig. 54: Password for User Group .......................................34

Fig. 55: Online > Login .....................................................34

Fig. 56: Security prompt: Program has changed ...................35

© Terex-Demag 2010, Jürgen Christmann 161


Service Training 13 Table of Illustrations

Fig. 57: Load in progress...................................................35

Fig. 58: Online > Download Datafile....................................36

Fig. 59: Open data file ......................................................36

Fig. 60: Online > Run .......................................................37

Fig. 61: Logging off and on................................................37

Fig. 62: System ...............................................................38

Fig. 63: IC-1 Uploader 2.5.................................................39

Fig. 64: Password request .................................................39

Fig. 65: IC-1 Uploader 2.5 connected ..................................40

Fig. 66: Choose file ..........................................................40

Fig. 67: Upload finished successfully ...................................41

Fig. 68: Readout of the Dlog software versions .....................42

Fig. 69: System ...............................................................44

Fig. 70: IC-1 Uploader 2.5.................................................45

Fig. 71: Password request .................................................45

Fig. 72: Config:sps ...........................................................46

Fig. 73: Choose File..........................................................46

Fig. 74: File creation finished successfully ............................47

Fig. 75: Config:sps loaded .................................................47

Fig. 76: KIBES Runtime ....................................................48

Fig. 77: KIBES postprocessors ...........................................49

Fig. 78: KIBES communication ...........................................49

Fig. 79: KIBES load PLC program........................................50

Fig. 80: Load in progress, PLC program to central computer ...50

Fig. 81: Online test...........................................................51

Fig. 82: Licence message, online test ..................................51

Fig. 83: Continue with left click ..........................................51

Fig. 84: Selection Config Gerätetyp.....................................52

Fig. 85: Selecting the crane type ........................................52

© Terex-Demag 2010, Jürgen Christmann 162


Service Training 13 Table of Illustrations

Fig. 86: Selection check ....................................................53

Fig. 87: Entry highlight cancelled........................................53

Fig. 88: Software icons .....................................................54

Fig. 89: Starting screen, Parameter Editor 32bit ...................54

Fig. 90: Load project ........................................................54

Fig. 91: Load project ........................................................55

Fig. 92: Parameter Editor with project .................................55

Fig. 93: Speed adaptation .................................................56

Fig. 94: Load application and parameter ..............................56

Fig. 95: Do not cut off power .............................................57

Fig. 96: Download in progress............................................57

Fig. 97: Select devices ......................................................57

Fig. 98: WinEEA connection ...............................................59

Fig. 99: Read Flash ..........................................................59

Fig. 100: Save flash .........................................................60

Fig. 101: Flash read in progress .........................................61

Fig. 102: Checksum verification .........................................61

Fig. 103: E2Prom Read/Write .............................................62

Fig. 104: Read E2Prom .....................................................62

Fig. 105: E2Prom save ......................................................63

Fig. 106: E2Prom read in progress......................................63

Fig. 107: Checksum..........................................................64

Fig. 108: Project selection .................................................64

Fig. 109: Choose Project dialogue.......................................65

Fig. 110: Edit parameters..................................................65

Fig. 111: Parameter dialogue .............................................66

Fig. 112: Select file ..........................................................66

Fig. 113: Parameter values................................................67

Fig. 114: Security prompt..................................................67

© Terex-Demag 2010, Jürgen Christmann 163


Service Training 13 Table of Illustrations

Fig. 115: Parameter Download ...........................................67

Fig. 116: WinEEA connection .............................................68

Fig. 117: WinEEA programming..........................................69

Fig. 118: Select Hex-file… .................................................69

Fig. 119: Programming flash…............................................70

Fig. 120: Flash programmed ..............................................70

Fig. 121: Choose File ........................................................71

Fig. 122: WinEEA Pause OK ...............................................71

Fig. 123: Erase Flash ........................................................72

Fig. 124: Programming Flash .............................................72

Fig. 125: Executed Action..................................................73

Fig. 126: Connection ........................................................74

Fig. 127: Program ............................................................74

Fig. 128: Hex file selection … .............................................75

Fig. 129: Loading .............................................................75

Fig. 130: Load in progress and checksum Flash ....................76

Fig. 131: C16x E2prom Read/Write.....................................76

Fig. 132: E2Prom write .....................................................77

Fig. 133: Select Hex file…..................................................77

Fig. 134: Load in progress and checksum E2Prom.................78

Fig. 135: Open with..........................................................81

Fig. 136: WinZip dialogue..................................................82

Fig. 137: Explorer Config\sps .............................................82

Fig. 138: Baud rate 57600.................................................83

Fig. 139: Baud rate 19200.................................................83

Fig. 140: Checking the firmware.........................................84

Fig. 141: Prosyd 1131 firmware .........................................85

Fig. 142: Retain_Data.......................................................86

Fig. 143: Success message................................................86

© Terex-Demag 2010, Jürgen Christmann 164


Service Training 13 Table of Illustrations

Fig. 144: Dlog crane setup ................................................87

Fig. 145: Quick menu .......................................................87

Fig. 146: Correction (K) values ..........................................88

Fig. 147: Value entry ........................................................88

Fig. 148: Manual telescope menu .......................................89

Fig. 149: TeleTeach ..........................................................89

Fig. 150: Value correction .................................................92

Fig. 151: Comparison of characteristics ...............................93

Fig. 152: Comparison of options .........................................93

Fig. 153: Adjusting the transmitter values ...........................94

Fig. 154: Quick menu with KW ...........................................94

Fig. 155: Loading the correction values ...............................95

Fig. 156: Manual telescope menu .......................................96

Fig. 157: TeleTeach ..........................................................96

Fig. 158: Crane setup, Diverses > Correction on...................99

Fig. 159: Crane screen > KW Korrektur ...............................99

Fig. 160: Correction values .............................................. 100

Fig. 161: Crane setup, Diverses > Calibration on ................ 102

Fig. 162: Crane screen, KA Kalibrierung ............................ 103

Fig. 163: Pressure transmitter calibration .......................... 103

Fig. 164: Example of an external length transmitter ............104

Fig. 165: Telescope length Teach function.......................... 104

Fig. 166: Get SPS...........................................................105

Fig. 167: Dlog main menu ...............................................106

Fig. 168: Joystick dialogue .............................................. 107

Fig. 169: Only for Terex-Demag personnel......................... 107

Fig. 170: Joystick Setup ..................................................107

Fig. 171: Joystick ........................................................... 108

Fig. 172: Dlog main menu ...............................................109

© Terex-Demag 2010, Jürgen Christmann 165


Service Training 13 Table of Illustrations

Fig. 173: CAN-ID - Superpin ............................................109

Fig. 174: Set Node ID .....................................................110

Fig. 175: Set Default ......................................................111

Fig. 176: Reset pressure transducer 1 ...............................111

Fig. 177: KIBES Runtime.................................................112

Fig. 178: Postprocessors .................................................112

Fig. 179: Online test ....................................................... 113

Fig. 180: Online test licence message ...............................113

Fig. 181: List of contents.................................................113

Fig. 182: fault mem clear ................................................114

Fig. 183: TB_ALL_ECU ON............................................ 114

Fig. 184: TB_ALL_ECU OFF............................................115

Fig. 185: Terminate online test ........................................ 115

Fig. 186: Finishing Onlinetest, Reboot CC2......................... 116

Fig. 187: Config .............................................................116

Fig. 188: TB_Call_Special ................................................117

Fig. 189: Setting the counter ........................................... 117

Fig. 190: Example for carrier operating hours..................... 118

Fig. 191: Menu PDM .......................................................119

Fig. 192: Server mode ....................................................119

Fig. 193: Connection not possible .....................................120

Fig. 194: Waiting for connection ....................................... 120

Fig. 195: Uploader, connect .............................................121

Fig. 196: Enter password ................................................ 121

Fig. 197: Uploader, save .................................................122

Fig. 198: Save Directory .................................................122

Fig. 199: Confirmation of successful download.................... 123

Fig. 200: Menu PDM .......................................................124

Fig. 201: Server mode ....................................................124

© Terex-Demag 2010, Jürgen Christmann 166


Service Training 13 Table of Illustrations

Fig. 202: Connection not possible .....................................125

Fig. 203: Waiting for connection ....................................... 125

Fig. 204: Uploader connect ..............................................126

Fig. 205: Enter Password.................................................126

Fig. 206: Uploader load...................................................127

Fig. 207: Choose File ......................................................127

Fig. 208: Confirmation of successful upload ....................... 128

Fig. 209: IFM Download tool ............................................ 128

Fig. 210: Interface RS232 ............................................... 129

Fig. 211: Checking connection ......................................... 129

Fig. 212: Announcement Call sign..................................... 129

Fig. 213: IFM Download .................................................. 130

Fig. 214: Open firmware .................................................130

Fig. 215: IFM Download firmware .....................................130

Fig. 216: IFM Download progress announcement ................131

Fig. 217: Download successful .........................................131

Fig. 218: Open application...............................................131

Fig. 219: Starting the control system ................................132

Fig. 220: Announcement after the start ............................. 132

Fig. 221: Get Identity .....................................................132

Fig. 222: Announcement Call sign..................................... 132

Fig. 223: Error message without firmware ......................... 133

Fig. 224: Error message Download ................................... 133

Fig. 225: Sensor calibration .............................................133

Fig. 226: Pulse Width Modulation...................................... 135

Fig. 227: PWM Parameter on ........................................... 136

Fig. 228: Service > Parameter settings ............................. 137

Fig. 229: Parameter settings............................................137

Fig. 230: Y8111 ............................................................. 138

© Terex-Demag 2010, Jürgen Christmann 167


Service Training 13 Table of Illustrations

Fig. 231: SET v Tele extend .............................................138

Fig. 232: Tele speed ....................................................... 139

Fig. 233: Set value.........................................................140

Fig. 234: logiCAD Project Wizard (Open project) ................. 141

Fig. 235: logiCAD Project Wizard (Project) ......................... 142

Fig. 236: Select project dialogue ...................................... 142

Fig. 237: logiCAD Project Wizard (Finish)...........................143

Fig. 238: Start download .................................................143

Fig. 239: Download successfully finished! ..........................144

Fig. 240: Open Configuration-Manager ..............................144

Fig. 241: Open Target System Parameter Sets ................... 145

Fig. 242: Download target system parameter sets .............. 145

Fig. 243: Open EEPROM Target System Parameter Sets .......146

Fig. 244: Download EEPROM target system parameter sets ..146

Fig. 245: Software icons..................................................146

Fig. 246: Starting screen, Parameter Editor 32bit................ 147

Fig. 247: Load project.....................................................147

Fig. 248: Parametereditor with project .............................. 148

Fig. 249: Load application and parameter .......................... 148

Fig. 250: Do not cut off power .........................................148

Fig. 251: Download in progress ........................................ 149

Fig. 252: Select devices ..................................................149

Fig. 253: Programming lead attached to the cable for the


emergency control system............................................... 150

Fig. 254: MCan2Flash launch ...........................................150

Fig. 255: Connect...........................................................151

Fig. 256: Transmission parameters ................................... 151

Fig. 257: Detect modules ................................................151

Fig. 258: Failed connection ..............................................152

Fig. 259: Operating system and application recognised........152

© Terex-Demag 2010, Jürgen Christmann 168


Service Training 13 Table of Illustrations

Fig. 260: No application ..................................................153

Fig. 261: Program transfer destination ..............................153

Fig. 262: Application > Option ......................................... 153

Fig. 263: Find and select file ............................................154

Fig. 264: Open file .........................................................154

Fig. 265: Initiate program transfer. .................................. 154

Fig. 266: Progress bar ....................................................155

Fig. 267: Application after transfer ................................... 155

Fig. 268: Reset module ...................................................155

Fig. 269: MOBA control (detail) ........................................156

Fig. 270: MTC ................................................................157

Fig. 271: IC-1 Uploader 2.5 .............................................158

Fig. 272: Password request .............................................158

Fig. 273: IC-1 Uploader 2.5 connected with MTC ................158

Fig. 274: Choose File ......................................................159

Fig. 275: Upload done.....................................................159

© Terex-Demag 2010, Jürgen Christmann 169

You might also like